METHOD OF CONSTRUCTING A BUILDING, AND A BUILDING CONSTRUCTION SYSTEM THEREFOR
20200385981 ยท 2020-12-10
Assignee
Inventors
- Stephen T. Houston (Lake Orion, MI, US)
- Joseph Michael Benvenuto (Monroe, MI, US)
- Yaroslav Stakhiv (Franklin, MI, US)
Cpc classification
E04B1/3516
FIXED CONSTRUCTIONS
E04B2001/3588
FIXED CONSTRUCTIONS
E04B1/3544
FIXED CONSTRUCTIONS
E04B1/3511
FIXED CONSTRUCTIONS
E04G21/167
FIXED CONSTRUCTIONS
E04G21/163
FIXED CONSTRUCTIONS
International classification
Abstract
A method of constructing a building includes constructing a vertical support core of the building, and attaching a climbing rail to an exterior of the vertical support core. The climbing rail includes holes spaced vertically. A first floor plate is constructed around a periphery of the vertical support core, at a ground elevation, and includes at least one connecting rail having vertically spaced holes. A climbing jack is attached to the climbing rail, and moved vertically upward on the climbing rail to raise the first floor plate to a first floor final elevation. The first floor plate is permanently attached to the climbing rail at the first floor final elevation by inserting a pin through aligned holes in the connecting rail and the climbing rail.
Claims
1. A building arranged on a foundation, comprising: a vertical support core disposed on a foundation; a climbing rail, wherein the climbing rail is attached to an exterior surface of the vertical support core, wherein the climbing rail extends vertically with the vertical support core, and wherein the climbing rail includes a first plurality of holes each spaced vertically relative to each other along the climbing rail; a hat beam; a plurality of floor plates, wherein each floor plate includes a structural support system having a connecting rail, wherein the connecting rail is disposed adjacent to the climbing rail, and wherein the connecting rail includes a second plurality of holes each spaced vertically relative to each other along the connecting rail; a plurality of pins, each pin disposed within and extending through one of the first plurality of holes of the climbing rail and one of the second plurality of holes of the connecting rail aligned therewith to secure one of the plurality of floor plates to the climbing rail; and a continuous column extending between the hat beam and the foundation, wherein the continuous column includes the connecting rail from one of the plurality of floor plates being attached to the connecting rail from an adjacent one of the plurality of floor plates.
2. The building of claim 1, further comprising the connecting rail being disposed adjacent to and parallel with the climbing rail.
3. The building of claim 1, further comprising the climbing rail extending vertically with and parallel to the vertical support core.
4. The building of claim 1, wherein the climbing rail being attached to the exterior surface of the vertical support core comprises the climbing rail being fixedly and permanently attached to the vertical support core.
5. The building of claim 1, wherein the structural support system comprises a plurality of frame members that are attached together.
6. The building of claim 1, wherein the vertical support core is arranged to transfer building load forces to ground via the foundation.
7. The building of claim 1, wherein each of the floor plates is fabricated around a periphery of the vertical support core at a ground elevation; and wherein each of the floor plates is raised to a final elevation via a climbing jack that interacts with the climbing rail.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
[0014]
[0015]
[0016]
[0017]
[0018]
[0019]
[0020]
DETAILED DESCRIPTION
[0021] Those having ordinary skill in the art will recognize that terms such as above, below, upward, downward, top, bottom, etc., are used descriptively for the figures, and do not represent limitations on the scope of the disclosure, as defined by the appended claims. Furthermore, the teachings may be described herein in terms of functional and/or logical block components and/or various processing steps. It should be realized that such block components may be comprised of any number of hardware, software, and/or firmware components configured to perform the specified functions.
