US20030159366A1

Movatterモバイル変換

Info

Publication number: US20030159366A1
Application number: US10/352,722
Authority: US
Inventors: William Christensen
Original assignee: Individual
Current assignee: Individual
Priority date: 2002-02-23
Filing date: 2003-01-28
Publication date: 2003-08-28

Abstract

A prefabricated housing component that includes at least one casting having a wall portion, a floor portion, a ceiling portion, wherein the wall portion, floor portion and ceiling portion cooperate to form an interior space, and a cabinet portion including a recessed portion within the interior space. The prefabricated housing component further includes a framework surrounding the casting, wherein the framework provides structural rigidity thereto.

Description

CROSS-REFERENCE TO RELATED APPLICATION

This application claims priority from U.S. Provisional Patent Application No. 60/359,403, filed on Feb. 23, 2002, entitled PREFABRICATED HOUSING COMPONENTS.[0001]

BACKGROUND OF THE INVENTION

The present invention relates to the housing industry and, in particular, to prefabricated components such as bathrooms and kitchens which are preferably built at a factory and shipped to a build site.[0002]

The housing construction industry is one of the largest sectors of the United States economy. In the construction industry there is considerable competition to continually produce an improved product, reduce costs, and speed construction. One way for a builder to reduce costs is to purchase less expensive materials. However, this approach often leads to an inferior product or building. Another approach to reducing costs is to reduce the amount of labor required to produce a house or building. This is accomplished by the use of continually improving tools such as nail guns, power tools, and the like. Labor is also reduced by the use of ready to install, standardized, or pre-ordered moldings, wall panels, trusses, floorings, trim, and the like. However, labor continues to be a significant cost of a house or building.[0003]

One aspect of the labor costs is associated with the electrical and plumbing work that must be done on site. The electricians and plumbers are skilled at their craft, but may cause a delay if they are not able to perform their work under a schedule desired by the builder. Further, government inspectors may be required to inspect the electrical and plumbing work before the drywall or other work can continue. Thus, delays or possible problems may delay construction and increase costs.[0004]

Another aspect of the construction industry is to increase the value and desirability of a building by including innovative, attractive, and more durable features. The continuing goal, therefore, is to find ways to reduce costs, increase durability and functionality, improve the aesthetic appeal, and improve efficiency.[0005]

SUMMARY OF THE INVENTION

To address the goals stated above and other goals, the inventive prefabricated housing components are manufactured using large-scale composite molding techniques to form wall, ceilings, floors, cabinets, and other features from a single casting. In the preferred embodiment, an entire room, such as a bathroom or a kitchen, is formed from only two such castings. The two castings are mated together and aligned with alignment pins to form a single unit. Support ribs are attached to the exterior of the casting. A framework, preferably made of wooden or metal studs, is constructed to enclose the casting. The casting is placed inside of the framework and the support ribs secure the casting to the framework while the casting continues to cure. The studs are then more securely attached to the casting by use of a composite material, mechanical fasteners and structural components, thereby increasing the structural resiliency and rigidity of the final structure.[0006]

Various portions of the casting are cutout to provide apertures for such things as medicine cabinets, towel cabinet drawers and doors, vanity doors and doors, plumbing access and electrical devices and switches. The component is then finished by connecting plumbing and electrical devices, adding doors, and drawers, installing flooring, sinks, counter tops, towel racks, and the like to complete the component.[0007]

The component is then shipped to the building site where the component is installed in place. The high strength of the component reduces the chance of damage during the shipping process. The plumbing and electrical work is done at the factory where it is also inspected. The work is completed indoors and can therefore be done efficiently regardless of outside weather conditions.[0008]

Finally, the unique construction technique of the invention permits aesthetically pleasing and useful shapes and designs that are not typically available using conventional construction techniques. For example, the molded construction technique permits the application of various curves and sculptured shapes. Rectangular cabinets and 90° corners may be replaced with smoothly sculptured cabinets and rounded comers. The possibility of designs is virtually limitless.[0009]

In some applications, an additional casting may be used when it is not practicable to use only two castings. For example, in a bathroom application, a tub/shower casting may be molded separately and installed into the component after the initial two halves are assembled.[0010]

