Patent Grant
10487493
Conventional construction is conducted in the field at the building job site. People in various trades (e.g., carpenters, electricians, and plumbers) measure, cut, and install material as though each unit were one-of-a-kind. Furthermore, activities performed by the trades are arranged in a linear sequence. The result is a time-consuming process that increases the risk of waste, installation imperfections, and cost overruns. One approach to improving efficiency in building construction may be modular construction. In the case of buildings with multiple dwelling units (e.g., apartments, hotels, student dorms, etc.), entire dwelling units (referred to as modules) may be built off-site in a factory and then trucked to the job site. The modules are then stacked and connected together, generally resulting in a low-rise construction (e.g., between one and six stories). Other modular construction techniques may involve the building of large components of the individual units off-site (e.g., in a factory) and assembling the large components in the field to reduce the overall construction effort at the job site and thereby reducing the overall time of erecting the building. However, shortcomings may exist with known modular building technologies and improvements thereof may be desirable.
Techniques are generally described that include methods and systems relating to building construction and more specifically relating to building design and construction using prefabricated components. An example method may include assembling a building unit in accordance with a floor plan of a building using prefabricated components, wherein the floor plan is designed to provide a total width of the building unit. The method may include installing a first prefabricated floor panel in a first position of the building unit, wherein the first floor panel is selected from a first plurality of prefabricated floor panels having a same first width; installing a second prefabricated floor panel in a second position of the building unit, wherein the second floor panel is selected from a second plurality of prefabricated floor panels having a same second width; and installing a third prefabricated floor panel in a third position of the building unit, wherein the third floor panel is selected from a third plurality of prefabricated floor panels, the floor panels in the third plurality of prefabricated floor panels having different widths, and wherein the third floor panel is selected such that a sum of the widths of the first, second, and third floor panels corresponds to the total width of the building unit in accordance with the floor plan.
In some examples, the first, second, and third pluralities of prefabricated floor panels may have a variable length. The first, second, and third floor panels may be selected to have the same length. The lengths of the first, second, and third floor panels may be selected to achieve a desired total length of the building unit.
In some examples, the first width of the first plurality of prefabricated floor panels may be equal to the second width of the second plurality of prefabricated floor panels. The first and second widths of the first and second pluralities of prefabricated floor panels may be greater than the widths of the third plurality of prefabricated floor panels.
In some examples, the third floor panel may be positioned between the first and second floor panels.
In some examples, the method may include installing a plurality of prefabricated walls to define one or more interior rooms of the building unit. Installing a plurality of prefabricated walls may include installing a prefabricated utility wall along a terminal side of the building unit, and installing a prefabricated demising wall along a terminal end of the building unit, the prefabricated demising wall configured to partition the building unit from an adjacent building unit. The first floor panel may be positioned adjacent to the utility wall. Installing a plurality of prefabricated walls may include installing a window wall along a terminal side of the building unit opposite the utility wall. The second floor panel may be positioned adjacent to the window wall. Installing a plurality of prefabricated walls may include installing a prefabricated end wall along a terminal end of the building unit opposite the demising wall, the prefabricated end wall positioned to extend along a terminal end of the building. Installing a plurality of prefabricated walls may include installing a prefabricated bedroom wall within the interior of the building unit to partition the building unit into a plurality of rooms.
Another example method includes assembling a building unit in accordance with a floor plan using prefabricated components. The method may include installing a first prefabricated floor panel to and between adjacent floor beams, installing a second prefabricated floor panel to and between the adjacent floor beams, installing a third prefabricated floor panel to and between the adjacent floor beams, installing a prefabricated demising wall above and along at least one of the adjacent floor beams, and installing a prefabricated utility wall between the adjacent floor beams. The first floor panel may be selected from a first plurality of prefabricated floor panels having a same first width. The second floor panel may be selected from a second plurality of prefabricated floor panels having a same second width. The third floor panel may be selected from a third plurality of prefabricated floor panels. Each floor panel in the third plurality of prefabricated floor panels may have a different width. The prefabricated demising wall may be selected from a plurality of prefabricated demising walls. Each demising wall in the plurality of prefabricated demising walls may have a different length. The demising wall may be configured to partition the building unit from an adjacent building unit. The prefabricated utility wall may be selected from a plurality of prefabricated utility walls. Each utility wall in the plurality of prefabricated utility walls may have a different length. The utility wall may be positioned along a terminal side of the building unit.
In some examples, the method may include installing a prefabricated end wall above and along at least one of the adjacent floor beams. The end wall may be selected from a plurality of prefabricated end walls. Each end wall in the plurality of prefabricated end walls may have a different length. The lengths of the prefabricated demising and end walls may vary according to the width of the prefabricated third floor panel.
In some examples, the method may include installing a window wall between the adjacent floor beams along a terminal side of the building unit opposite the prefabricated utility wall.
In some examples, the first floor panel, the second floor panel, and the third floor panel may have the same lengths.
