Construction unit for a modular building

A modular construction unit for use as a floor or ceiling of a modular building, comprising:

• a generally rectangular poured concrete slab with a smooth planar top surface comprising:
• a plurality of longitudinal beams extending downwardly from the bottom of the slab and integral with the slab;
• a plurality of transverse purlins extending downwardly from the bottom of the slab and integral with the slab;
• the beams and purlins defining a plurality of rectangular voids on the underside of the slab;
• insulating material substantially filling the rectangular voids to form an integral unit with said slab;
• a plurality of ribs extending downwardly from the bottom of the slabs, the downward extent of the ribs less than the downward extent of the beams and purlins, the ribs extending to the outer peripheral edge of the slab;
• and
• an internal metal reinforcement matrix within the slab, comprising:
• a plurality of parallel deformed bar reinforcing metal rods extending horizontally within and along the length of at least some of the beams and purlins;
• a plurality of continuous steel channels extending along the bottom edges of the beams and purlins;
• a plurality of metal studs spaced at intervals and affixed to and extending upwardly from the channels into the concrete of the beams and purlins, with hooks at the ends extending over the topmost reinforcing metal rod into the concrete;
• and
• a metal wire grid embedded within an upper region of the slab and affixed to one of said deformed bar reinforcing metal rods.

A modular construction unit for use as a floor or ceiling of a modular building, comprising:

• a generally rectangular poured concrete slab with a planar top surface comprising:
• a plurality of longitudinal beams extending downwardly from the bottom of the slab and integral with the slab, the longitudinal beams disposed spaced inwardly a predetermined distance from an outer peripheral edge of the slab thereby defining a cantilever region;
• a plurality of transverse purlins extending downwardly from the bottom of the slab and integral with the slab, with a pair of said transverse purlins disposed coterminous with opposite outer peripheral edges of the slab;
• the beams and purlins defining a plurality of rectangular voids on the underside of the slab;
• rigid foam insulating material filling the rectangular voids and integral with the slab;
• a plurality of ribs extending downwardly from the bottom of the slab, the downward extent of the ribs less than the downward extent of the beams and purlins, the ribs extending transversely and parallel to the purlins out to a peripheral edge of the slab;
• an internal metal reinforcement matrix within the slab, comprising:
• a plurality of deformed bar reinforcing metal rods extending horizontally within the beams, purlins, and ribs;
• a plurality of continuous steel channels extending along the bottom edges of the beams and purlins;
• a plurality of metal studs spaced at intervals and affixed to and extending upwardly from the channels into the beams and purlins, the metal studs including hooks at the upward ends thereof and extending into the concrete of the slab;
• a metal wire grid embedded within an upper region of the slab;
• a plurality of support tubes embedded into corners of the slab, affixed to the steel channels, and opening into the top surface of the slab for receiving vertical support members utilized in a modular building, the support tubes affixed to the deformed bar reinforcing metal rods within purlins that extends to the corners of the slab.

A modular construction unit for use as a floor or ceiling of a modular building, comprising:

• a generally rectangular poured concrete slab with a planar top surface comprising:
• a plurality of longitudinal beams extending downwardly from the bottom of the slab and integral with the slab;
• a plurality of transverse purlins extending downwardly from the bottom of the slab and integral with the slab;
• the beams and purlins defining a plurality of rectangular voids on the underside of the slab filled substantially with insulating material to form an integral unit with said slab;
• a plurality of ribs extending downwardly from the bottom of the slabs, positioned between the purlins, the downward extent of the ribs less than the downward extent of the beams and purlins;
• an internal metal reinforcement matrix within the slab, comprising:
• deformed bar reinforcing metal extending horizontally within the beams and purlins;
• a plurality of continuous steel channels extending along the bottom edges of the beams and purlins;
• a metal wire grid embedded within an upper region of the slab;
• and
• a plurality of support tubes embedded into corners of the slab and opening into the top surface of the slab for receiving vertical support members utilized in a modular building.