One aspect of the present invention is to provide a prefabricated housing component that comprises at least one casting including a wall portion, a floor portion, a ceiling portion, wherein the wall portion, floor portion and ceiling portion cooperate to form an interior space, and a cabinet portion including a recessed portion located within the interior space. The prefabricated housing component further includes a framework surrounding the casting, wherein the framework provides structural rigidity thereto.[0011]

Another aspect of the present invention is to provide a method of manufacturing a prefabricated housing component that includes the steps of applying a composite material to a mold that includes a wall portion, a ceiling portion and a floor portion, allowing the composite material to at least partially cure, thereby resulting in a casting, and removing the casting from within the mold. The method further includes inserting the casting into a cavity as defined by a framework, and securing the casting to the framework.[0012]

It is clear that the invention is a significant improvement over the prior art systems. Additional features and advantages of the invention will be set forth in the detailed description which follows, and in part will be readily apparent to those skilled in the art from that description or recognized by practicing the invention as described in the detailed description which follows, the claims, as well as the appended drawings.[0013]

It is to be understood that the foregoing description is exemplary of the invention only and is intended to provide an overview for the understanding of the nature and character of the invention as it is defined by the claims. The accompanying drawings are included to provide a further understanding of the invention and are incorporated and constitute part of this specification. The drawings illustrate various features and embodiments of the invention which, together with their description serve to explain the principals and operation of the invention.[0014]

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a cutaway top perspective view of a casting embodying the present invention, wherein the casting comprises a bathroom;[0015]

FIG. 2 is a front elevational view of a vanity, a medicine cabinet, and a towel cabinet of the bathroom of FIG. 1;[0016]

FIG. 3 is a top plan view of the bathroom of FIG. 1;[0017]

FIG. 4 is a top plan view of a recessed portion and an insert cut away to show an interlocking joint;[0018]

FIG. 5 is a front elevational view of the recessed portion of the casting;[0019]

FIG. 6 is an exploded perspective view of the castings and framework associated therewith;[0020]

FIG. 7 is a cross-sectional side elevational view along section VII-VII, FIG. 1;[0021]

FIG. 8 is a top perspective view of a stud, a support rib, and a bracket according to the invention;[0022]

FIG. 9 is a top perspective view of an insert according to the invention;[0023]

FIG. 10 is a cross-sectional side elevational view of an alignment pin and an associated flooring;[0024]

FIG. 11 is a cross-sectional top plan view of a wall of the casting;[0025]

FIG. 12 is a cross-sectional view of a strengthened portion of the casting;[0026]

FIG. 13 is a cross-sectional view of the floor and the wall of the casting;[0027]

FIG. 14 is a top plan view of an alternative casting of the present invention, wherein the alternative casting comprises a kitchen;[0028]

FIG. 15 is a cross-sectional side elevational view of a lower drain pan;[0029]

FIG. 16 is a top perspective view of a bath/shower casting;[0030]

FIG. 17 is a side elevational view of the housing component supported by a trolley assembly; and[0031]

FIG. 18 is a perspective view of the trolley assembly.[0032]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

Reference will now be made in detail to the present preferred embodiments of the invention, examples of which are illustrated in the accompanying drawings. Wherever possible, the same reference numerals will be used throughout the drawings to refer to the same or like parts.[0033]

An exemplary embodiment of a prefabricated housing component according to the present invention is shown in FIG. 1, and is designated generally throughout by[0034]

reference numeral

10. Parts of theprefabricated housing component10 of the present invention will first be briefly described and then described in detail. The most common use for the invention is as a bathroom or kitchen for a home, a duplex, an apartment, a hotel, and the like. However, those skilled in the art will appreciate that the invention may be adapted for other applications as well. The following discussion will describe the invention in relation to a bathroom application.

As illustrated in FIG. 1,[0035]

prefabricated housing component

10 comprises afirst casting11A, asecond casting11B and anexternal framework12. The

castings

11A and11B are formed into avanity cabinet13A, atowel cabinet13B, amedicine cabinet13C and alight bar13D. Other parts of the construction comprisewalls14A, aceiling14B, and afloor14C. The

castings

11A and11B are constructed out of fiberglass or composite type materials. The invention may also be practiced with other types of materials such as plastics which may be molded. The fiberglass construction comprises multiple layers of flame retardant resin and glass fibers with a colored gel layer as the finishing layer. A strengthening material, or core material, is included inside the layers of resin and glass fibers. Preferably, this material is a quarter inch layer of wood, and preferably balsa wood. Some portions of the construction include stronger strengthening layers such as ½ inch plywood. Such strengthened portions are used, for example, where drawers or cabinet doors are attached. The two

castings

11A and11B are aligned and attached together using an appropriate adhesive.

