TECHNICAL FIELD
The present application relates generally to wall systems and, more particularly, to an apparatus, system, and method for attaching an assembled wall module to a building structure.
BACKGROUND
The standard construction methodology for insulated metal panel (“IMP”) cladding over a steel stud wall involves labor-intensive aerial construction of the stud wall followed by a similar construction process to install the metal panels. Most of this work must be performed by workers in boom lifts or other aerial working platforms with the materials being maneuvered into place using cranes. This standard construction methodology is an established, tried, and true process with known challenges and rate of work. However, such working conditions present serious fall risks for workers. Additionally, the workers are encumbered with 50-75 lbs. of gear while working and spend approximately half of their time getting into position to perform the work. Thus, the inefficiencies of working at a height that requires fall protection result in a prolonged job schedule. Therefore, what is needed is an apparatus, system, and/or method to address one or more of the foregoing issued, and/or one or more other issued.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1A is a simplified exploded perspective view of a building structure, a building substructure, and a wall module including framing sections and sheeting sections, according to one or more embodiments.
FIG. 1B is a diagrammatic illustration of the wall module of FIG. 1A installed onto the building sub-structure, according to one or more embodiments.
FIG. 1C is a diagrammatic illustration of the wall module of FIG. 1A, according to one or more alternative embodiments.
FIG. 2A-1 is a diagrammatic illustration of a lifting apparatus in a first operational state or configuration, according to one or more embodiments.
FIG. 2A-2 is a perspective view of the lifting apparatus of FIG. 2A-1 in the first operational state or configuration, according to one or more embodiments.
FIG. 2A-3 is an elevational view of the lifting apparatus of FIG. 2A-1 in the first operational state or configuration, according to one or more embodiments.
FIG. 2B-1 is a diagrammatic illustration of the lifting apparatus of FIG. 2A-1 in a second operational state or configuration, the lifting apparatus having been actuated from the first configuration to the second configuration by a crane, according to one or more embodiments.
FIG. 2B-2 is a diagrammatic illustration of the lifting apparatus of FIG. 2A-1 in the second operational state or configuration, the lifting apparatus having been actuated from the first configuration to the second configuration by one or more hydraulic cylinders, according to one or more embodiments.
FIG. 2B-3 is a perspective view of the lifting apparatus of FIG. 2B-1 in the second operational state or configuration, according to one or more embodiments.
FIG. 2B-4 is an elevational view of the lifting apparatus of FIG. 2B-1 in the second operational state or configuration, according to one or more embodiments.
FIG. 3A is a perspective view of a lift table of the lifting apparatus of FIGS. 2A-1 through 2B-4, according to one or more embodiments.
FIG. 3B is a top plan view of the lift table of the lifting apparatus of FIGS. 2A-1 through 2B-4, according to one or more embodiments.
FIG. 3C is an elevational view of the lift table of the lifting apparatus of FIGS. 2A-1 through 2B-4, according to one or more embodiments.
FIG. 4A is a perspective view of a base of the lifting apparatus of FIGS. 2A-1 through 2B-4, according to one or more embodiments.
FIG. 4B is a top plan view of the base of the lifting apparatus of FIGS. 2A-1 through 2B-4, according to one or more embodiments.
FIG. 4C is an elevational view of the base of the lifting apparatus of FIGS. 2A-1 through 2B-4, according to one or more embodiments.
FIG. 5 is a flow diagram of a method for implementing one or more embodiments of the present disclosure.
FIG. 6A is a diagrammatic illustration of a system including the lifting apparatus of FIGS. 2A-1 through 2B-4, the system being in a third operational state or configuration during the execution of FIG. 5's method, according to one or more embodiments.
FIG. 6B is a diagrammatic illustration of the system including the lifting apparatus of FIGS. 2A-1 through 2B-4, the system being in a fourth operational state or configuration during the execution of FIG. 5's method, according to one or more embodiments.
FIG. 6C is a diagrammatic illustration of the system including the lifting apparatus of FIGS. 2A-1 through 2B-4, the system being in a fifth operational state or configuration during the execution of FIG. 5's method, according to one or more embodiments.
FIG. 6D is a diagrammatic illustration of the system including the lifting apparatus of FIGS. 2A-1 through 2B-4, the system being in a sixth operational state or configuration during the execution of FIG. 5's method, according to one or more embodiments.
FIG. 7A is a perspective view of a framing section, according to one or more embodiments.
FIG. 7B is an enlarged perspective view of a portion of the framing section of FIG. 7A, according to one or more embodiments.
FIG. 7C is an enlarged perspective view of another portion of the framing section of FIG. 7A, according to one or more embodiments.
FIG. 7D is an enlarged perspective view similar to FIG. 7C, except that certain feature(s)/component(s) of the another portion of the framing section are rendered transparently, according to one or more embodiments.
FIG. 7E is an enlarged perspective view of yet another portion of the framing section of FIG. 7A, according to one or more embodiments.
FIG. 8A is a perspective view of a wall frame including the framing section of FIG. 7A connected to another framing section, according to one or more embodiments.
FIG. 8B is an enlarged perspective view of a portion of the wall frame of FIG. 8A, according to one or more embodiments.
FIG. 8C is an enlarged perspective view similar to FIG. 8B, except that certain feature(s)/component(s) of the portion of the wall frame are rendered transparently, according to one or more embodiments.
DETAILED DESCRIPTION
The present disclosure introduces a modularized wall system that allows for entire wall modules to be constructed at ground level by workers without the need for fall protection. Most of the work of constructing the wall modules is done at ground level, resulting in the modularized wall system of the present disclosure being safer than the standard construction methodology described above by reducing the fall risk to the level of normal tripping hazards inherent to all construction activity. Further, workers are not required to wear heavy fall protection restraints or carry tools on their person, resulting in the modularized wall system of the present disclosure being more efficient than the standard construction methodology described above by enabling workers to get into position to perform their work in seconds rather than minutes. Further still, the modularized wall system of the present disclosure allows a portion of the structural work to be pre-fabricated ahead of time at an off-site location, resulting in the modularized wall system of the present disclosure being more efficient than the standard construction methodology described above. To achieve these advantages (and others), the modularized system of the present disclosure requires careful planning to prepare for the risks and challenges.
