Abstract
The present invention is a modular structural building method consisting of prefabricated, precast, composite reinforced concrete raised floor and steel beam panels with adjustable levelling connection assemblies between panels, supported by columns. The system has the ability to accommodate the use of the floor by construction personnel during the on-site assembly process. The perimeter of the raised floor slab can be provided with ducts for a field installed conventional reinforcement means to create a continuous structural diaphragm for the floor panel.
Claims
1. A method of using a modular structural building system to install raised floors comprising the steps of: a. precasting a plurality of raised floor panels, said raised floor panels having a top and a bottom and a plurality of edges, one or more of said edges being generally angled such that the tops of the plurality of said raised floor panels have less surface area than the bottoms; b. precasting said plurality of raised floor panels by precasting an amount of wet concrete to a plurality of beams selected from the group consisting of wide flange steel beams, timber beams, and light gauge steel sections; c. transporting the precast raised floor panels to a final panel location; d. attaching the plurality of precast raised floor panels to at least one column such that the plurality of precast raised floor panels are suspended and stable enough for construction personnel to walk on the plurality of precast raised floor panels, said plurality of precast floor panels having a perimeter, said perimeter containing hollow ducts configured to accommodate a conventional reinforcement means selected from the group consisting of cable, rebar, prestressed concrete strand, and post-tensioned concrete strand, said conventional reinforcement means configured to provide a continuous structural diaphragm for the plurality of precast raised floor panels, said ducts configured to receive grout after receiving said conventional reinforcement means; e. creating a receptacle by said angled edges of adjacent raised floor panels of said plurality of raised floor panels; and f. filling the receptacle with grout; g. installing within the receptacle created by said angled edges of adjacent raised floor panels of said plurality of raised floor panels at least one adjustable levelling connection assembly, said adjustable levelling connection assembly configured to be capable of using torque to draw two adjacent raised floor panels level; and h. applying torque to the adjustable levelling connection assembly until the adjacent precast raised floor panels are level.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
(1) FIG. 1 is a bottom perspective view of the modular structural building system.
(2) FIG. 2 is a magnification of the circled area of FIG. 1 showing a front view of the receptacle created when adjacent angled edges are connected.
(3) FIG. 3 is a bottom perspective view of a precast raised floor panel.
(4) FIG. 4 is a front view of the precast raised floor panel of FIG. 3.
(5) FIG. 5 is a side view of the precast raised floor panel of FIG. 3.
(6) FIG. 6 is a side view of the beam.
(7) FIG. 7 is a side view of the modular structural building system and column assembly.
(8) FIG. 8 is a cross-section of two adjacent, connected concrete slabs.
(9) FIGS. 9 and 10 show two embodiments of a levelling connection assembly.
(10) FIGS. 11 and 12 show two embodiments of perimeter slab reinforcement means to create a continuous raised floor diaphragm.
(11) FIG. 13 is a side view of an embodiment wherein the column is a horizontal wide flange girder.
(12) FIG. 14 is a bottom perspective view the modular structural building system connected to a column. Connection details and other details are omitted for simplicity.
(13) FIG. 15 is flow chart of the method of the present invention.
DETAILED DESCRIPTION OF THE DRAWINGS
(14) FIG. 1 shows the modular structural building system 12 comprising a plurality of precast raised floor panels 13, each precast raised floor panel 13 comprising a reinforced concrete slab 14 (concrete reinforcing means not shown, see FIGS. 4 and 5) having a top 15 and a bottom 16, each reinforced concrete slab 14 also having a plurality of edges 17, at least one edge 17 being generally angled such that the top 15 of the reinforced concrete slab 14 has less surface area than the bottom 16, at least one beam 18, and a means 19 of coupling the beam 18 to the bottom 16 of the reinforced concrete slab 14 (coupling means not shown, see FIGS. 4-6), a means 20 for connecting adjacent angled edges 17 of the precast raised floor panels 13 to each other, wherein once adjacent angled edges 17 are connected a receptacle 21 is created, said receptacle 21 being filled with grout 22.