Another example method includes constructing a building from a limited set of prefabricated components, the building having a length and a width. The method may include erecting a structural frame and installing first and second prefabricated floor panels to the structural frame. The structural frame may include first and second rows of columns along the length of the building and a plurality of floor beams coupled to and between the first and second rows of columns such that the plurality of floor beams extend substantially parallel to one another along the width of the building. The first and second prefabricated floor panels may be installed to and between adjacent floor beams of the plurality of floor beams. The first prefabricated floor panel may have a width. The second prefabricated floor panel may be selected from a plurality of prefabricated floor panels, each floor panel in the second plurality of prefabricated floor panels having a different width. The width of the second prefabricated floor panel may be selected such that a sum of the width of the first prefabricated floor panel and the width of the second prefabricated floor panel is less than or equal to a total width of a building unit.
In some examples, the method may include installing a third prefabricated floor panel to and between the adjacent floor beams of the plurality of floor beams, the third prefabricated floor panel having a width. The width of the second prefabricated floor panel may be selected such that the sum of the widths of the first, second, and third prefabricated floor panels corresponds to the total width of the building unit. The width of the third prefabricated floor panel may be equal to the width of the first prefabricated floor panel. The second prefabricated floor panel may be positioned between the first and third prefabricated floor panels.
In some examples, the method may include installing a plurality of prefabricated walls to define one or more building units of the building. Installing a plurality of prefabricated walls may include installing a prefabricated utility wall along a first side of the building unit such that the prefabricated utility wall extends along at least a portion of the length of the building and at least partially defines the envelope of the building. Installing a plurality of prefabricated walls may include installing a prefabricated demising wall along a second side of the building unit such that the prefabricated demising wall extends along at least a portion of the width of the building. The prefabricated demising wall may be configured to partition the building unit from an adjacent building unit. Installing a plurality of prefabricated walls may include installing a window wall opposite the utility wall. Installing a plurality of prefabricated walls may include installing a prefabricated end wall opposite the demising wall, the prefabricated end wall positioned to at least partially define the envelope of the building. Installing a plurality of prefabricated walls may include installing a prefabricated bedroom wall within the interior of the building unit to partition the building unit into a plurality of rooms.
The foregoing summary is illustrative only and is not intended to be in any way limiting. In addition to the illustrative aspects, embodiments, and features described above, further aspects, embodiments, and features will become apparent by reference to the drawings and the following detailed description.
The foregoing and other features of the present disclosure will become more fully apparent from the following description and appended claims, taken in conjunction with the accompanying drawings. Understanding that these drawings depict only several examples in accordance with the disclosure and are, therefore, not to be considered limiting of its scope, the disclosure will be described with additional specificity and detail through use of the accompanying drawings, in which:
all arranged in accordance with at least some embodiments of the present disclosure.
In the following detailed description, reference is made to the accompanying drawings, which form a part hereof. In the drawings, similar symbols typically identify similar components, unless context dictates otherwise. The illustrative examples described in the detailed description, drawings, and claims are not meant to be limiting. Other examples may be utilized, and other changes may be made, without departing from the spirit or scope of the subject matter presented herein. It will be readily understood that the aspects of the present disclosure, as generally described herein, and illustrated in the Figures, can be arranged, substituted, combined, separated, and designed in a wide variety of different configurations, all of which are implicitly contemplated herein.
This disclosure is drawn, inter alia, to methods, systems, products, devices, and/or apparatus generally related to constructing a building from prefabricated components. In some examples, the prefabricated components may be assembled off-site (such as in a shop) and then transported to the building site for constructing a building. At the building site, the prefabricated components may be attached together and/or to a building frame, either directly or indirectly. The building frame may be an external frame. The term external frame, also referred to as external structural frame, will be understood to refer to a structural frame of a building which is arranged generally externally to the envelope of the building. This is, in contrast to other types of structural frames that include vertical and horizontal load bearing members located within the perimeter defined by the building envelope, as is typical in timber construction for example, the external frame is arranged outside the perimeter of the building envelope. As is generally known in the field of structural engineering, the structural frame is the load-resisting or load-bearing system of a building which transfers loads (e.g., vertical and lateral loads) into the foundation of the building trough interconnected structural components (e.g., load bearing members, such as beams, columns, load-bearing walls, etc.).
In some examples of the present disclosure, a building design and construction using prefabricated components is provided. For example, according to various examples described herein, a method of assembling a building unit in accordance with a floor plan of a building using prefabricated components is provided. As described herein, the method includes installing a plurality of prefabricated components to define one or more building units of the building. In this manner, the building may be constructed with improved efficiency and/or reduced cost compared to typical multi-story building construction. For example, the building sequence disclosed herein may remove one or more steps from a conventional building construction process, such as removing the step of pouring/curing concrete walls and floors as is typical in some multi-story building construction.
As one example, the method may include installing a first prefabricated floor panel in a first position of the building unit, installing a second prefabricated floor panel in a second position of the building unit, and installing a third prefabricated floor panel in a third position of the building unit. The first floor panel may be selected from a first plurality of prefabricated floor panels having a same first width. The second floor panel may be selected from a second plurality of prefabricated floor panels having a same second width. The third floor panel may be selected from a third plurality of prefabricated floor panels, the floor panels in the third plurality of prefabricated floor panels having different widths. The third floor panel may be selected such that a sum of the widths of the first, second, and third floor panels corresponds to the total width of the building unit in accordance with the floor plan.