The interior of the component is finished by cutting openings in the[0036]

casting

11A for the drawers, cabinetry doors, light bar assemblies, and pluming and electrical connections. Conventional doors, drawers, countertops15A, sinks, faucets,toilets15B,bath tubs15C, lights, andelectrical outlets15D are attached or installed in a conventional manner.

One aspect of the invention is that once a mold (not shown) is formed or constructed, castings may be made quickly and easily from such mold. The first step in constructing the mold is to construct a female plug (not shown) in the shape of the desired casting such as[0037]

castings

11A and11B. The plug is virtually identical in shape to thecasting11A but without the added hardware, faucets and sink. The plug is preferably made of wood and is primed and waxed to a smooth surface. A male mold (not shown) is made from the plug in a conventional manner and the female castings are then created by placing multiple layers of fiberglass surrounding a wood layer on the mold. The casting, such as casting11A and11B is removed from the mold and inserted inside of theframework12. A plurality ofsupport ribs16A are secured to the

casting

11A or11B prior to placing the

casting

11A or11B into theframework12. Theribs16A are secured to a plurality ofstuds16B of theframework12.

The electrical and plumbing is completed on the[0038]

component

10 in the factory and is inspected to meet the required building codes. The plumbing and electrical are of a conventional nature, however, a preferred embodiment includes utilizing electrical harnesses and systems that are configured to minimize the number of electrical and plumbing connections required to be made at the construction site.

Other aspects of the invention include curved or sculptured portions of the castings[0039]11. Because of the manufacturing technique used, atypical shapes may be introduced into the castings. For example,rounded corners17 may be used extensively. Other portions may also be curved or contoured surfaces, including cabinetry, walls, floors, and ceilings to provide an appealing, innovative and upscale appearance. The atypical shapes may also be used to provide improved utility such as improved ergonomics, more usable storage and safety features

FIG. 2 is a front view of the finished cabinetry of FIG. 1. Shown in FIG. 2 are the[0040]

lights

21,electrical outlets15D,electrical switches22, medicinecabinet mirror doors23,towel holders24,drawers25 andcabinet doors26. Themedicine cabinet13C and thetowel cabinet13B are typically each provided withshelves27. To provideshelves27 and to provide an aesthetically pleasing and useful interior, an insert is provided which is secured into the interior of themedicine cabinet13C and thetowel cabinet13B.

FIG. 3 illustrates a cutaway top view of the[0041]

castings

11A and11B. Shown in the figure is thevanity top31, sink32 andfaucets33. A pair of alignment pins34 are shown along aseam35 located between the

castings

11A and11B. Alignment pins34, or other alignment devices, are utilized to keep the edges of the

castings

11A and11B aligned with one another while the

castings

11A and11B are bonded together. The alignment pins34 save time and reduce the risk of misalignment or imperfections in alignment.

As illustrated in FIG. 3, the[0042]

lips

36 of the

cabinetry

13B and13C where adrawer25 ordoor26 are attached are preferably reinforced with a rigid reinforcement material, such as ½ inch plywood and the like. As mentioned above, the

castings

11A and11B are preferably reinforced with ¼ inch balsa wood bonded inside at least two layers of fiberglass.

The apertures for the[0043]

drawers

25, thetowel cabinet13B and themedicine cabinet13C are cut from theoriginal casting11A. The mold if formed to create recessed portions in thecasting11A so that it is readily apparent where the cuts are to be made. FIGS. 4 and 5 illustrate acutout line51 and a preferred water resistant joint40 for use with aninsert41, such as thedrawers25 and the

cabinets

13B and13C. The casting11A is first cut along the edge of the recessedportion50 as illustrated by thecutout line51. Thelip36 of the recessed portion is preferably reinforced with ½ inch plywood, or other suitably functioning reinforcing material as discussed above, for securing and mounting thedrawers25 and

doors

23 and26. Theinserts41 are sized to fit within theaperture52 created by cutting along thecutout line51. The edges of theinsert41 and the edge of theaperture52 form the interlocking water resistant joint40 to securely hold theinsert41 within theaperture52. Adhesive is applied to the joint40 for added strength and water resistance.Inserts41 are preferably utilized to create thetowel cabinet13B and themedicine cabinet13C.