[0022] Referring to the Figures, wherein like numerals indicate like parts throughout the several views, a building construction system is generally shown at 20. Referring to
[0023] As used herein, the term floor plate 22 may include all structural or frame members 56, e.g., joists and/or purlins, flooring, e.g., concrete floor, interior walls, exterior curtain walls, modular room subassemblies, e.g., a lavatory module, utilities, etc., that form a floor or level of the building 26. The term floor plate 22 may include a plate for a roof of the building 26, as well as a plate for a floor or level of the building 26. Accordingly, it should be appreciated that the term floor plate 22 is used herein to refer to both a roof structure for the roof of the building 26, as well as a floor structure for a floor or level of the building 26. As used herein and shown in the Figures, the reference numeral 22 may refer and indicate any floor plate 22 of the building 26, whereas the reference numeral 22A refers to and indicates a first floor plate 22A, and the reference numeral 22B refers to and indicates a second floor plate 22B.
[0024] The vertical support core 24 is designed to carry all of the building 26 load forces. As such, the vertical support core 24 transfers the vertical load from each floor plate 22 to a foundation 28 of the vertical support core 24, which supports the building 26 on the soil, i.e., ground. The foundation 28 of the vertical support core 24 may be constructed in a manner suitable for the specific soil, weather, and seismic conditions of the building site. Additionally, the foundation 28 and the vertical support core 24 are designed to carry any bending moments introduced into the building 26, such as from a wind load or a seismic load. The specific type and construction of the foundation 28 of the vertical support core 24 is not pertinent to the teachings of this disclosure, is well known to those skilled in the art, and is therefore not described in detail.
[0025] The vertical support core 24 may be constructed using a vertical slip form system that forms a wall 30 of the vertical support core 24 from a hardenable material, while moving vertically upward from a ground elevation to a finished top elevation. The hardenable material may include, but is not limited to, a concrete mixture or other similar composition. The wall 30 of the vertical support core 24 may include reinforcing steel as understood in the art. The specific design and construction of the vertical support core 24 using the vertical slip form system are known to those skilled in the art, is dependent upon the specific application and location, is not pertinent to the teachings of this disclosure, and is therefore not described in detail herein.
[0026] Alternatively, the vertical support core 24 may be constructed using some other process. For example, the vertical support core 24 may be constructed using pre-formed molds that are stacked together to form a cavity. Reinforcing steel may be added to the cavity as needed, and a hardenable material may be poured into the cavity to form the wall 30 of the vertical support core 24. An example of a pre-formed mold system may include, but is not limited to, the REDICOR Modular Steel Form System by Vulcraft. It should be appreciated that the vertical support core 24 may be constructed in some other manner not specifically described herein.
[0027] A hat beam 32 is disposed above and on top of the vertical support core 24, and is attached to the vertical support core 24. The hat beam 32 is attached to the vertical support core 24 in a manner that enables the building 26 load forces to be transferred between the vertical support core 24 and the hat beam 32. The hat beam 32 may include a structural component, such as a steel beam, that is sized to carry the building 26 load forces. The specific manner in which the hat beam 32 is attached to the top of the vertical support core 24 is not pertinent to the teachings of this disclosure, are well known by those skilled in the art, and is therefore not described in detail herein.
[0028] As shown in
[0029] Referring to
[0030] The climbing rail 34 is further attached to the hat beam 32 and the foundation 28. The climbing rail 34 may be attached to the hat beam 32 and the foundation 28 using a suitable process that enables building 26 load forces to be transmitted between the climbing rail 34 and the hat beam 32, and between the climbing rail 34 and the foundation 28. For example, the climbing rail 34 may be attached to the hat beam 32 and the foundation 28 using brackets bolted and/or welded to each other. The specific manner in which the climbing rail 34 is attached to the hat beam 32 and the foundation 28 is understood by those skilled in the art, is not pertinent to the teachings of this disclosure, and is therefore not described in detail herein.
[0031] The climbing rail 34 includes a web 40 forming a plurality of holes 42. In one embodiment, each of the holes 42 is a through-hole. Each of the holes 42 of the climbing rail 34 is spaced vertically relative to the other holes 42 of the climbing rail 34 along the vertical length of the climbing rail 34. The spacing between adjacent holes 42 in the climbing rail 34 is dependent upon the specific application. Additionally, the size of each of the holes 42 in the climbing rail 34 is dependent upon the specific application. The function of the holes 42 in the climbing rail 34 is described in greater detail below.