Referring to FIGS. 1A through 1C, in an embodiment, a wall module is generally referred to by the reference numeral 1001. As shown in FIG. 1A, the wall module 1001 includes framing sections 1051-3 and sheeting sections 1101-2. In some embodiments, the wall module 1001 is or includes structural steel. As shown in FIG. 1A the sheeting sections 1101-2 are attached to the framing sections 1051-3 to form the wall module 1001. More particularly, the framing sections 1051-3 are constructed into an integrated wall frame 115 to which the wall sheeting sections 1101-2 are attached. This construction allows the framing sections 1051-3 to be prefabricated off site and then assembled into the wall frame 115 on site and at ground level. The wall module 1001 can then be finished on site by attaching the sheeting sections 1101-2 to the wall frame 115 at ground level, lifting the completed wall module 1001 into place, as will be described in further detail herein, and securing the completed wall module 1001 to a building sub-structure 120, which building sub-structure 120 is part of a building structure 125 such as, for example, a multi-story warehouse structure.
More particularly, as shown in FIG. 1B, in an embodiment, the wall module 1001 and a plurality of additional wall modules 1002-N are adapted to be aligned with each other and secured to the building sub-structure 120. In some embodiments, the additional wall modules 1002-N are substantially identical to the wall module 1001 described above in connection with FIG. 1A and, therefore, will not be described in further detail. The building sub-structure 120 to which the wall modules 1001-N are secured may be or include structural members such as, for example, wall columns, wall girts, wall purlins, wall bracing, the like, or a combination thereof.
Although shown in FIG. 1A and described above as including three framing sections 1051-3, one or more of the wall modules 1001-N such as, for example, the wall module 1001 shown in FIG. 1C (according to an alternative embodiment), may instead include one, two, four, or more framing sections 1051-N, which framing sections 1051-N together form the wall frame 115. In addition, or instead, although shown in FIG. 1A and described above as including two sheeting sections 1101-2, one or more of the wall modules 1001-N such as, for example, the wall module 1001 shown in FIG. 1C (according to an alternative embodiment), may instead include one, three, or more sheeting sections 1101-N attached to the wall frame 115, as shown in FIG. 1C.
The wall modules 1001-N of the present disclosure are substituted in place of the steel studs used in conventional wall systems. As a result, the modularized wall system of the present disclosure: is stronger, delivering a better product; can be partially assembled off site; and creates a more rigid platform that allows for modularization of the wall frame 115 and the sheeting sections 1101-N, as described herein. To achieve such modularization, each of the framing sections 1051-N of the wall frame 115 may be pre-fabricated in a controlled shop environment. For example, as in FIG. 1C, the wall frame 115 may contain multiple separate ones of the framing sections 1051-N to enable using standard methods of transport to the project site. In some embodiments, the framing sections 1051-N are or include structural steel. All welding is done in the shop and the framing sections 1051-N are checked for alignment prior to shipping. Once on site, the separate framing sections 1051-N are fastened together on a ground level platform (i.e., on the lifting apparatus described herein) to form the wall frame 115. The completed wall frame 115 is then ready for the sheeting sections 1101-N to be attached thereto before being rigged up and lifted into place for securing to the building structure 125, that is, the building sub-structure 120, as will be described in further detail below.
The construction of the wall frame 115 improves quality control by allowing tolerances, welds, and alignment to be verified in a well-lit, covered shop environment. Further, inspection is made more convenient by allowing the inspector to verify performance of the framing sections 1051-N and/or the integrated wall frame 115 with an inspection at any point during the construction process (prior to final installation) without requiring special accommodations to access the work (e.g., boom lifts, fall protection, etc.). Further still, as described above, the safety and efficiency of the work constructing the wall frame 115 is improved by minimizing the amount of work performed by personnel at heights requiring fall protection. Further still, the efficiency of equipment use is improved by minimizing the need for crane rigging, hoisting, and boom lift use. Finally, the construction of the wall frame 115 reduces labor costs, and, most significantly, shortens the overall construction schedule.
Additionally, the construction of the wall frame 115 achieves a strong, rigid frame that enables the installation of the sheeting sections 1101-N at ground level, that is, on the lifting apparatus described herein. In some embodiments, the sheeting sections 1101-N are insulated metal panels (“IMPs”). Conventionally, the installation of sheeting involves a minimum of an eight (8) man crew, two boom lifts, and a crane. Due to the complexities of working at such a height and the coordination required between all the equipment, the process is slow and laborious. However, with the implementation of the modular wall system described herein, the sheeting sections 1101-N can be fastened to the assembled wall frame 115 to complete the wall module 1001 before rigging up the completed wall module 1001 and lifting it into place for securing to the building structure 125, that is, the building sub-structure 120, as will be described in further detail below.
The ground level installation of the sheeting sections 1101-N improves quality control by allowing the completed work to be more closely examined from ground level prior to its being lifted into place. Further, inspection is made more convenient by allowing the inspector to verify performance with an inspection at any point during the constructions process (i.e., prior to final installation) without requiring special accommodations to access the work (e.g., boom lifts, fall protection, etc.). Further still, the safety and efficiency of the work installing the sheeting sections 1101-N is improved by minimizing the amount of work required to be performed by personnel at heights requiring fall protection. Further still, equipment use is decreased since the work installing the sheeting sections 1101-N can be performed with minimal crane rigging, hoisting, and boom lift use.
Installing the sheeting sections 1101-N onto the wall frame 115 at ground level before lifting the completed wall module 1001 into position presents some challenges, including, for example: the need to protect the facade of the sheeting sections 1101-N during lifting and installation; the need to protect the sheeting sections 1101-N from excessive deflection during lifting; the need to align the completed wall modules 1001-N on the building structure 125, that is, the building sub-structure 120; and the need for site conditions permitting use of the modularized wall system of the present disclosure (including a sufficient staging area). The present disclosure addresses these challenges, especially those associated with protecting the sheeting sections 1101-N during lifting and installation, by providing a lifting apparatus and method for picking and lifting the wall modules 1001-N into position.