As another example, the method may include installing a first prefabricated floor panel to and between adjacent floor beams, installing a second prefabricated floor panel to and between the adjacent floor beams, installing a third prefabricated floor panel to and between the adjacent floor beams, installing a prefabricated demising wall above and along at least one of the adjacent floor beams, and installing a prefabricated utility wall between the adjacent floor beams. The first floor panel may be selected from a first plurality of prefabricated floor panels having a same first width. The second floor panel may be selected from a second plurality of prefabricated floor panels having a same second width. The third floor panel may be selected from a third plurality of prefabricated floor panels. Each floor panel in the third plurality of prefabricated floor panels may have a different width. The prefabricated demising wall may be selected from a plurality of prefabricated demising walls. Each demising wall in the plurality of prefabricated demising walls may have a different length. The demising wall may be configured to partition the building unit from an adjacent building unit. The prefabricated utility wall may be selected from a plurality of prefabricated utility walls. Each utility wall in the plurality of prefabricated utility walls may have a different length. The utility wall may be positioned along a terminal side of the building unit.
As another example, the method may include erecting a structural frame and installing first and second prefabricated floor panels to the structural frame. The structural frame may include first and second rows of columns along the length of the building and a plurality of floor beams coupled to and between the first and second rows of columns such that the plurality of floor beams extend substantially parallel to one another along the width of the building. The first and second prefabricated floor panels may be installed to and between adjacent floor beams of the plurality of floor beams. The first prefabricated floor panel may have a width. The second prefabricated floor panel may be selected from a plurality of prefabricated floor panels, each floor panel in the second plurality of prefabricated floor panels having a different width. The width of the second prefabricated floor panel may be selected such that a sum of the width of the first prefabricated floor panel and the width of the second prefabricated floor panel is less than or equal to a total width of a building unit.
In referring now to the drawings, repeating units of the same kind or generally fungible kind are designated by the part number and a letter (e.g., 214n), where the letters “a”, “b”, “c” and so on refer to a discrete number of the repeating items. General reference to the part number followed by the letter “n” indicates there is no predetermined or established limit to the number of items intended. The parts are listed as “a-n” referring to starting at “a” and ending at any desired number “n”.
Using prefabricated components 106, the building 100 may be constructed or assembled in reduced time and with a reduced amount of waste when compared to traditional construction methods. For example, in typical multi-story building construction, the various systems of a building may be constructed or assembled in situ, sometimes requiring large or vast storage and staging areas, numerous tools and construction equipment, as well as complicated (and inefficient) inventory and scheduling management. Large amounts of waste are also produced in typical multi-story building construction as each system is assembled or constructed on site. This waste may be detrimental to the construction process, such as increasing building costs and/or cluttering the construction area, which may cause otherwise preventable injuries from trips and falls.
On the other hand, implementing the various examples herein may reduce waste and reduce the time necessary to construct building 100. For example, and without limitation, because the various prefabricated components 106 fit, or are otherwise coupled, together, there is little to no construction waste produced at the jobsite, thereby creating a cleaner (and more efficient) jobsite. The examples of the present disclosure may also require storage and staging areas that are substantially smaller than those of typical multi-story building construction. For example, the prefabricated components 106 may be lifted off of a delivery truck and immediately placed in position without requiring preparation of the components in a staging area. Thus, the examples of the present disclosure may be beneficial for building sites where there is little to no room for storage or staging areas, such as in crowded metropolitan areas.
As shown in
The building units 110 may be standardized and repetitive, or unique and individualized. Mixed units of standard size and shape may be combined with unique units in the same story 104, or in independent arrangement on separate stories 104. Additionally or alternatively, the building units 110 of each story 104 may be repetitive or mixed. For example, each building unit 110 on one story 104 may be identical to one another. In such examples, each building unit 110 on another story 104 may be identical to one another but different from other stories 104. Additionally or alternatively, a story 104 of the building 100 may include multiple building units 110 with a building unit 110 of the story 104 assembled differently than at least another building unit 110 of the same story 104. In one example, the building units 110 on the same end of the building 100 may be assembled identically. In other examples, the building units 110 within the interior of each story 104 may be assembled identically. In some examples, each vertically adjacent building unit 110 may be assembled identically. The foregoing examples are meant to be illustrative only, and the building units 110 of the building 100 may be assembled in accordance with any permutation or combination of configurations.
With continued reference to
The beams 122 may extend between and be attached to adjacent columns 120 to at least partially define a structural framework of the building 100. For example, the structural frame 102 may include first and second rows of columns 124, 126 extending along the length L of the building 100, and a plurality of beams 122 coupled to and between the first and second rows of columns 124, 126 such that the beams 122 extend substantially parallel to one another along the width W of the building 100. For example, a plurality of first floor beams 130 may be installed to and between the columns 120 (e.g., to and between the first and second rows of columns 124, 126) to at least partially define a structural framework for a first story 104A of the building 100. Similarly, a plurality of vertically adjacent beams 122, such as a plurality of second floor beams 132, may be installed to and between the columns 120 (e.g., to and between the first and second rows of columns 124, 126) to at least partially define a structural framework for a vertically adjacent story 104 (e.g., a second story 104B) of the building 100. In like manner, a plurality of third floor beams 134 may be installed to and between the columns 120 (e.g., to and between the first and second rows of columns 124, 126) to at least partially define a structure framework for a third story 104C of the building 100. This framework may be repeated to define a desired number of stories 104 of the building 100, such as up to an nth story 104N of the building 100, as explained below.