[0032] Referring to
[0033] As is understood by those skilled in the art, the pin climbing jack 44 includes an upper post 46 for engaging the holes 42 of the climbing rail 34, a lower post 48 for engaging the holes 42 of the climbing rail 34, and a hydraulic jack 50 operable to extend and retract to move the upper post 46 and the lower post 48 away from and toward each other. In operation, the pin climbing jack 44 sequentially disengages the upper post 46 from a hole 42 in the climbing rail 34, extends the hydraulic jack 50, re-engages the disengaged upper post 46 into another hole 42 in the climbing rail 34, disengages the lower post 48 from a hole 42 in the climbing rail 34, retracts the hydraulic jack 50, and then re-engages the disengaged lower post 48 into another hole 42 in the climbing rail 34, to climb up the climbing rail 34 and raise the individual floor plates 22. The process may be executed in reverse to move the climbing jack 44 vertically downward to an initial jack elevation at ground level.
[0034] As shown in
[0035] Referring to
[0036] The structural support system 54 includes at least one connecting rail 58A, 58B. In the embodiment that is illustrated in the Figures, with reference to
[0037] Referring to
[0038] Referring to
[0039] As shown in
[0040] A method of constructing the building 26 using the building construction system 20 described above, is also provided. The method includes constructing the foundation 28 and the vertical support core 24 of the building 26. As noted above, the vertical support core 24 is designed to carry the building 26 load forces from the floor plates 22 to the foundation 28. The foundation 28 transfers the building 26 load forces to the ground. The specific design of the foundation 28 and the vertical support core 24 is dependent upon the specifics of the building 26, location, soil type, etc., are well understood by those skilled in the art. The foundation 28 and the vertical support core 24 may be constructed in any suitable manner. The processes used to construct the foundation 28 and the vertical support core 24 ware well understood by those skilled in the art. Therefore, the design and process of constructing the foundation 28 and the vertical support core 24 are not described in detail herein.
[0041] Once the vertical support core 24 has been constructed, the hat beam 32 is positioned on top of the vertical support core 24, and is fixedly and permanently attached to the vertical support core 24. The hat beam 32 is attached to the vertical support core 24 in a manner that allows the building 26 load forces to be transferable between the hat beam 32 and the vertical support core 24. The manner in which the hat beam 32 is attached to the vertical support core 24 is within the knowledge of those skilled in the art, and is therefore not described in detail herein.
[0042] The climbing rail 34 is then attached to an exterior of the vertical support core 24. As noted above, the climbing rail 34 extends vertically, and is substantially parallel with the vertical support core 24. The climbing rail 34 is further attached to the hat beam 32 and the foundation 28. The climbing rail 34 may be attached to the vertical support core 24, the hat beam 32 and the foundation 28, in any suitable manner that fixedly and permanently attaches the climbing rail 34 to the hat beam 32 the vertical support core 24, and the foundation 28, and allows the building 26 load forces to be transmitted therebetween. Accordingly, the building 26 load forces may be transmitted from the climbing rail 34 directly to the foundation 28, from the climbing rail 34 to the hat beam 32, from the hat beam 32 to the vertical support core 24, and then from the vertical support core 24 to the foundation 28. As such, it should be appreciated that the climbing rail 34 is a structural load bearing component of the vertical support core 24 and/or of the building 26, and may be used to transfer the building 26 load forces to the foundation 28.
[0043] The climbing jack 44 may then be attached to the climbing rail 34 at an initial jack elevation. The initial jack elevation is an elevation that is below an assembly elevation of the floor plates 22. As such, the climbing jack 44 may at least partially support the individual floor plates 22 during assembly of the individual floor plates 22, and supports the floor plates 22 while raising them to their respective final elevation.
[0044] The climbing jack 44 may be attached to the climbing rail 34 in any suitable manner. The manner in which the climbing jack 44 is attached depends upon the specific type and operation of the climbing jack 44. For example, if the climbing jack 44 is embodied as the pin climbing jack 44 described herein, then the lower post 48 and the upper post 46 of the pin climbing jack 44 may be inserted through respective holes 42 in the climbing rail 34 to attach the climbing jack 44 to the climbing rail 34.