FIG. 2A-1 is a diagrammatic illustration of such a lifting apparatus, generally referred to by the reference numeral 130, in a first operational state or configuration (i.e., a “loading” configuration), according to one or more embodiments. Referring to FIG. 2A-1, in an embodiment, the lifting apparatus 130 includes a base 135 and a lift table 140. In some embodiments, in the first configuration, the lift table 140 and the base 135 are spaced in a parallel relation. The lift table 140 includes a hinge part 145a. The base 135 includes a hinge part 145b. The lift table 140 is hingedly connected to the base 135 via the hinge parts 145a-b. The lift table 140 is adapted to accommodate successive ones of the wall modules 1001-N described above in connection with FIGS. 1A and 1B. Additionally, the lifting apparatus 130 is constructed so that it can be leveled on site. More particularly, the lifting apparatus 130 includes a plurality of leveling jacks 150 secured to the base 135 and adapted to level the lifting apparatus 130 for each setup. The lifting apparatus 130 further includes a plurality of counterweights 155, which counterweights 155 are attached to the base 135 to hold the base 135 in position on site when the lifting apparatus 130 is actuated from the first configuration, as shown in FIG. 2A-1, to a second configuration, as will be shown and described below in connection with FIGS. 2B-1 through 2B-4. FIGS. 2A-2 and 2A-3 are perspective and elevational views, respectively, of the lift table 140 and the base 135 of FIG. 2A-1 in the first operational state or configuration, according to one or more embodiments. In some embodiments, as in FIGS. 2A-2 and 2A-3, the lifting apparatus 130 is constructed with bolted connections to allow for quick and easy disassembly and reassembly on the project site. Moreover, the lifting apparatus 130 is designed to allow it to be lifted with a crane once positioned on site. For example, a crawler crane may be used on site to position and subsequently re-position the lifting apparatus 130 for installation of successive ones of the wall modules 1001-N, thus providing the option to pick and carry the lifting apparatus 130 to another location quickly and efficiently.
FIGS. 2B-1 and 2B-2 are diagrammatic illustrations of the lifting apparatus 130 of FIG. 2A-1 in a second operational state or configuration (i.e., an “unloading” configuration), according to one or more embodiments. In some embodiments, in the second configuration, the lift table 140 is spaced at an 80-degree angle from the base 135. Alternatively, the lift table 140 may be spaced at another angle from the base 135 in the second configuration, such as, for example, an angle in the range of 79 to 81-degrees, an angle in the range of 75 to 85-degrees, an angle in the range of 70 to 90-degrees, an angle of greater than 79 degrees, an angle of greater than 75 degrees, an angle of greater than 70 degrees, an angle of greater than 65 degrees, an angle of greater than 60 degrees, an angle of greater than 55 degrees, an angle of greater than 50 degrees, an angle of greater than 45 degrees, or another angle. Referring to FIG. 2B-1, in an embodiment, the lift table 140 includes pick points 160. The pick points 160 are adapted to be rigged to a crane 165 to enable the crane 165 to actuate the lifting apparatus 130 from the first configuration to the second configuration. More particularly, the pick points 160 are positioned opposite the hinge part 145a so that, when the crane 165 is rigged to the pick points 160 and hoists the lift table 140, the lift table 140 pivots about the hinge points 145a-b into the second configuration. Referring to FIG. 2B-2, in an alternative embodiment, the pick points 160 are omitted in favor of one or more hydraulic cylinders 170 connected between the base 135 and the lift table 140 to actuate the lifting apparatus 130 from the first configuration to the second configuration. FIGS. 2B-3 and 2B-4 are perspective and elevational views, respectively, of the lift table 140 and the base 135 of FIGS. 2B-1 and 2B-2 in the second operational state or configuration, according to one or more embodiments.
FIGS. 3A through 3C are perspective, top plan, and elevational views, respectively, of the lift table 140 of FIGS. 2A-1 through 2B-4, according to one or more embodiments. In some embodiments, the lift table 140 is or includes structural steel. Referring to FIGS. 3A through 3C, in an embodiment, the lift table 140 includes a lifting frame 175, a nose plate 180, and the pick points 160. The lifting frame 175 is rectangular in shape. The lifting frame 175 includes a plurality of interconnected structural members, such as, for example, interconnected beams, braces, angles, and brackets. More particularly, as shown in FIGS. 3A through 3B, the lifting frame 175 includes lengthwise beams 185 spaced apart in a parallel relation. Although described as including the four (4) lengthwise beams 185, the lifting frame 175 may instead include two (2), three (3), five (5) or more lengthwise structural beams spaced apart in a parallel relation. Further, the lifting frame 175 includes widthwise beams 190 interconnecting the lengthwise beams 185 such that the lifting frame 175 forms the rectangular shape. Further still, the lifting frame 175 includes braces 195 extending in alternating diagonal directions between respective outer pairs of the lengthwise beams 185. The braces 195 provide extra structural support to prevent, or at least reduce, deflection of the lifting frame 175 when successive ones of the wall modules 1001-N are supported on the lift table 140. In some embodiments, the lifting frame 175 has a widthwise dimension W1 of about 40 feet and a lengthwise dimension L1 of about 60 feet. The nose plate 180 extends (e.g., perpendicularly) along a widthwise edge E1 of the lifting frame 175 and is adapted to support successive ones of the wall modules 1001-N when the lifting apparatus 130 is in the second configuration, as will be described in further detail below. The pick points 160 are positioned at an opposite widthwise edge E2 of the lifting frame 175. An Appendix forms part of the '268 Applications, which is hereby incorporated herein by reference in its entirety; pages 2 through 41 of the Appendix of the '268 Applications illustrate detailed build plans for the lift table 140 shown in FIGS. 3A through 3C of the drawings.