Another aspect of the[0044]

housing component

10 according to the invention is theframework12 into which the

castings

11A and11B are inserted. Theframework12 is constructed according to approved building standards and is preferably constructed of a plurality ofstuds12B, such as 2×4's and the like. Because theframework12 is assembled at the factory, it reduces the framing required to be done at the construction site and saves time and money. In a preferred embodiment, thehousing component10 is shipped on a plurality of castors (not shown), thereby allowing the builder to merely lower the completed component to the correct floor within the building, roll thecomponent10 to the desired location, and secure thecomponent10 to the associated sub-floor.

In assembly, the[0045]

castings

11A and11B are aligned with the alignment pins34 and secured within thesupport ribs16. Thesupport ribs16 are bonded to the exterior of the

castings

11A and11B and are preferably made of furring strips (e.g., wood strips) of approximately 1 inch by 3 inches.

The[0046]

framework

12 is constructed such that asidewall12C is separated from theframework12 until the

castings

11A and11B are inserted into aframework aperture12C. Once the

castings

11A and11B are in place, thesidewall12A is attached to the balance of theframework12.

The[0047]

castings

11A and11B are then secured to theframework12 via a plurality of metal brackets71 (FIG. 8), as shown in FIG. 7. Thebrackets71 are L-shaped brackets withoval apertures71A extending therethrough to provide for adjustment as the nail or screws secure thebrackets71 to thestuds12B. Eachbracket71 attaches to both therib16 and thestud12B. Theoval apertures71A in thebracket71 provide adjustment as needed. By using the technique of adjustably securing the

castings

11A and11B to theframework12, the

castings

11A and11B are able to be assembled to theframework12 while the

castings

11A and11B complete the curing process. This design allows for higher throughput by reducing the cycle time required to create each

casting

11A and11B. Preferably, using the adjustable technique, permits the

castings

11A and11B to be removed from the mold in approximately ½ the time required to attain a fully cured casting. In other words, the productively of each mold is doubled.

In assembly, alignment pins[0048]34 are located about the circumference of the

castings

11A and11B. However, once the

castings

11A and11B are adhesively bonded, the alignment pins34 located near thefloor14C are ground off or cut off to provide a level floor surface.

For greater strength, the[0049]

studs

12B offramework12 are then “glassed” i.e., bonded with thecomposite material72, to the exterior of the

castings

11A and11B. Thebond72 extends along the entire length ofstuds12B. This construction makes theoverall component10 very strong. The strength of the completedcomponent10 is contemplated to make it the strongest room of a construction. Therefore, it may also provide improved safety from storms, earthquakes, or similar dangerous conditions. It is also unlikely to be damaged or cracked during shipment to the construction site.

As illustrated in FIG. 9, the[0050]

insert

41 of the medicine cabinet13 includes adjustable shelving as provided byholes91A that support pins91B for supporting shelves in a conventional manner. Of course, other types of medicine cabinet units may also be used with the invention. Similar type shelving construction may also be utilized within thevanity cabinet13A and thetowel cabinet13B.

11A and11B is illustrated in FIG. 10. Thealignment pin34 is no longer need after the

castings

11A and11B have bonded together via an adhesive102 and thealignment pin34 is typically removed. Those of ordinary skill in the art recognize that various configurations of alignment pins, grooves or ridges may be utilized with the invention. Thefloor14C of the

castings

11A and11B is preferably covered with aflooring material103 that provides the desired color or texture of the builder, and comprise linoleum, tile and the like. Theflooring material103 also covers and hides the seam between the

11A and11B are each constructed of multiple layers offiber glass111 and epoxy113 with acolored layer112 that provides the finished surface visible to the user. Thecolored layer112 is preferably a gel coating. Sandwiched between the layers of thefiber glass111 and the epoxy113 is a layer ofsupport material114. Thesupport material114 may be cardboard, corrugated cardboard, wood, or other material that can provide adequate support. It is also desirable if the material provides some stress reduction such that the composite materials can move slightly if stress builds sufficiently. The most preferred support materials are ¼ inch bolsa wood for most surfaces, and ½ inch plywood for high stress areas such as thelips36 of theapertures52, where drawers or doors attach. An alternative embodiment utilized a layer of gas trapped between the multiple layers. FIG. 12 is another illustration of the composite construction where the support material is wood.