The beams 122 may be attached or otherwise coupled to the columns 120 in substantially any suitable manner, such as by welding and/or by bolting the components together. In such examples, various prefabricated components 106 (e.g., prefabricated floors and walls) may be attached or otherwise coupled to the beams 122 and/or to the columns 120. For example, as detailed below, prefabricated floors and walls may be attached or otherwise coupled to the beams 122 and/or to the columns 120 to define the various building units 110 of each story 104 of the building 100.
In some embodiments, the structural frame 102 may include additional structural elements, such as one or more cross braces 128 extending between, such as obliquely to, the columns 120 and the beams 122, to provide additional stiffness to the structural frame 102, such as increasing the lateral stability of the building 100. The structural frame 102 may be configured to provide most, or substantially all, the structural support for the building 100. In some embodiments, the structural frame 102 may provide a desired aesthetic appeal (e.g., architectural design, decoration, etc.) or added support to the building 100.
The various components shown in
Each building unit 110 has a unit width WUnit and a unit length LUnit extending along the building's width W and length L, respectively. In at least one example, a studio residence may have a first length L1, a one-bedroom residence may have a second length L2, and a 2-bedroom residence may have a third length L3. The third length L3 may be greater than the second length L2. The second length L2 may be greater than the first length L1. The unit width WUnit of each building unit 110 may be arranged depending on the particular building arrangement. For example, each building unit 110 on the same story 104 may have the same unit width WUnit. In some examples, each building unit 110 in the building 100 may have the same unit width WUnit.
Depending on the particular application, each story 104 of the building 100 may include building units 110 assembled in accordance with the various floor plans of one or more of the first, second, and third pluralities of building units 140, 142, 144. For example, each story 104 of the building 100 may be assembled to include any combination of studio, one-bedroom, and two-bedroom residences. For example, as shown in
Each floor plan includes a plurality of prefabricated floor panels 150 and a plurality of prefabricated walls 152 (such as any suitable combination of prefabricated demising walls 154, end walls 156, window walls 158, utility walls 160, and bedroom walls 162, as explained below). Each floor plan is designed to provide a desired characteristic of the respective building unit 110. For example, each floor plan may be designed to provide the unit width WUnit, the unit length LUnit, and/or a desired look and feel (e.g., flow) of the building unit 110, among others. The various components and floor plans shown in
As described herein, the prefabricated walls 152 may include walls that partition the building 100 into the various building units 110, walls that partition the interior of each building unit 110 into two or more rooms, walls that include utility components, walls that include window components, walls that define terminal ends of the building 100, and others. Walls that define partitions between building units 110 may be referred to as demising walls (e.g., demising wall 154). Walls that define partitions between rooms within a single building unit 110 may be referred to as bedroom walls (e.g., bedroom wall 162). In a preferred example, the demising and bedroom walls 154, 162 are internal walls positioned within the envelope of the building 100 such that the walls are not exposed to the elements. In similar fashion, walls that include utility components may be referred to as utility walls (e.g., utility wall 160), walls that include window components, such as one or more windows, may be referred to as window walls (e.g., window wall 158), and walls that define the terminal ends of the building 100 may be referred to as end walls (e.g., end wall 156). In such examples, the utility and window walls 160, 158 may define the terminal sides of the building 100. In some examples, the utility walls 160, window walls 158, and/or end walls 156 may be positioned around at least a portion of the perimeter of the building 100 to at least partially define the envelope of the building 100. In some examples, each wall may be prefabricated for a single purpose. For instance, the utility components (e.g., plumbing, sewer, electrical, etc.) of the building 100 may run through only the utility walls 160, the window components of the building 100 may be arranged within only the window walls 158, and so on. As further example, the end walls 156 may be prefabricated to enclose only the opposite ends of the building 100 to define the length L of the building 100. In such examples, the utility walls 160 and the window walls 158 may be prefabricated to enclose the opposite sides of the building 100 to define the building's width W.