FIGS. 4A through 4C are perspective, top plan, and elevational views, respectively, of the base 135 of FIGS. 2A-1 through 2B-4, according to one or more embodiments. In some embodiments, the base 135 is or includes structural steel. Referring the FIGS. 4A through 4C, in an embodiment, the base 135 includes a base frame 200 and lifting point stiffener plates 205. The base frame 200 is rectangular in shape. The base frame 200 includes a plurality of interconnected structural members, such as, for example, interconnected beams and brackets. More particularly, as shown in FIGS. 4A through 4B, the base frame 200 includes lengthwise beams 210 spaced apart in a parallel relation. Although described as including the four (4) lengthwise beams 210, the base frame 200 may instead include two (2), three (3), five (5) or more lengthwise structural beams spaced apart in a parallel relation. Further, the base frame 200 includes widthwise beams 215 interconnecting the lengthwise beams 210 such that the base frame 200 forms the rectangular shape. In some embodiments, the base frame 200 has a widthwise dimension W2 of about 40 feet and a lengthwise dimension L2 of about 60 feet. In some embodiments, as in FIGS. 4A through 4C, the lifting point stiffener plates 205 are attached to the lengthwise beams 210 of the base frame 200. For example, the lifting point stiffener plates 205 may be attached to the lifting frame 175 in a grid of twelve (12) different locations. For another example, the lifting point stiffener plates 205 may be attached to the lifting frame 175 in a grid of nine (9) different locations. For yet another example, the lifting point stiffener plates 205 may be attached to the lifting frame 175 in a grid of at least five (5) different locations. Pages 42 through 54 of the Appendix of the '268 Applications illustrate detailed build plans for the base 135 shown in FIGS. 4A through 4C of the drawings.
Each location at which the lifting point stiffener plates 205 are attached to the lifting frame 175 corresponds one of the leveling jacks 150 (shown in FIGS. 2A-1, 2B-1, and 2B-2), which leveling jacks 150 are adapted to be connected to the lifting point stiffener plates 205 to level the base 135 on site. Further, in some embodiments, the counterweights 155 (shown in FIGS. 2A-1, 2B-1, and 2B-2) include two (2) counterweights 155. In some instances, the first counterweight 155 is adapted to be hung from one or more of the lifting point stiffener plates 205 positioned along a widthwise edge E3 of the base frame 200. Moreover, the second counterweight 155 is adapted to be hung from one or more of the lifting point stiffener plates 205 positioned along an opposite widthwise edge E4 of the base frame 200. Detailed build plans for the counterweights 155 are illustrated on pages 62 through 65 of the Appendix of the '268 Application. Finally, in some embodiments, one or more of the lifting point stiffener plates 205, such as the lifting point stiffener plates 205 positioned along the widthwise edge E3 of the base frame 200, may serve as the hinge part 145b (shown in FIGS. 2A-1, 2B-1, and 2B-2) of the base 135.
Referring to FIG. 5, a method 220 of installing the wall module 1001 on the building structure 125, that is, the building sub-structure 120, is illustrated according to one or more embodiments. The method 220 includes at a step 225, assembling the wall module 1001 shown in FIG. 1C on the lift table 140 with the lifting apparatus 130 in the first configuration shown in FIGS. 2A-1 through 2A-3. FIG. 6A diagrammatically illustrates the wall module 1001 assembled on the lift table 140 with a pick bar 226 attached to the wall module 1001. Pages 55-58 of the Appendix of the '268 Application illustrate detailed build plans for the pick bar 226. In one or more embodiments, to assemble the wall module 1001 on the lift table 140 at the step 225, the framing sections 1051-N shown in FIG. 1C are pre-assembled offsite. The framing sections 1051-N are then interconnected on site to form the wall frame 115 supported on the lift table 140. Finally, the sheeting sections 1101-N are secured to the wall frame 115 supported on the lift table 140 to complete the wall module 1001.
At a step 230 of the method 220 shown in FIG. 5, the lifting apparatus 130 is actuated from the first configuration to the second configuration shown in FIGS. 2B-1 through 2B-4 while the wall module 1001 is supported on the lift table 140. FIG. 6B diagrammatically illustrates the crane 165 rigged to the pick points 160 of the lift table 140 to actuate the lifting apparatus 130 from the first configuration to the second configuration, as also shown in FIG. 2B-1. Alternatively, the pick points 160 may be omitted from the lift table 140 in favor of the hydraulic cylinders 170 connected between the lift table 140 and the base 135 to actuate the lifting apparatus 130 from the first configuration to the second configuration, as shown in FIG. 2B-2. At the step 230, the wall module 1001 pivots together with the lift table 140 about the hinge parts 145a-b to the second configuration. During this pivoting, the counterweights 155 hold the base 135 and the leveling jacks 150 in position.
At a step 235 of the method 220 shown in FIG. 5, while the lifting apparatus 130 is in the second configuration, the wall module 1001 is hoisted, using a crane 236, off of the lift table 140 and into position on the building sub-structure 120 shown in FIG. 1B. FIG. 6C illustrates the crane 236 hoisting the wall module 1001 into position on the building sub-structure 120 via the pick bar 226 connected to the wall module 1001. Page 61 of the Appendix of the '268 Application illustrates the rigging scheme by which the crane 236 hoists the wall module 1001. In those embodiments in which the crane 165 is used at the step 230 to actuate the lifting apparatus 130 from the first configuration to the second configuration, a different crane, such as the crane 236, may be used to hoist the wall module 1001 off of the lift table 140 and into position on the building sub-structure 120. Alternatively, the lifting apparatus 130 may be locked in the second configuration using a locking mechanism (not shown) and the crane 165 may be re-rigged to the wall module 1001 to hoist the wall module 1001 into position on the building sub-structure 120.
Finally, at a step 240 of the method 220 shown in FIG. 5, the wall module 1001 is secured to the building sub-structure 120. Page 67 of the Appendix of the '268 Application describes and illustrates the manner in which the wall module 1001 is secured to the building sub-structure 120.
Referring to FIG. 6D, after the method 220 has been completed, the pick bar 226 is detached from the wall module 1001 in preparation for installing a next one of the wall modules 1002-N using the pick bar 226. Moreover, the lift table 140 is lowered back into the first configuration so that the next one of the wall modules 1002-N may be loaded onto the lift table 140 for installation onto the building sub-structure 120. The manner in which the wall modules 1002-N are installed onto the building sub-structure 120 is substantially identical to the manner in which the wall module 1001 is installed onto the building sub-structure 120 using the method 220 and, therefore, will not be described in further detail. In some instances, before the next one of the wall modules 1002-N can be installed onto the building sub-structure 120, the lifting apparatus 130 must be moved to a different position relative to the building structure 125. Pages 59 and 60 of the Appendix of the '268 Application illustrate the rigging scheme by which the crawler crane hoists the lifting apparatus 130 to move the lifting apparatus 130 to a different on-site location. In some embodiments, the counterweights 155 are moved separately from the remainder of the lifting apparatus 130 to the new on-site location. For example, page 66 of the Appendix of the '268 Application illustrates the rigging scheme by which the crawler crane separately hoists each of the counterweights 155 of the lifting apparatus 130 to move the counterweights 155 to the different on-site location.
