The present invention generally relates to the construction methods for multi-floor buildings and specifically to a multi-floor building construction system and method for progressively constructing floors on a foundation as the occupational need to do so arises while allowing previously constructed floors to be occupied.
Construction projects of multi-floor and tall buildings are becoming more and more important in terms of number of floors, number of employees involved in their construction, the financing requirements and the impact such projects have on the urban life of the project neighborhood.
Many construction projects are completed in regions where weather conditions have a direct impact on workers productivity and security. The contractors also need to respect codes and standards for environment, safety and ergonomics that apply with increasing rigor. The traditional construction method poses real challenges when it comes to vertical transportation of the materials and workers. Working high on open structures, using tower cranes and boom lifts handling materials up in the air represent a major source of incidents, injuries and even death of employees on a regular basis. Tower cranes also represent significant cost charges for taller buildings. Furthermore, the control of an open work environment is complex and difficult to maintain.
A fair amount of construction projects for multi-floor buildings are held by a lack of sufficient financing or a lower leasing ratio than expected. Those constraints are even more important and regular during difficult economical times where the initial leasing ratio target often increases in order to reduce the risk associated with long term financing. Other projects highly desirable on a long term time scale are impossible to realize with the conventional method because of the impact they would have in high density urban area or other specific area very sensible to the impacts of such projects. The current construction methods are not flexible and very sensitive to changes and unpredictable situations that may arise during the project, sometimes affecting very badly the project profitability. The owners and contractors have no flexibility on schedule and project scale when it comes to adapting to a sudden specific situation. So far, construction projects methods only allowed occupancy after substantial completion of the construction, which delays significantly the revenues and affects the project financial balance. The investments are so important for taller buildings that only a very small group of selected contractors and owners can consider such projects. Even with the best planning, large construction projects still represent important risks for those responsible for their completion.
The system of the present invention includes a permanent roof structure equipped with multiple means for vertical displacement, such as extensible load support means, secured in said permanent roof structure. The multiple extensible load support means are synchronized and controlled to allow the permanent roof structure to be lifted in order to create a secure and protected construction zone, under the permanent roof structure, for at least one additional occupational floor to be built. The permanent roof structure can be lifted to create new construction zone as lower floors are completed and occupational need to do so arises. In order to provide the construction zone with the required materials, components, tools and workers, one or multiple means of vertical transportation and material handling, such as dedicated high capacity freight elevators are also part of the system. Such material handling means will allow construction to occur without affecting occupants of the building, its surroundings and its neighborhood and will avoid public space occupancy that typically occurs during conventional building construction. Vertical transportation of occupants is achieved with dedicated extensible elevators having the suspension and electric cables accumulated and available for future extension.
To secure the construction zone, the permanent roof structure is equipped with a wall enclosure system. The wall enclosure shields the construction zone on its entire perimeter, eliminating losses due to inclement weather conditions and protecting workers and neighborhood from the risks associated with the conventional method of construction. The disclosed construction system also incorporates adaptations to the elevators, and the mechanical and electrical systems of the building to allow their extensions when adding occupational floors without affecting services to the completed occupational floors below the construction area and to provide continuous services to the permanent roof structure and to workers in the construction zone.