The prefabricated floor panels 150 and the prefabricated walls 152 (e.g., the prefabricated demising walls 154, bedroom walls 162, utility walls 160, and/or end walls 156) may be configured to reduce the overall number of separate parts delivered to the jobsite as may be required to construct the floor and wall systems of the building 100. For example, the floor panels 150 include all components or substantially all of the components (e.g., except finished floor surfaces, including the finished floor surfaces, etc.) for a floor system of the building 100. In like manner, the prefabricated walls 152 (e.g. the prefabricated demising walls 154, bedroom walls 162, utility walls 160, and/or end walls 156) may include most or all of the components (e.g., except finished wall surfaces, including finished wall surfaces, etc.) for a wall system of the building 100. According to some examples herein, the floor panels 150 may be sized such that they span a portion or a full length L of a building unit 110, such as a full length between opposite walls of the building unit 110, which in some cases may correspond to the opposite exterior walls of the building 100. In some examples, the floor panels 150 may be sized such that two or more floor panels 150 (e.g., two floor panels 150, three floor panels 150, six floor panels 150, etc.) are joined together to form the floor system of an entire building unit 110 and/or story 104 of the building 100. For example, two or more floor panels 150 may be joined side-to-side to define one of the dimensions of the building unit 110 (e.g., the unit width WUnit) while the other dimension may be defined by the length of one or more floor panels 150 connected on end.
On the other hand, the present disclosure describes prefabricated components and methods for building construction and specifically for constructing a building 100 using prefabricated walls and floor panels, and without the use of onsite floor and wall construction. In one example, floor systems implementing the examples herein may weigh and cost significantly less, such as weighing about 10 lb/ft2 and costing about $10/ft2. In addition, floor systems implementing the examples herein may be significantly faster to construct compared to conventional slab construction. Similar results may be achieved implementing the prefabricated wall systems described herein.
The floor panels 150 may be prefabricated in any suitable manner. As one example,
Each floor panel 150 may take on any suitable shape or configuration. For instance, and without limitation, each floor panel 150 may be quadrilateral in shape and may include opposite ends 182 and opposite sides 184 extending between the opposite ends 190 (see
Each floor panel 150 may be operable to carry loads (e.g., diaphragm loads) to the structural frame 102. For example, to provide structural rigidity and strength to the floor panels 150, the joists 174 may extending between the opposite ends 182 of the floor panel 150 and in spaced arrangement along the width of the floor panel 150 (such as equidistantly spaced between the opposite sides 184 of the floor panel 150). In such embodiments, the joists 174 may define supporting members that span between the opposite ends 182 of the floor panel 150 to support the floor and ceiling layers 176, 178 of the floor panel 150. For instance, each of the floor and ceiling structures 176, 178 of the floor panel 150 may be attached to the joists 174 (e.g., via adhesive, fasteners, or the like). The joists 174 may be arranged generally parallel to one another, such as along the length of the floor panel 150. In some examples, the joists 174 may be spaced at regular intervals along the width of the floor panel 150 (e.g., on 6 inch centers, on 12 inch centers, on 16 inch centers, on 36 inch centers, etc.) to define a joist cavity 186 between adjacent joists 194. In such embodiments, the joist cavities 186 may accommodate plumbing, wiring, HVAC ductwork, or other elements that support dwelling or commercial activities in the building 100. For example, the insulative material 180 may be positioned within the joist cavities 186 to provide a degree of thermal insulation and/or sound deadening quality to the floor panel 150.
Each floor panel 150 may be fabricated using discrete (e.g., separable) pre-manufactured construction elements (e.g., boards, studs, paneling, etc.), which may be fabricated offsite, such as in a factory or other location remote from the construction site. According to the present disclosure, each floor panel 150 is prefabricated (e.g., in a factory) and delivered to the construction site for installation as part of the building 100. Each floor panel 150 may be formed of any suitable material. For example, the frame 170 may be formed from metal, such as aluminum or steel. In some embodiments, the frame 170 may be formed of a non-metallic material, such as wood, plastic, fiber reinforced composites, or other material. In the illustrated example of
The frame 170 may be arranged to suit the particular needs of a building project. For instance, the number of joists 174, the spacing of the joists 174, the length of the joists 174 (which also defines the length of the floor panel 150), and/or the lengths of the opposite ends 182 of the floor panel 150 may be selected based on the load and/or dimensional requirements of the floor panel 150. For example, a higher load requirement may require a greater number of joists 174, and vice-versa. Similarly, a wider floor panel 150 may require a greater number of joists 174, and vice-versa. Accordingly, the specific configuration illustrated in
As shown, each demising wall 154, bedroom wall 162, utility wall 160, and end wall 156 may include a frame 190 operable to carry loads to the structural frame 102, and one or more outer layers 192 attached to the frame 190 to provide a desired aesthetic and/or functional characteristic. For instance, the outer layers 192 may be attached to the frame 190 such that the frame 190 is positioned at least partially between the outer layers 192. In one example, the outer layers 192 of each prefabricated wall 152 may provide an attachment point to which to install various interior and/or exterior finishes of the building 100 (e.g., interior drywall, exterior paneling or siding, etc.). Each prefabricated wall 152 may also include an insulative material 194 (e.g., mineral wool batt insulation) positioned between the outer layers 192, such as within the frame 190. Similar to the floor panels 150, each prefabricated wall 152 may include connection structures configured to couple the walls 152 to the structural frame 102 (such as to the columns 120 and/or to the beams 122) and/or to an adjacent floor panel. As shown in
To aid construction efficiency, in some embodiments, illustrated in
The second plurality of prefabricated floor panels 222 may be configured similarly. Namely, the second plurality of prefabricated floor panels 222 may have a same second width, which may be equal to the first width of the first plurality of prefabricated floor panels 220 depending on the application. As such, the second plurality of prefabricated floor panels 222 may differ from one another only in length such that the second plurality of prefabricated floor panels 222 is considered to have a variable length.