The lifting apparatus 130 and the method 220 described herein provide a safe, ground-level working platform on which to assemble each wall frame 115, install the sheeting sections 1101-N, and then to transition the completed wall module 1001 from a horizontal orientation to a vertical orientation (e.g., an 80-degree vertical position). Conventionally, to transition a wall section from a horizontal position to a vertical position, rolling blocks have been used to lift the wall section from four (4) points. However, this required attachment points on the face of the wall section, which attachment points would be incompatible with the present wall modules 1001-N. Additionally, the process of lifting and rotating such a wall section to vertical created a bending moment in the structural elements of the wall section, causing a deflection greater than what the connections attaching sheeting to the wall section could tolerate. Both of these challenges are addressed by the lifting apparatus 130 and the method 220 of the present disclosure. More particularly, the lifting apparatus 130 and the method 220 of the present disclosure minimize stresses within each wall module 1001-N by, for example, limiting the maximum deflection of each wall module 1001-N to one inch or less. Further, the efficiency of crane rigging is improved by the lifting apparatus 130 and the method 220 of the present disclosure because the wall module 1001-N are rigged for vertical lifting via the pick bar 226 only once at ground level. Further still, the lifting apparatus 130 and method 220 of the present disclosure protect the facade of the sheeting sections 1101-N because no rigging is required on or across the face of the wall module 1001. Further still, the lifting apparatus 130 and the method 220 of the present disclosure provide a level working platform (i.e., the lift table 140) at a safe height not requiring fall protection. Finally, the lifting apparatus 130 and the method 220 of the present disclosure accommodate the ground-level construction of the wall modules 1001-N, as previously discussed herein.
Referring to FIG. 7A, in an embodiment, a framing section is generally referred to by the reference numeral 250, which framing section 250 is generally rectangular in shape. In one or more embodiments, the framing section 250 is, includes, or is part of one or more of the framing sections 1051-N(shown in FIGS. 1A and 1C). The framing section 250 includes a plurality of interconnected beams, angles, and brackets, and may be or include structural steel. More particularly, the framing section 250 includes structural members 255a-g (e.g., lengthwise beams) spaced apart in a parallel relation. Although shown and described as including the seven (7) structural members 255a-g, the framing section 250 may instead include two (2), three (3), four (4), five (5), six (6), eight (8), or more structural members (e.g., lengthwise beams) spaced apart in a parallel relation. The framing section 250 also includes structural members 260a-h (e.g., widthwise beams) interconnecting the structural members 255a-g such that the framing section 250 forms the rectangular shape. In one or more embodiments, the structural members 260a-d are adapted to extend between a foundation and a roof of the building structure 125, and the structural members 260e-h are adapted to extend at or above the roof of the building structure 125. Although shown and described as including the eight (8) structural members 260a-h, the framing section 250 may instead include two (2), three (3), four (4), five (5), six (6), seven (7), nine (9), or more structural members (e.g., widthwise beams) interconnecting the structural members 255a-g. In some embodiments, the framing section 250 has a widthwise dimension W3 of about 35 feet and a lengthwise dimension L3 of about 60 feet.
The structural members 260a-h are substantially identical to one another and, therefore, in connection with FIG. 7A, only the structural member 260a will be described in detail below; however, the description below applies equally to the structural members 260b-h. As shown in FIG. 7A, in an embodiment, the structural member 260a includes beam segments 260a1-6 interconnecting the structural members 255a-g. More particularly, the beam segment 260a1 interconnects the structural members 255a and 255b, the beam segment 260a2 interconnects the structural members 255b and 255c, the beam segment 260a3 interconnects the structural members 255c and 255d, the beam segment 260a4 interconnects the structural members 255d and 255e, the beam segment 260a5 interconnects the structural members 255e and 255f, and the beam segment 260a6 interconnects the structural members 255f and 255g.
Referring to FIGS. 7B through 7E, with continuing reference to FIG. 7A, in an embodiment, the framing section 250 also includes couplers 265a-g (e.g., bottom couplers), couplers 270a-c (e.g., intermediate couplers), and couplers 275a-g (e.g., top couplers) for connecting the framing section 250 to the foundation, floors, and roof, respectively, of the building structure 125 (shown in FIGS. 1A, 1B, 6B, 6C, and 6D).
The couplers 265a-g (which may also be referred to as “feet”) are connected to the structural members 255a-g, respectively, and are substantially identical to one another; therefore, in connection with FIG. 7B, only the coupler 265d will be described in detail below; however, the description below applies equally to the couplers 265a, 265b, 265c, 265e, 265f, and 265g. As shown in FIG. 7B, in an embodiment, the coupler 265d is connected to an end portion 280a of the structural member 255d, and includes a base 285 (e.g., a base plate) and a support member 290 (e.g., a support plate). The base 285 and the support member 290 may extend in a perpendicular relation; for example, in one or more embodiments, the coupler 265d is an angle. The base 285 is adapted to be connected to the foundation of the building structure 125 so that movement of the structural member 255d in a direction 296 and relative to the coupler 265d (and thus relative the foundation of the building structure 125) is permitted. A slot 295 is formed through the support member 290, which slot 295 is elongated in the direction 296. In one or more embodiments, the direction 296 is parallel to the structural member 255d and perpendicular to the base 285. A fastener 300 extends through the slot 295 and into a hole (not visible in FIG. 7B) formed in the end portion 280a of the structural member 255d; as a result, the fastener 300 connects the coupler 265d to the structural member 255d, and relative movement is permitted between the coupler 265d and the structural member 255d along the slot 295 (i.e., in the direction 296).
In an alternative embodiment, the slot 295 is formed through the end portion 280a of the structural member 255d instead of the coupler 265d, and the hole (not visible in FIG. 7B) is formed in the coupler 265d instead of the end portion 280a of the structural member 255d. In another alternative embodiment, the slot 295 is formed through both the end portion 280a of the structural member 255d and the coupler 265d, and the hole is omitted. In yet another alternative embodiment, the slot 295 and the hole are both omitted and replaced with another suitable mechanism to connect the coupler 265d to the end portion 280a of the structural member 255d while permitting relative movement between the coupler 265d and the structural member 255d in the direction 296.