(15) FIG. 2 is a magnification of the circled area of FIG. 1 and shows two representative edges 17, both edges 17 being generally angled such that the top 15 of the reinforced concrete slab 14 will have less surface area than the bottom 16, and a receptacle 21 being created by connecting the angled edges 17 together (connection means not show, see FIGS. 7, 9, and 10). A small gap, approximately one-half inch wide, may be present after the angled edges are connected for structural purposes. Tape or insulation may be used to seal the gap while grout is being poured into the receptacle.
(16) FIG. 3 shows a precast raised floor panel 13, said precast raised floor panel 13 comprising a reinforced concrete slab 14 (concrete reinforcing means not shown, see FIGS. 4 and 5) having a top 15 and a bottom 16, said reinforced concrete slab 14 also having a plurality of edges 17, at least one edge 17 being generally angled such that the top 15 of the concrete slab has less surface area than the bottom 16, at least one beam 18, and a means 19 of coupling the beam 18 to the bottom 16 of the reinforced concrete slab 14 (coupling means not shown, see FIGS. 4-6).
(17) FIG. 4 is a front view of the precast raised floor panel 13 of FIG. 3, said precast raised floor panel 13 comprising a reinforced concrete slab 14 having a top 15 and a bottom 16, and conventional reinforcing means 23, said reinforced concrete slab 14 also having a plurality of edges 17, at least one edge 17 being generally angled such that the top 15 of the concrete slab has less surface area than the bottom 16, at least one beam 18, and a means 19 of coupling the beam 18 to the bottom 16 of the reinforced concrete slab 14.
(18) FIG. 5 is a side view of the precast raised floor panel 13 of FIG. 3, said precast raised floor panel 13 comprising a reinforced concrete slab 14 having conventional reinforcement means 23, at least one beam 18, and a means 19 of coupling the beam 18 to the bottom 16 of the reinforced concrete slab 14. In this embodiment, the beam includes a web 25, said web 25 containing at least one opening 26 to accommodate the routing of building construction materials. Also in this embodiment, the means 19 of coupling the beam 18 to the bottom 16 of the reinforced concrete slab 14 is headed anchor studs that are welded to the top flange of a hot rolled steel beam 18 and extend into the concrete slab 14. Size and quantity vary depending on project requirements.
(19) In an alternative embodiment, the means 19 of coupling the beam 18 to the bottom 16 of the reinforced concrete slab 14 is a plurality of light gauge composite clips that attach to the top of the beam 18 and extend into the concrete slab 14 so that composite action is formed between the beam 18 and concrete slab 14.
(20) FIG. 6 shows one beam 18, said beam comprised of two flanges 24, said flanges 24 being parallel to each other and connected to each other perpendicularly by a web 25 running the length of the flanges 24, said web 25 containing at least one opening 26 to accommodate the routing of building construction materials and a means 19 of coupling the beam 18 to the reinforced concrete slab 14 (slab not shown, see FIGS. 3-5).