The third plurality of prefabricated floor panels 224 may be configured differently than the first and second pluralities of prefabricated floor panels 220, 222. For example, rather than having the same width, the floor panels in the third plurality of prefabricated floor panels 224 may have different widths. In such embodiments, the third floor panel 206 may be selected such that a sum of the widths of the first, second, and third floor panels 202, 204, 206 corresponds to the total width of the building unit 110 (e.g., the unit width WUnit) in accordance with a floor plan. Depending on the particular application, the widths of the first and second floor panels 202, 204 may be greater than the width of the selected third floor panel 206. In some embodiments, the widths of the first and second pluralities of prefabricated floor panels 220, 222 may be greater than the widths of the third plurality of prefabricated floor panels 224
Like the first and second pluralities of prefabricated floor panels 220, 222, the third plurality of prefabricated floor panels 224 may differ from one another in length such that the third plurality of prefabricated floor panels 224 is considered to have a variable length. In such embodiments, the first, second, and third floor panels 202, 204, 206 may be selected to have the same length (such as the unit length LUnit of the building unit 110). In at least one example, the lengths of the first, second, and third floor panels 202, 204, 206 may be selected to achieve a desired total length of the building unit 110, whether in combination with adjacent floor panels (see
The first, second, and third floor panels 202, 204, 206 are named as such for convenience only. Thus, the second floor panel 204 may be referred to alternatively as the third floor panel 206, and the third floor panel 206 may be referred to alternatively as the second floor panel 204, among others. In such embodiments, the floor system 200A, 200B of the building unit 110 may be assembled by installing first and second prefabricated floor panels (e.g., the first floor panel 202 and the third floor panel 206) in respective positions (see
The first, second, and third floor panels 202, 204, 206 may be installed in any suitable manner. For example, the first, second, and third floor panels 202, 204, 206 may be attached or otherwise coupled to the structural frame 102 (e.g., to the beams 122 of the structural frame 102). According to at least one example of the present disclosure, the first, second, and third floor panels 202, 204, 206 may be installed to and between adjacent beams 122 in a manner to support anticipated loads thereon (e.g., building occupants, furniture, furnishings, etc.). For example, the connection structures of the first, second, and third floor panels 202, 204, 206 may facilitate the ends of the floor panels to be attached or otherwise coupled to adjacent beams 122, such as by welding, bolting, interlocking structural features or other suitable manner.
In accordance with various examples of the present disclosure, the prefabricated walls 152 may be configured to be installed in interchangeable positions or may be configured to be installed in specific locations. For instance, and without limitation, the plurality of prefabricated walls 152 may include one or more prefabricated utility walls (e.g., utility wall 160) arranged to provide utilities (e.g., water, sewer, electrical, etc.) to each building unit 110, one or more prefabricated demising walls (e.g., demising wall 154) arranged to partition each story 104 into two or more building units 110, one or more window walls (e.g., window wall 158) arranged to define a terminal side of each story 104 of the building 100, one or more prefabricated end walls (e.g., end wall 156) arranged to define the terminal ends of each story 104 of the building 100, one or more prefabricated bedroom walls (e.g., bedroom wall 162) arranged to partition a building unit 110 into two or more interior rooms 242, or any combination thereof. In such embodiments, the utility, demising, window, end, and bedroom walls 160, 154, 158, 156, 162 may be installed interchangeably within various building units 110. For example, and without limitation, the demising wall 154 of one building unit 110 may be used interchangeably for the demising wall 154 of another building unit 110. In some embodiments, the utility, demising, window, end, and bedroom walls 160, 154, 158, 156, 162 may be configured to be installed in particular building units 110 in accordance with a floor plan.
As one example, as illustrated in
The plurality of prefabricated demising walls 246, the plurality of prefabricated end walls 248, and the plurality of prefabricated bedroom walls 252 may be configured similarly. In particular, the plurality of prefabricated demising walls 246 may differ from one another only in length such that the plurality of prefabricated demising walls 246 may be considered to have a variable length. In like manner, the plurality of prefabricated end walls 248 may differ from one another only in length such that the plurality of prefabricated end walls 248 may be considered to have a variable length. Similarly, the plurality of prefabricated bedroom walls 252 may differ from one another only in length such that the plurality of prefabricated bedroom walls 252 may be considered to have a variable length. In the embodiments described herein, the lengths of the prefabricated demising, end, and bedroom walls 154, 156, 162 may vary to accommodate the widths of the various building unit floor plans. For instance, one building unit 110 may have a relatively narrower unit width WUnit requiring a relatively shorter demising wall 154, end wall 156, and/or bedroom wall 162. Similarly, another building unit 110 may have a relatively wider unit width WUnit requiring a relatively longer demising wall 154, end wall 156, and/or bedroom wall 162. Because the lengths of the demising walls 154, end walls 156, and bedroom walls 162 may be associated with the unit width WUnit of the building units 110, the lengths of the demising walls 154, end walls 156, and bedroom walls 162 may vary according to the width of the third floor panel 206.