Turning briefly back to FIG. 7A, in operation, the couplers 265a-g are adapted to be connected to the building structure 125 (e.g., to the foundation of the building structure 125) so that movement of the structural members 255a-g (and thus the entire framing section 250) in the direction 296 and relative to the couplers 265a-g (and thus relative the building structure 125) is permitted. For example, one or more of the couplers 265a-g may be movably connected (via, for example, the slot 295) to the structural members 255a-g, respectively, and fixedly connected to the building structure 125 (e.g., via welding, fasteners, embedding in the foundation of the building structure, etc.). For another example, one or more of the couplers 265a-g may be fixedly connected to the structural members 255a-g, respectively (via welding, fasteners, etc.), and movably connected (via, for example, the slot 295) to the building structure 125. For yet another example, one or more of the couplers 265a-g may be movably connected to the structural members 255a-g, respectively, and movably connected to the building structure 125.
The couplers 270a-c (which may also be referred to as “floor couplers”) interconnect the structural members 255a-g, and are substantially identical to one another; therefore, in connection with FIGS. 7A, 7C, and 7D, only the coupler 270b will be described in detail below; however, the description below applies equally to the couplers 270a and 270c. As shown in FIG. 7A, in an embodiment, the coupler 270b includes support segments 2711-6 interconnecting the structural members 255a-g and a coupler body 272 connected to the support segments 2711-6. More particularly, the support segment 2711 interconnects the structural members 255a and 255b, the support segment 2712 interconnects the structural members 255b and 255c, the support segment 2713 interconnects the structural members 255c and 255d, the support segment 2714 interconnects the structural members 255d and 255e, the support segment 2715 interconnects the structural members 255e and 255f, and the support segment 2716 interconnects the structural members 255f and 255g. Although shown and described as including the six (6) support segments 2711-6, the coupler 270b may instead include one (1), two (2), three (3), four (4), five (5), seven (7), or more support segments, provided that the total number of support segments is one (1) less than the total number of structural members 255; for example, in FIG. 7A, the framing section 250 includes the seven (7) structural members 255a-g and the coupler 270b includes the six (6) support segments 2711-6. In one or more embodiments, the coupler body 272 is an angle.
The support segments 2711-6 are substantially identical to one another; therefore, in connection with FIGS. 7C and 7D, only the support segment 2713 will be described in detail below; however, the description below applies equally to the support segments 2711, 2712, 2714, 2715, and 2716. As shown in FIGS. 7C and 7D, in an embodiment, the support segment 2713 includes a support beam 305a to which the coupler body 272 is connected, and a support beam 305b spaced in a parallel relation with the support beam 305a. The coupler body 272 is also connected to the support segment 2714, straddling the structural member 255d. As shown in FIG. 7D, the support beams 305a and 305b are connected to a support member 310 (e.g., a support plate) using, for example, angles 315a and 315b, respectively. A slot 320 is formed through the support member 310, which slot 320 is elongated in a direction 325. In one or more embodiments, the direction 325 is parallel to the structural member 255d. In addition, or instead, the direction 325 may be the same as the direction 296 when the couplers 265a-g and the coupler 270b are connected to the building structure 125. A fastener 330 extends through the slot 320 and into a hole (not visible in FIG. 7D) formed in the structural member 255d; as a result, the fastener 330 connects the support segment 2714 to the structural member 255d, and relative movement is permitted between the support segment 2714 and the structural member 255d along the slot 320 (i.e., in the direction 325).
In an alternative embodiment, the slot 320 is formed through the structural member 255d instead of the support member 310, and the hole (not visible in FIG. 7B) is formed in the support member 310 instead of the structural member 255d. In another alternative embodiment, the slot 320 is formed through both the structural member 255d and the support member 310, and the hole is omitted. In yet another alternative embodiment, the slot 320 and the hole are both omitted and replaced with another suitable mechanism to connect the support segment 2714 to the structural member 255d while permitting relative movement between the support segment 2714 and the structural member 255d in the direction 325. Although not visible in FIGS. 7C and 7D, the manner in which the support segment 2714 is connected to the structural member 255c mirrors the manner in which the support segment 2714 is connected to the structural member 255d and, therefore, will not be described in further detail.
Turning briefly back again to FIG. 7A, in operation, the respective couplers 270a-c are adapted to be connected to the building structure 125 (e.g., to respective floors of the building structure 125) so that movement of the structural members 255a-g (and thus the entire framing section 250) in the direction 325 and relative to the couplers 270a-c (and thus relative to the building structure 125) is permitted. For example, the support segments 2711-6 of one or more of the couplers 270a-c may be movably connected (via, for example, the slot 320) to, and interposed between, the structural members 255a-g, respectively, while the coupler body 272 of the one or more of the couplers 270a-c is fixedly connected to the building structure 125 (e.g., via welding, fasteners, embedding in the concrete of one of the floors of the building structure 125, etc.). For another example, the support segments 2711-6 of one or more of the couplers 270a-c may be fixedly connected to, and interposed between, the structural members 255a-g, respectively (e.g., via welding, fasteners, etc.), while the coupler body 272 of the one or more of the couplers 270a-c is movably connected (via, for example, the slot 320) to the building structure 125. For yet another example, the support segments 2711-6 of one or more of the couplers 270a-c may be movably connected to, and interposed between, the structural members 255a-g, respectively, while the coupler body 272 of the one or more of the couplers 270a-c is movably connected to the building structure 125.