(21) FIG. 7 shows the modular structural building system 12 comprising a plurality of precast raised floor panels 13, each panel comprising a reinforced concrete slab 14 having a top 15 and a bottom 16, said reinforced concrete slab 14 having a plurality of edges 17, at least one edge 17 being generally angled such that the top 15 of the reinforced concrete slab 14 has less surface area than the bottom 16, at least one beam 18 comprised of two flanges 24, said flanges 24 being parallel to each other and connected to each other perpendicularly by a web 25 running approximately the length of the flanges 24. Also shown is a means 19 of coupling the beam 18 to the bottom of the reinforced concrete slab 14, a means 20 for connecting adjacent angled edges 17 of the precast raised floor panels 13 to each other, wherein once adjacent angled edges 17 are connected, a receptacle 21 is created, said receptacle 21 being filled with grout 22. In the embodiment shown here, the means 23 for reinforcing the reinforced concrete slab 14 is welded wire fabric that extends beyond at the angled edge 17 of the reinforced concrete slab 14 such that the means 20 for connecting the adjacent angled edges 17 together is the overlapping and connecting of each reinforced concrete slab's 14 welded wire fabric. The beam 18 is attached to a column 28 and the web 25 of at least one beam extends beyond the edge of the reinforced concrete slab 14 such that the extended web 25 can be received by and attached to the column 28. The column 28 in this embodiment is a double angle steel column 28 so that the web 25 of the beam 18 extends and projects between the two components of the double angle column 28. This removes the need of a shear tab and places the bolts in double shear. Column 28 size, bolt size, spacing, and quantities vary depending on project requirements. Also, in this embodiment, the means 19 of coupling the beam to the bottom 16 of the reinforced concrete slab 14 is a plurality of headed anchor studs. The system of this embodiment uses bolted connections between the web 25 of the beam 18 and column 28 sections. Bolt size, spacing, and quantities vary depending on project requirements. All bolts, nuts, and washers have standard specifications as per American Institute of Steel Construction (AISC). In some embodiments, the available length of columns 28 may be limited or there may be transportation and erection constraints. In that case, a plurality of columns 28 may be connected to each other in the same plane, or along their length, using a column splice 39. Many column options allow for pre-installation of columns 28 in the modular structural building system so that the system can be installed in a “folding table” at the building site.
(22) A structural footer and ground floor concrete slab are shown in FIG. 7 for context but are not part of the claimed invention.
(23) FIG. 8 is a cross-section of two adjacent, connected reinforced concrete slabs 14 each reinforced concrete slab 14 also having a plurality of edges 17, at least one edge 17 being generally angled such that the top 15 of the concrete slab has less surface area than the bottom 16, a means 20 for connecting adjacent angled edges 17 of the precast raised floor panels 13 to each other, wherein once adjacent angled edges 17 are connected a receptacle 21 is created, said receptacle 21 being filled with grout 22. In this embodiment, the means 23 for reinforcing the reinforced concrete slab 14 is rebar which extends beyond at least one edge 17 of the concrete slab 14 such that the means 20 for connecting the adjacent angled edges 17 together is the overlapping and connecting of each reinforced concrete slab's 14 rebar.
(24) FIGS. 9 and 10 show two embodiments of a levelling connection assembly 29 comprised of a plurality of steel plates 30 connected by at least one mechanical fastening assembly 31 wherein torque is applied to the mechanical fastening assembly 31 to draw, or push/pull, two adjacent precast raised floor panels 13 level in the vertical direction providing for a level raised floor. The levelling connection assemblies 29 are located in the receptacles 21 and spaced apart at pre-determined locations based on project size and project levelness and flatness requirements. The levelling connection assemblies 29 are ultimately concealed by the grout 22. In the preferred embodiment, the levelling connection assembly 29 is located on the long sides of the floor panels.
(25) For example, FIG. 9 shows one embodiment of a levelling connection assembly 29 comprised of overlapping steel angle plates 30 embedded into adjacent reinforced concrete slabs 14 and attached to a weldable conventional reinforcing means 23 such as rebar. In this embodiment, the mechanical fastening assembly 31 is comprised of a weldable rebar 27 that is welded to the bottom and side of a steel angle 30, and a threaded bolt 31 or threaded rod that is then welded to the bottom angle and inserted through a hole in the other panel's angle where the steel angles 30 overlap. The threaded bolt 31 projects up into the receptacle 21 between adjacent angled edges 17 of reinforced concrete panels 13. Washers and nuts are then installed on the threaded rod or bolt. The tightening of the nut on the bolt or rod draws the two adjacent precast raised floor panels 13 level in the vertical direction providing for a level raised floor. This levelling connection assembly 29 also serves as the means 20 for connecting adjacent angled edges 17 of the precast raised floor panels 13 to each other.