The prefabricated walls 152 may be installed in any suitable manner. For example, and without limitation, the prefabricated walls 152 may be attached or otherwise coupled to the structural frame 102 (e.g., to the beams 122 of the structural frame 102) and/or to the floor system 200A, 200B (e.g., to any combination of the first, second, and third floor panels 202, 204, 206). For example, each demising wall 154 may be installed above and along at least one of the floor beams 122 extending between the first and second rows of columns 124, 126. Similarly, each end wall 156 may be installed adjacent (such as above and along) at least one of the floor beams 122 extending between the first and second rows of columns 124, 126 and along a terminal end of the building 100. Each utility wall 160 may be installed along a length of the building 100 and between adjacent floor beams 122, such as along a terminal side of the building 100. Similarly, each window wall 158 may be installed along a length of the building 100 and between adjacent floor beams 122, such as along a terminal side of the building 100 opposite the utility wall 160. Installing the window wall 158 may include attaching a window along corresponding tracks pre-installed on the prefabricated floor panels. Each bedroom wall 162 may be installed within the interior of the building unit 110 to partition the building unit 110 into a plurality of rooms, such as along a length and/or a width of the first, second, and/or third floor panels 202, 204, 206. In such embodiments, the connection structures of the prefabricated walls 152 may facilitate the prefabricated walls 152 to be easily attached or otherwise coupled to the structural frame 102 and/or to the floor system, such as by welding, bolting, interlocking structural features, or other suitable manner.
Referring to
The method 260 may include additional steps in some examples. For instance, the method 260 may include installing a plurality of prefabricated walls 152 to define one or more interior rooms 242 of the building unit 110 in accordance with the floor plan (see block 268 in phantom). In such examples, block 268 may include installing a prefabricated utility wall 160 along a terminal side of the building unit 110, such as along a length of the building 100. Additionally or alternatively, block 268 may include installing a prefabricated demising wall 154 along a terminal end of the building unit 110 to partition the building unit 110 from an adjacent building unit 110. Additionally or alternatively, block 268 may include installing a window wall 158 along a terminal side of the building unit 110 opposite the utility wall 160. Additionally or alternatively, block 268 may include installing a prefabricated end wall 156 along a terminal end of the building unit 110 opposite the demising wall 154. As explained above, the end wall 156 may be positioned to extend along a terminal end of the building 100. Additionally or alternatively, block 268 may include installing a prefabricated bedroom wall 162 within the interior of the building unit 110 to partition the building unit 110 into a plurality of rooms in accordance with the floor plan.
With continued reference to
The method 280 may include additional steps in some examples. For instance, the method 280 may include installing a prefabricated end wall 156 above and along at least one of the adjacent floor beams 122 (see block 292 in phantom). Like the other prefabricated walls, the end wall 156 may be selected from a plurality of prefabricated end walls 248, each end wall 156 in the plurality of prefabricated end walls 248 having a different length, as explained above. In some embodiments, the method 280 may include installing a window wall 158 between the adjacent floor beams 122 and along a terminal side of the building unit 110 opposite the utility wall(s) 160 (see block 294 in phantom).
The method 300 may include additional steps in some examples. For instance, the method 300 may include installing a third prefabricated floor panel to and between the adjacent floor beams 122, the third floor panel 206 having a width (see block 306 in phantom). In such embodiments, the width of the second floor panel 204 may be selected such that the sum of the widths of the first, second, and third floor panels 202, 204, 206 corresponds to the unit width WUnit of the building unit 110. In some examples, the method 300 includes installing a plurality of prefabricated walls 152 to define one or more building units 110 of the building 100 (see block 308 in phantom). As noted above, the step of installing a plurality of prefabricated walls 152 may include installing a prefabricated utility wall 160, a prefabricated demising wall 154, a prefabricated end wall 156, a prefabricated bedroom wall 162, and/or a window wall 158 in any suitable combination.
The blocks included in the described example methods are for illustration purposes. In some embodiments, the blocks may be performed in a different order. In some embodiments, two or more blocks may be performed concurrently. In other embodiments, the blocks may be performed serially, with subsequent blocks not being performed until all previous blocks are fully completed. In some embodiments, various blocks may be eliminated. In still other embodiments, various blocks may be divided into additional blocks, supplemented with other blocks, or combined together into fewer blocks. Other variations of the illustrative blocks are contemplated, including changes in the order of the blocks, changes in the content of the blocks being split or combined into other blocks, etc. For example, blocks 262, 264, and 266 (as well as blocks 282, 284, and 286; and blocks 288 and 290) may be performed in reverse order or performed concurrently.