The permanent roof structure is also equipped with adjustable hoisting means, such as manually installed hooks, that will allow workers to hook and locate the construction material and components sub-assembly they are completing at the most ergonomic and comfortable height, variable for any tasks of the assembly. For example, the sub-assembly of all the horizontally oriented conduits and components for plumbing, electrical, fire protection and other systems are completed at optimal ergonomic and productive heights. When electrical and mechanical horizontal conduits are assembled, the extensible load support means lift the permanent roof structure and the hooked construction sub-assembly to allow the installation of a temporary or permanent load supporting means for the construction sub-assembly. This allows to pour concrete, when applicable, fabricate the interior divisions, install vertically oriented construction materials and connect the resulting vertical sub-assembly to the horizontal construction sub-assembly above which will lead to the completion of the construction of the new occupational floor. For concrete constructions, the extensible load support means are retracted back in the permanent roof structure before the concrete is poured. The construction sub-assembly can be supported by temporary load support means that are also used as concrete forms to pour concrete. The temporary load supporting forms are equipped with a top interface that is capable of supporting the construction sub-assembly and provide the next attachment points for the base of the extensible load support means. The extensible load support means retracts inside the temporary load supporting forms and are re-attached on the top portion of the temporary load supporting forms using interface elements. An alternate location of the extensible load support means could be offset from the permanent load supporting means of the building when the building structure is designed accordingly.
The system and method of the present invention provides several features and advantages such as providing more flexibility in the construction project management by offering the possibility to add floors as the occupational need to do so arises, within a given pre-determined number of floors range. It also reduces the initial financing requirement by allowing to lease the first lower floors as soon as they are completed without waiting for the complete building to be constructed and therefore preempt revenues much sooner in the project cash flow.
The present invention also increases flexibility in the project management by allowing more work to be done in factory and by offering the possibility to sub-divide the work schedule into smaller work lots and therefore increase the competitiveness of subcontractors offer. It also facilitates the human resources management for contractors by leveling the work load, reducing the amount of interruptions, reducing overtime and giving the possibility to work on multiple smaller projects simultaneously instead of only a few very large projects and be impacted by their variable schedules.
The invention further improves health and safety conditions and the quality of the craftsmanship by improving the work environment, independent from outside weather conditions, by providing much better ergonomics at work and by reducing the use of high risk equipment such as tower cranes, boom lifts, ladders and scaffoldings.
The invention also increases the productivity by allowing to complete the structural work of a new floor while standing on the floor and then locate the construction sub-assembly at the desired height for best ergonomic position during the balance of the assembly work.
The invention further reduces or eliminate inconveniences that large urban construction sites impose by concentrating and optimizing trucks unloading, material storage and material vertical transportation inside the building or a controlled area, and therefore allowing to restore building neighborhood much more quicker than for projects with conventional methods and to reduce charges for public occupancy. It also increases post-construction building efficiency for renovation projects, client relocation, or any other situation in the building life that requires efficient vertical material handling and isolation of construction area.
According to a broad aspect of the present invention there is provided a multi-floor building construction system for progressively constructing floors on load-bearing means of a foundation as the occupational need to do so arises and while sub-floors can be occupied. The system comprises a permanent roof structure of any desired architectural shape displaceably supported over an uppermost floor of at least an upper one of one or more occupational first floor space constructed over the foundation. Extensible load support means is secured in the roof structure and adapted to rest upon and push against the uppermost floor to support a total load of the permanent roof structure. Means is provided to operate the extensible load support means in synchronization to elevate the permanent roof structure to create a construction zone over the uppermost floor of the building structure where an occupational floor space is to be constructed under the permanent roof structure with the permanent roof structure held elevated from the uppermost floor by the extensible load support means. Means is also provided to transport construction materials within dedicated and enclosed spaces isolated from the occupational floor spaces. Occupant services providing means is adapted to the further occupational floor space and integrated with existing occupational floor spaces.
According to a further broad aspect of the present invention there is provided a method of constructing a multi-floor building progressively, floor-by-floor, by adding floors above an uppermost occupational space as the need to do so arises and while sub-floors can be occupied. The method comprises the steps of providing a load-bearing floor with load-bearing means. A permanent roof structure is constructed over the load-bearing floor. Extensible load support means is secured in the permanent roof structure and aligned to rest upon or in close proximity to at least some of the load-bearing means to support a total load of the permanent roof structure. The extensible load support means is adapted to be operated in synchronization. The permanent roof structure is lifted a predetermined distance above an upper occupational floor space to create a construction zone above the occupational floor space to construct one or more additional occupational floor spaces as the need to do so arises. Material is provided to the construction zone with at least one vertical transportation means displaceable in a dedicated enclosure isolated from the occupational floor space. Occupant services are provided to the one or more additional occupational floor spaces and integrated with existing occupational floor spaces.