[0045] Referring to
[0046] Referring to
[0047] Once the first floor plate 22A has been raised to the first floor final elevation, then the first floor plate 22A is attached to the climbing rail 34 at the first floor final elevation. Preferably, the location at which the first floor plate 22A is attached to the climbing rail 34 is disposed vertically above the first floor plate 22A, such that a worker making the connection does not have to be located underneath the first floor plate 22A prior to the first floor plate 22A being securely fastened to the climbing rail 34.
[0048] For example, attaching the first floor plate 22A to the climbing rail 34 may include inserting the pin 66 through holes 42 in the climbing rail 34 aligned with the holes 64 in the connecting rails 58A, 58B. The aligned holes 42 of the climbing rail 34 and the connecting rails 58A, 58B are disposed above the first floor plate 22A, such that the pin 66 may be inserted through the aligned holes from a position above the first floor plate 22A. It should be appreciated that multiple pins 66 may be used to secure the first floor plate 22A to the climbing rail 34, with each pin 66 extending through respective holes 64 in the connecting rails 58A, 58B that are aligned with a respective hole 42 in the climbing rail 34.
[0049] The connecting rails 58A, 58B of the first floor plate 22A are attached to the hat beam 32, such that the building 26 load forces are transferable between the connecting rails 58A, 58B and the hat beam 32. The connecting rails 58A, 58B may be attached to the hat beam 32 in any suitable manner, such as but not limited to a bolted and/or welded connection. By attaching the connecting rails 58A, 58B of the subsequent floor plates 22 together and to the foundation 28, the connecting rails 58A, 58B form a structural column of the building 26, through which the building 26 load forces may be transmitted.
[0050] Once the first floor plate 22A has been attached to the climbing rail 34, the climbing jack 44 may be moved vertically downward to the initial jack elevation. Because the climbing jack 44 was located underneath the first floor plate 22A while raising the first floor plate 22A, the climbing jack 44 does not need to be detached from the climbing rail 34, and instead may be controlled by the computer to move vertically downward on the climbing rail 34 using the reverse of the process described above for moving vertically up the climbing rail 34.
[0051] The second floor plate 22B may then be constructed around the periphery of the vertical support core 24 at the ground elevation. Constructing the second floor plate 22B includes constructing the structural support system 54 of the second floor plate 22B, which includes connecting the connecting rails 58A, 58B to the frame members 56 of the structural support system 54 of the second floor plate 22B. The second floor plate 22B is constructed in a similar manner as the first floor plate 22A, with the connecting rails 58A, 58B of the second floor plate 22B positioned adjacent to and parallel with the climbing rail 34. In the embodiment described and illustrated herein, the connecting rails 58A, 58B of the second floor plate 22B include a portion that extends upward from the second floor plate 22B for attachment to the lower portion of the connecting rails 58A, 58B of the first floor plate 22A. Additionally, the connecting rails 58A, 58B of the second floor plate 22B may include a shorter, lower portion that extends downward from the second floor plate 22B to attachment to a subsequent lower level floor plate 22.
[0052] Referring to
[0053] As shown in
[0054] Similar to the climbing rail 34, the connecting rails 58A, 58B form a structural load path for transferring building 26 load forces to the foundation 28. For example, the building 26 load forces may be transferred directly from the connecting rails 58A, 58B to the foundation 28. Alternatively, the building 26 load forces may be transferred to the hat beam 32, which in turn transfers the building 26 load forces to the vertical support core 24 and/or the climbing rail 34, which in turn may transfer the building 26 load forces to the foundation 28. The building construction system 20 described herein provides multiple different load paths for the building 26 load forces. Accordingly, should one of the available load paths be damaged, the building 26 still maintains two other viable load paths to support the building 26 load forces.
[0055] The detailed description and the drawings or figures are supportive and descriptive of the disclosure, but the scope of the disclosure is defined solely by the claims. While some of the best modes and other embodiments for carrying out the claimed teachings have been described in detail, various alternative designs and embodiments exist for practicing the disclosure defined in the appended claims.