The present disclosure is not to be limited in terms of the particular examples described in this application, which are intended as illustrations of various aspects. Many modifications and examples can be made without departing from its spirit and scope, as will be apparent to those skilled in the art. Functionally equivalent methods and apparatuses within the scope of the disclosure, in addition to those enumerated herein, will be apparent to those skilled in the art from the foregoing descriptions. Such modifications and examples are intended to fall within the scope of the appended claims. The present disclosure is to be limited only by the terms of the appended claims, along with the full scope of equivalents to which such claims are entitled. It is to be understood that this disclosure is not limited to particular methods, reagents, compounds compositions or biological systems, which can, of course, vary. It is also to be understood that the terminology used herein is for the purpose of describing particular examples only, and is not intended to be limiting.
With respect to the use of substantially any plural and/or singular terms herein, those having skill in the art can translate from the plural to the singular and/or from the singular to the plural as is appropriate to the context and/or application. The various singular/plural permutations may be expressly set forth herein for sake of clarity.
It will be understood by those within the art that, in general, terms used herein, and especially in the appended claims (e.g., bodies of the appended claims) are generally intended as “open” terms (e.g., the term “including” should be interpreted as “including but not limited to,” the term “having” should be interpreted as “having at least,” the term “includes” should be interpreted as “includes but is not limited to,” etc.).
It will be further understood by those within the art that if a specific number of an introduced claim recitation is intended, such an intent will be explicitly recited in the claim, and in the absence of such recitation no such intent is present. For example, as an aid to understanding, the following appended claims may contain usage of the introductory phrases “at least one” and “one or more” to introduce claim recitations. However, the use of such phrases should not be construed to imply that the introduction of a claim recitation by the indefinite articles “a” or “an” limits any particular claim containing such introduced claim recitation to examples containing only one such recitation, even when the same claim includes the introductory phrases “one or more” or “at least one” and indefinite articles such as “a” or “an” (e.g., “a” and/or “an” should be interpreted to mean “at least one” or “one or more”); the same holds true for the use of definite articles used to introduce claim recitations. In addition, even if a specific number of an introduced claim recitation is explicitly recited, those skilled in the art will recognize that such recitation should be interpreted to mean at least the recited number (e.g., the bare recitation of “two recitations,” without other modifiers, means at least two recitations, or two or more recitations).
Furthermore, in those instances where a convention analogous to “at least one of A, B, and C, etc.” is used, in general such a construction is intended in the sense one having skill in the art would understand the convention (e.g., “a system having at least one of A, B, and C” would include but not be limited to systems that have A alone, B alone, C alone, A and B together, A and C together, B and C together, and/or A, B, and C together, etc.). In those instances where a convention analogous to “at least one of A, B, or C, etc.” is used, in general such a construction is intended in the sense one having skill in the art would understand the convention (e.g., “a system having at least one of A, B, or C” would include but not be limited to systems that have A alone, B alone, C alone, A and B together, A and C together, B and C together, and/or A, B, and C together, etc.). It will be further understood by those within the art that virtually any disjunctive word and/or phrase presenting two or more alternative terms, whether in the description, claims, or drawings, should be understood to contemplate the possibilities of including one of the terms, either of the terms, or both terms. For example, the phrase “A or B” will be understood to include the possibilities of “A” or “B” or “A and B.”
In addition, where features or aspects of the disclosure are described in terms of Markush groups, those skilled in the art will recognize that the disclosure is also thereby described in terms of any individual member or subgroup of members of the Markush group.
As will be understood by one skilled in the art, for any and all purposes, such as in terms of providing a written description, all ranges disclosed herein also encompass any and all possible subranges and combinations of subranges thereof. Any listed range can be easily recognized as sufficiently describing and enabling the same range being broken down into at least equal halves, thirds, quarters, fifths, tenths, etc. As a non-limiting example, each range discussed herein can be readily broken down into a lower third, middle third and upper third, etc. As will also be understood by one skilled in the art all language such as “up to,” “at least,” “greater than,” “less than,” and the like include the number recited and refer to ranges which can be subsequently broken down into subranges as discussed above. Finally, as will be understood by one skilled in the art, a range includes each individual member. Thus, for example, a group having 1-3 items refers to groups having 1, 2, or 3 items. Similarly, a group having 1-5 items refers to groups having 1, 2, 3, 4, or 5 items, and so forth.
The herein described subject matter sometimes illustrates different components contained within, or connected with, different other components. It is to be understood that such depicted architectures are merely examples, and that in fact many other architectures can be implemented which achieve the same functionality. In a conceptual sense, any arrangement of components to achieve the same functionality is effectively “associated” such that the desired functionality is achieved. Hence, any two components herein combined to achieve a particular functionality can be seen as “associated with” each other such that the desired functionality is achieved, irrespective of architectures or intermedial components. Likewise, any two components so associated can also be viewed as being “operably connected”, or “operably coupled”, to each other to achieve the desired functionality, and any two components capable of being so associated can also be viewed as being “operably couplable”, to each other to achieve the desired functionality. Specific examples of operably couplable include but are not limited to physically mateable and/or physically interacting components and/or wirelessly interactable and/or wirelessly interacting components and/or logically interacting and/or logically interactable components.
While various aspects and examples have been disclosed herein, other aspects and examples will be apparent to those skilled in the art. The various aspects and examples disclosed herein are for purposes of illustration and are not intended to be limiting, with the true scope and spirit being indicated by the following claims.
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