An example of the contoured surfaces and the curves that are readily implemented by the use of the invention is illustrated in FIG. 13, showing a[0053]

curve

130 from thewall14A down to thefloor14C. The invention can also accommodate formation of a recessedportion131 appropriate for receiving theflooring material103.

Those skilled in the art understand that there are some limitations to the shapes that can be reasonably fabricated using molds. Accordingly, it is understood that some shapes, such as a bathtub[0054]150 (FIG. 14) are more easily formed as a separate casting and then mounted into the appropriate location in the

castings

11A and11B. In the alternative, various other tub/shower units may be purchased and installed in the unit in a conventional manner.

Another aspect of the present invention is to provide a lower drain pain[0055]170 (FIG. 15) located proximate thebathtub150, and adapted to prevent water from leaking pipes associated with thebathtub150. It should be noted that while thedrain pan170 is described in relation tobathtub150, thedrain pan170 may be utilized with a multitude of plumbing fixtures and applications. In the illustrated example, thedrain pan170 includes ahousing member172 having a peripherally extendingattachment flange174, and acollar member175 having a peripherally extendingattachment flange176. In assembly, thehousing member172 is placed below the floor of thehousing component10 proximate a location of water pipes associated with thebathtub150, such as adrain pipe178, anover-flow pipe180, and the like. Thehousing member172 is connected to the floor of thehousing component10 via a plurality of mechanical fasteners and caulk. Thecollar member175 is aligned with thehousing member172, and theflange176 of thecollar member175 is attached to an upper surface of the floor of thehosing component10 via a plurality of mechanical fasteners and caulk.

In another aspect of the invention, a kitchen room[0056]140 (FIG. 16) may be implemented with similar advantages as discussed for the bathroom. Similar to the

casting

11A and11B of thebathroom component9, castings141 of thekitchen room140 are formed and bonded together. Inserts such as cabinets and counters142 are formed in a similar manner as described above. Locations for accessories such assinks143,ovens144,dishwashers145 and arefrigerator146 are also provided. The advantages of pre-plumbing and electrical wiring provide savings similar to thebathroom component9 described above.

As illustrated in FIGS. 17 and 18, a plurality of[0057]

trolley assemblies

150 utilized to support thehousing component10 during the installation process. Eachtrolley assembly150 includescastor wheel152 connected to an associatedstud16B via ssupport bracket154 and mounting hardware. Each support bracket includes a mountingportion156 adapted to connect to thestud16B, and awheel support portion158 integral with and extending substantially orthogonal to mountingportion156. The mountingportion156 includes a plurality of elongated, longitudinally extendingslots160, and a plurality ofapertures162, all of which are adapted to receive mounting hardware such aslugs164 therein. In assembly, thetrolleys150 are located with respect to thehousing component10 so as to provide clearance between a sub-floor166 and thehousing component10, thereby allowing the housing component to be rolled along thesub-floor166. Thelugs164 are tightened within theslots160 to maintain this clearance. Additionally, thelugs164 may be placed withinapertures162, thereby preventing the possibility of thelugs164 sliding within theslots160 and thehousing component10 touching thesub-floor166. Once thehousing component10 is delivered to the proper located within the building, thelugs164 are removed from within theapertures162 and theslots160, thereby allowing thehousing component10 to rest on thesub-floor166.

It will become apparent to those skilled in the art that various modifications to the preferred embodiment of the invention as described herein can be made without departing from the spirit or scope of the invention as defined by the appended claims.[0058]

Claims

The invention claimed is:

1. A prefabricated housing component, comprising:

at least one casting, comprising:

a wall portion;

a floor portion;

a ceiling portion, wherein the wall portion, floor portion and ceiling portion cooperate to form an interior space; and

a cabinet portion including a recessed portion located within the interior space; and

a framework surrounding the casting, wherein the framework provides structural rigidity thereto.

2. The prefabricated housing component ofclaim 1, wherein the casting comprises fiberglass.

3. The prefabricated housing component ofclaim 2, wherein the casting comprises a resin.

4. The prefabricated housing component ofclaim 3, wherein the resin is fire retardant.

5. The prefabricated housing component ofclaim 1, wherein the casting comprises plastic.

6. The prefabricated housing component ofclaim 1, wherein the at least one casting includes a first casting and a second casting matable theretogether; and further comprising:

an alignment portion including an alignment pin and an alignment aperture.