(26) FIG. 10 shows another embodiment of a levelling connection assembly 29 comprised of opposing steel plates 30 embedded into adjacent reinforced concrete slabs 14 and attached to a weldable conventional reinforcing means 23 such as rebar. In this embodiment, the mechanical fastening assembly 31 is comprised of weldable rebar 27 that is welded to the bottom of each steel plate 30 and threaded bolts or rods 31 that are then welded to the top surface of each steel plate 30. These threaded bolts project up into the receptacle 21 between adjacent angled edges 17 of reinforced concrete panels 13. A third plate 30 with two holes is placed upon the first two steel plates 30 and over the two threaded bolts or rods. Washers and nuts are then installed on the two threaded rods or bolts 31. The tightening of the nuts on the bolts or rods draws the two adjacent precast raised floor panels 13 level in the vertical direction providing for a level raised floor. This levelling connection assembly 29 also serves as the means 20 for connecting adjacent angled edges 17 of the precast raised floor panels 13 to each other.
(27) FIGS. 11 and 12 show two embodiments of modular structural building system 12 further comprising at least one perimeter precast raised floor panel 40 comprising a reinforced perimeter concrete slab 32 having a plurality of edges 33, at least one edge 33 being generally flat, said flat edge being connected to a building's perimeter walls. At least one duct 34 is located inside the reinforced perimeter concrete slab 32 that is generally parallel to and near the flat edge 33, said duct 34 being capable of receiving a conventional reinforcement means 23, said conventional reinforcing means 23 being installed in all perimeter precast raised floor panels 40 in a continuous manner such that, when overlapping the reinforcing means 23 of the concrete slab 14, a raised floor structural diaphragm is created.
(28) FIG. 11 shows one embodiment where the duct 34 is a metal duct 35 embedded in the reinforced concrete slab 14 during the precasting process. A continuous cable 36 is field placed through the embedded metal duct 35.
(29) FIG. 12 shows another embodiment where the conventional reinforcing means 23 being installed in all perimeter precast raised floor panels 40 in a continuous manner is rebar.
(30) FIG. 13 shows an embodiment wherein the column 28 is a horizontal wide flange girder 37. A sheer tab or angle 38 is welded or bolted to the horizontal wide flange girder 37 and connected to the web 25 of the beam 18.
(31) FIG. 14 depicts the modular structural building system 12 comprising a plurality of precast raised floor panels 13, each precast raised floor panel 13 comprising a reinforced concrete slab 14 having a top 15 and a bottom 16, at least one beam 18, said beam comprised of two flanges 24, said flanges 24 being parallel to each other and connected to each other perpendicularly by a web 25 running the length of the flanges 24, and a means 19 of coupling the beam 18 to the reinforced concrete slab 14 (coupling not shown, see FIGS. 3-5), wherein the beam 18 is attached to a column 28. In this embodiment, the column 28 is a double angle column. For simplicity, connection details and other details are not shown in FIG. 14.
(32) FIG. 15 is a flow chart depicting the method of the present invention using the modular structural building system described herein to install raised floors comprising the steps of precasting a plurality of raised floor panels, transporting the precast raised floor panels to the building site, attaching each precast raised floor panel to at least one column such that the precast raised floor panels are suspended and stable enough for construction personnel to walk on the precast raised floor panels, connecting adjacent angled edges of the precast raised floor panels to each other, installing within the receptacle created by connecting adjacent angled edges to each other at least one adjustable levelling connection assembly, said assembly being capable of using torque to draw two adjacent raised floor panels level, applying torque to the adjustable levelling connection assembly until the adjacent precast raised floor panels are level; and filling the receptacle with grout.
(33) Whereas the figures and description have illustrated and described the concept and preferred embodiment of the present invention, it should be apparent to those skilled in the art that various changes may be made in the form of the invention without affecting the scope thereof. The detailed description above is not intended in any way to limit the broad features or principles of the invention, or the scope of patent monopoly to be granted.