The couplers 275a-g (which may also be referred to as “roof couplers”) are connected to the structural members 255a-g, respectively, and are substantially identical to one another; therefore, in connection with FIG. 7E, only the coupler 275d will be described in detail below; however, the description below applies equally to the couplers 275a, 275b, 275c, 275e, 275f, and 275g. As shown in FIG. 7E, in an embodiment, the coupler 275d is connected to an end portion 280b of the structural member 255d, which end portion 280b is opposite the end portion 280a (labelled in FIG. 7B). The coupler 275d includes a support member 335 (e.g., a support plate), which support member 335 is adapted to be connected to the roof of the building structure 125 so that movement of the structural member 255d in a direction 345 and relative to the coupler 275d (and thus relative the roof of the building structure 125) is permitted. A slot 340 is formed through the support member 335, which slot 340 is elongated in the direction 345. In one or more embodiments, the direction 345 is parallel to the structural member 255d. In addition, or instead, the direction 345 may be the same as: the direction 296 when the couplers 265a-g and the couplers 275a-g are connected to the building structure 125; the direction 325 when the couplers 270a-c and the couplers 275a-g are connected to the building structure 125; or both. A fastener 350 extends through the slot 340 and into a hole (not visible in FIG. 7E) formed in the end portion 280b of the structural member 255d; as a result, the fastener 350 connects the coupler 275d to the structural member 255d, and relative movement is permitted between the coupler 275d and the structural member 255d along the slot 340 (i.e., in the direction 345).
In an alternative embodiment, the slot 340 is formed through the end portion 280b of the structural member 255d instead of the coupler 275d, and the hole (not visible in FIG. 7E) is formed in the coupler 275d instead of the end portion 280b of the structural member 255d. In another alternative embodiment, the slot 340 is formed through both the end portion 280b of the structural member 255d and the coupler 275d, and the hole is omitted. In yet another alternative embodiment, the slot 340 and the hole are both omitted and replaced with another suitable mechanism to connect the coupler 275d to the end portion 280b of the structural member 255d while permitting relative movement between the coupler 275d and the structural member 255d in the direction 345.
Turning back again to FIG. 7A, in operation, the couplers 275a-g are adapted to be connected to the building structure 125 (e.g., to the roof of the building structure 125) so that movement of the structural members 255a-g (and thus the entire framing section 250) in the direction 345 and relative to the couplers 275a-g (and thus relative the building structure 125) is permitted. For example, one or more of the couplers 275a-g may be movably connected (via, for example, the slot 340) to the structural members 255a-g, respectively, and fixedly connected to the building structure 125 (e.g., via welding, fasteners, another fixed connection to a roof portion of the building structure 125, etc.). For another example, one or more of the couplers 275a-g may be fixedly connected to the structural members 255a-g, respectively (via welding, fasteners, etc.), and movably connected (via, for example, the slot 340) to the building structure 125. For yet another example, one or more of the couplers 275a-g may be movably connected to the structural members 255a-g, respectively, and movably connected to the building structure 125.
Referring to FIGS. 8A through 8C, in an embodiment, another framing section 250′ is connected to the framing section 250. In one or more embodiments, the framing section 250′ is, includes, or is part of, one or more of the framing sections 1051-N(shown in FIGS. 1A and 1C). As shown in FIG. 8A, the framing section 250′ includes feature(s)/component(s) substantially identical to corresponding feature(s)/component(s) of the framing section 250, which substantially identical feature(s)/component(s) are given the same reference numerals.
Support segments 355a-c connect the framing section 250′ to the framing section 250′. More particularly, the support segments 355a-c are connected to the couplers 270a-c, respectively, of the framing sections 250 and 250′, and include feature(s)/component(s) substantially similar to corresponding feature(s)/component(s) of the support segments 2711-6 (shown in FIG. 7A), which substantially similar feature(s)/component(s) are given the same reference numerals. The support segment 355a-c are substantially identical to one another; therefore, in connection with FIGS. 8B and 8C, only the support segment 355b will be described in detail below; however, the description of the support segment 355b below applies equally to the support segments 355a and 355c. The support segment 355b extends between, and is movably connected to, the structural member 255a of the framing section 250 and the structural member 255g of the framing section 250′. The coupler body 272 of the coupler 270b of the framing section 250 is connected to the support segment 355b. Likewise, the coupler body 272 of the coupler 270b of the framing section 250′ is connected to the support segment 355b. As a result, the support segment 2711 of the framing section 250, the support segment 2716 of the framing section 250′, and the support segment 355b are interconnected and together movable relative to the structural members 255a-g of the framing sections 250 and 250′. Accordingly, the coupler 270b of the framing section 250, the coupler 270b of the framing section 250′, and the support segment 355b may together be referred to as a “coupler.”
In one or more embodiments, the “couplers” described herein permit “flexing” of the building structure 125 (e.g., from temperature changes, seismic activity, etc.) while preventing, or at least reducing, any corresponding deformation of the framing sections 250 and 250′. Moreover, any of the wall modules 1001-N including the framing section 250 (and/or the framing section 250′) are allowed to “float” relative to the building structure 125; this “floating” permits the wall modules 1001-N to rest on the foundation of the building structure 125, rather than being carried by the building structure 125, thereby reducing wear and fatigue on the building structure 125.
In some embodiments, one or more of the embodiments of the present application are provided in whole or in part as described and illustrated in the Appendix of the '268 Application, which forms part of the present application.
In some embodiments, one or more of the embodiments described and illustrated in the Appendix of the '268 Application are combined in whole or in part with one or more of the embodiments described above and/or one or more of the other embodiments described and illustrated in the Appendix.
A system has been disclosed. The system generally includes: a building structure; and a framing section connected to the building structure, the framing section including: a plurality of structural members; and a first coupler connected to a first structural member of the plurality of structural members; wherein the first coupler permits relative movement between the framing section and the building structure in a first direction. In one or more embodiments, the first coupler includes: a support plate; and a fastener; the fastener extends through an elongated slot to movably connect the support plate to the first structural member; and the elongated slot is formed in the support plate, the first structural member, or both. In one or more embodiments, the system further includes: a plurality of sheeting sections connected to the framing section on a side of the framing section opposite the building structure. In one or more embodiments: (i) the first coupler is movably connected to the first structural member; and the first coupler is fixedly connected to the building structure; (ii) the first coupler is fixedly connected to the first structural member; and the first coupler is movably connected to the building structure; or (iii) the first coupler is movably connected to the first structural member; and the first coupler is movably connected to the building structure. In one or more embodiments, the framing section further includes a second coupler; and the second coupler permits relative movement between the framing section and the building structure in a second direction, which second direction is the same as the first direction. In one or more embodiments: (iv) the second coupler is movably connected to the first structural member; and the second coupler is fixedly connected to the building structure; (v) the second coupler is fixedly connected to the first structural member; and the second coupler is movably connected to the building structure; or (vi) the second coupler is movably connected to the first structural member; and the second coupler is movably connected to the building structure. In one or more embodiments: (iv) the second coupler is movably connected to a second structural member of the plurality of structural members; and the second coupler is fixedly connected to the building structure; (v) the second coupler is fixedly connected to the second structural member; and the second coupler is movably connected to the building structure; or (vi) the second coupler is movably connected to the second structural member; and the second coupler is movably connected to the building structure.