7. The prefabricated housing component ofclaim 1, wherein the framework is fixedly attached to the casting.

8. The prefabricated housing component ofclaim 6, wherein the framework includes at least one stud fixedly attached to the casting via resin and fiberglass.

9. The prefabricated housing component ofclaim 7, further comprising:

at least one support rib attached to the exterior of the casting.

10. The prefabricated housing component ofclaim 9, further comprising:

at least one bracket securing the at least one support rib to a stud of the framework.

11. The prefabricated housing component ofclaim 10, wherein the at least one bracket is adjustable.

12. The prefabricated housing component ofclaim 1 further comprising:

at least one support rib attached to the exterior of the casting.

13. The prefabricated housing component ofclaim 1, wherein the castings comprise a stress relieving material encased in layers of resin and fiber material.

14. The prefabricated housing component ofclaim 12, wherein the stress relieving material includes cardboard.

15. The prefabricated housing component ofclaim 14, wherein the stress relieving material includes wood.

16. The prefabricated housing component ofclaim 1, wherein the floor portion of the casting comprises a rigid core material surrounded by layers of resin and fiber material.

17. The prefabricated housing component ofclaim 18, wherein the core material is wood.

18. The prefabricated housing component ofclaim 1, wherein a lip portion of the casting surrounding the recessed portion includes a layer of wood material.

19. The prefabricated housing component ofclaim 1, further comprising:

a cabinet insert, wherein the recessed portion of the cabinet portion is cutout to receive the cabinet insert.

20. The prefabricated housing component ofclaim 22, wherein a lip portion of the casting surrounding the recessed portion is hook shaped, and wherein an edge of an insert received within the recessed portion is hook shaped, such that the lip portion of the casting and the edge of the insert interlock.

21. The prefabricated housing component ofclaim 1, wherein the floor portion is recessed for receiving a flooring material.

22. The prefabricated housing component ofclaim 1, wherein the composite casting further comprises a feature selected from a group consisting of a light mount recess, a sculpted edge, a sculpted joint and a sculpted corner.

23. The prefabricated housing component ofclaim 22, wherein the sculpted edges, sculpted joints and sculpted corners comprise rounded edges, rounded joints and rounded corners.

24. The prefabricated housing component ofclaim 1, further including:

a trolley assembly detachably connected to the housing component and adapted to rollably support the housing component.

25. The prefabricated housing component ofclaim 1, further including:

a drain pan attached to the floor portion and adapted to collect water that leaks through the floor proximate the drain pan.

26. A method of manufacturing a prefabricated housing component comprising the steps of:

applying a composite material to a mold that includes a wall portion, a ceiling portion and a floor portion;

allowing the composite material to at least partially cure, thereby resulting in a casting;

removing the casting from within the mold;

inserting the casting into a cavity as defined by a framework; and

securing the casting to the framework.

27. The method of manufacturing a prefabricated housing component ofclaim 24, further comprising:

securing a support rib to an exterior of the casting prior to inserting the casting.

28. The method of manufacturing a prefabricated housing component ofclaim 27, further comprising:

securing the rib to the framework.

29. The method of manufacturing a prefabricated housing component ofclaim 28, wherein the step of securing the rib to the framework includes securing the rib to the framework with an L-shaped bracket.

30. The method of manufacturing a prefabricated housing component ofclaim 29, wherein the step of securing the rib to the framework is accomplished prior to the composite material fully curing.

31. The method of manufacturing of a prefabricated housing componentclaim 26, wherein the step of applying a composite material comprises applying corrugated cardboard to the mold.

32. The method of manufacturing a prefabricated housing component ofclaim 26, wherein the step of applying a composite material comprises applying balsa wood to the mold.

33. The method of manufacturing a prefabricated housing component ofclaim 26, wherein the mold defines a recessed portion within an interior of the casting.

34. The method of manufacturing a prefabricated housing component ofclaim 33, further including:

cutting out a portion of the recessed portion, thereby forming an aperture within the recessed portion;

providing an insert portion; and

inserting the insert portion into the aperture within the recessed portion.

35. The method of manufacturing a prefabricated housing component ofclaim 26, wherein the step of securing the casting to the framework comprises bonding the framework to the casting with a composite material.

36. The method of manufacturing a prefabricated housing component ofclaim 26, further including:

supporting the framework by at least one trolley assembly, thereby providing clearance below the housing component.