A method has also been disclosed. The method generally includes: connecting a framing section to a building structure, the framing section including: a plurality of structural members; and a first coupler connected to a first structural member of the plurality of structural members; and after connecting the framing section to the building structure, permitting, via the first coupler, relative movement between the framing section and the building structure in a first direction. In one or more embodiments, the method further includes: before connecting the framing section to the building structure, connecting a plurality of sheeting sections to the framing section. In one or more embodiments, connecting the framing section to the building structure includes: (i) movably connecting the first coupler to the first structural member; and fixedly connecting the first coupler to the building structure; (ii) fixedly connecting the first coupler to the first structural member; and movably connecting the first coupler to the building structure; or (iii) movably connecting the first coupler to the first structural member; and movably connecting the first coupler to the building structure. In one or more embodiments, the framing section further includes a second coupler; and the method further includes: after connecting the framing section to the building structure, permitting, via the second coupler, relative movement between the framing section and the building structure in a second direction, which second direction is the same as the first direction. In one or more embodiments, connecting the framing section to the building structure further includes: (iv) movably connecting the second coupler to the first structural member; and fixedly connecting the second coupler to the building structure; (v) fixedly connecting the second coupler to the first structural member; and movably connecting the second coupler to the building structure; or (vi) movably connecting the second coupler to the first structural member; and movably connecting the second coupler to the building structure. In one or more embodiments, connecting the framing section to the building structure further includes: (iv) movably connecting the second coupler to a second structural member of the plurality of structural members; and fixedly connecting the second coupler to the building structure; (v) fixedly connecting the second coupler to the second structural member; and movably connecting the second coupler to the building structure; or (vi) movably connecting the second coupler to the second structural member; and movably connecting the second coupler to the building structure.
An apparatus has also been disclosed. The apparatus generally includes: a framing section adapted to be connected to a building structure, the framing section including: a plurality of structural members; and a first coupler connected to a first structural member of the plurality of structural members; wherein, when the framing section is connected to the building structure, the first coupler is adapted to permit relative movement between the framing section and the building structure in a first direction. In one or more embodiments, the first coupler includes: a support plate; and a fastener; wherein the fastener extends through an elongated slot to movably connect the support plate to the first structural member; and wherein the elongated slot is formed in the support plate, the first structural member, or both. In one or more embodiments, the apparatus further includes: a plurality of sheeting sections adapted to be connected to the framing section, on a side of the framing section opposite the building structure. In one or more embodiments: (i) the first coupler is movably connected to the first structural member; and the first coupler is adapted to be fixedly connected to the building structure; (ii) the first coupler is fixedly connected to the first structural member; and the first coupler is adapted to be movably connected to the building structure; or (iii) the first coupler is movably connected to the first structural member; and the first coupler is adapted to be movably connected to the building structure. In one or more embodiments, the framing section further includes a second coupler; and, when the framing section is connected to the building structure, the second coupler is adapted to permit relative movement between the framing section and the building structure in a second direction, which second direction is the same as the first direction. In one or more embodiments: (iv) the second coupler is movably connected to the first structural member; and the second coupler is adapted to be fixedly connected to the building structure; (v) the second coupler is fixedly connected to the first structural member; and the second coupler is adapted to be movably connected to the building structure; or (vi) the second coupler is movably connected to the first structural member; and the second coupler is adapted to be movably connected to the building structure. In one or more embodiments: (iv) the second coupler is movably connected to a second structural member of the plurality of structural members; and the second coupler is adapted to be fixedly connected to the building structure; (v) the second coupler is fixedly connected to the second structural member; and the second coupler is adapted to be movably connected to the building structure; or (vi) the second coupler is movably connected to the second structural member; and the second coupler is adapted to be movably connected to the building structure.
It is understood that variations may be made in the foregoing without departing from the scope of the present disclosure.
In one or more embodiments, the elements and teachings of the various embodiments may be combined in whole or in part in some or all of the embodiments. In addition, one or more of the elements and teachings of the various embodiments may be omitted, at least in part, and/or combined, at least in part, with one or more of the other elements and teachings of the various embodiments.
Any spatial references, such as, for example, “upper,” “lower,” “above,” “below,” “between,” “bottom,” “vertical,” “horizontal,” “angular,” “upwards,” “downwards,” “side-to-side,”“left-to-right,” “right-to-left,” “top-to-bottom,” “bottom-to-top,” “top,” “bottom,” “bottom-up,” “top-down,” etc., are for the purpose of illustration only and do not limit the specific orientation or location of the structure described above.
In one or more embodiments, while different steps, processes, and procedures are described as appearing as distinct acts, one or more of the steps, one or more of the processes, and/or one or more of the procedures may also be performed in different orders, simultaneously and/or sequentially. In one or more embodiments, the steps, processes, and/or procedures may be merged into one or more steps, processes and/or procedures. In one or more embodiments, one or more of the operational steps in each embodiment may be omitted. Moreover, in some instances, some features of the present disclosure may be employed without a corresponding use of the other features. Moreover, one or more of the embodiments disclosed above and in the Appendix of the '268 Application, or variations thereof, may be combined in whole or in part with any one or more of the other embodiments described above and in the Appendix, or variations thereof.
Although several embodiments have been described in detail above and in the Appendix of the '268 Application, the embodiments described are illustrative only and are not limiting, and those skilled in the art will readily appreciate that many other modifications, changes and/or substitutions are possible in the embodiments without materially departing from the novel teachings and advantages of the present disclosure. Accordingly, all such modifications, changes, and/or substitutions are intended to be included within the scope of this disclosure as defined in the following claims. In the claims, any means-plus-function clauses are intended to cover the structures described herein as performing the recited function and not only structural equivalents, but also equivalent structures. Moreover, it is the express intention of the applicant not to invoke 35 U.S.C. § 112(f) for any limitations of any of the claims herein, except for those in which the claim expressly uses the word “means” together with an associated function.
Patent Grant
11519179