The method further comprises at least one extensible occupants elevator being extended as the demand to do so arises using the extensible load support means or another lifting means to locate the mechanisms of the elevator and release suspension and electric cables to accommodate the new extended stroke or travel.
According to a still further broad aspect of the present invention there is provided a business method of constructing a multi-floor building comprising constructing a permanent roof structure over a foundation and elevating the permanent roof structure a predetermined distance over an occupational floor space thereunder as the occupational need to do so arises upon the pre-sale of at least portions of a further occupational floor space to obtain the financing to construct the further occupational floor space. The permanent roof structure remaining on the multi-floor building when completed.
A preferred embodiment of the present invention will now be described with reference to the accompanying drawings in which:
Vertically Displaceable Permanent Roof Structure
Referring now to the drawings, the present invention will be described. A permanent roof structure 1 is first assembled on a foundation 48 for the building construction. The shape of the foundation 48 needs to be similar to the shape desired for the floors to build in the future. The permanent roof structure 1 can have any shape, as long as it extends equal to or greater than the desired shape of the floor to build in the future.
The permanent roof structure 1 includes a structure 5 similar to those of conventional roof assemblies. The permanent roof structure 1 is moveable vertically using extensible load support means 6 that are motorized, synchronized and controlled. In order to add a floor when the occupational need to do so arises, the permanent roof structure 1 is raised to create a construction zone 3 under the permanent roof structure for at least one additional floor. Examples of extensible load support means 6 are shown in
The extensible load support means 6 are normally supported on an interface element 11 that sits directly on the last floor constructed or can even be embedded in the concrete slab and remain there permanently. For concrete structures, the interface elements 11 have sufficient openings that allow concrete to flow through to fill the temporary load support forms 35 with the re-bars 51 inside. The interface elements 11 are specifically designed for each project and also incorporate vibration dampers (not shown) to reduce vibration transmission from the driving mechanism of the permanent roof structure 1 into the building structure and reduce noise, if required, to the occupied floors thereunder.
The permanent roof structure 1 is equipped with electrical power, lighting, heating, compressed air, and fresh water supply and has multiple outlets as required in any construction site. These services to the permanent roof structure 1 are permanently connected to the building services through valves, flexible conduits and cable trays.
Control System and Electrical Power
The control system of the permanent roof structure 1 includes at least one control panel 10 housing a programmable logic control element and electrical control relays where all the safety interlocks and operation interface are connected to control the operation of the permanent roof structure 1. The control panel 10 is located at any safe and convenient location and can be wired with extensible cables (not shown) or through a cable tray (not shown) if required. The electrical brake-motors are connected to power disconnect junction boxes (not shown). Permanent junction boxes (not shown) are located on the last floor 34 in any required location to allow electrical connections and continuity. An interface panel (not shown) is provided to the operator to communicate any fault during the operation. The permanent roof structure 1 also incorporates all the safety devices required for a safe operation (visual warnings, audible warnings, interference detectors, stroke limit switches . . . ) (not shown).
Adjustable Hoisting Means
The permanent roof structure 1 is equipped with adjustable hoisting means 13 as shown in
When beginning the construction, a new construction sub-assembly 44 is assembled on the foundation 48, or the last floor constructed 34. The construction sub-assembly 44 incorporates all the construction materials and components of a typical building floor, without the vertical elements. The adjustable hoisting means 13 purpose is first to hook the construction sub-assembly 44 to the permanent roof structure 1 in order to synchronize the vertical movement of the construction sub-assembly 44 to the extensible load support means of the permanent roof structure 1. Second, the purpose of the adjustable hoisting means 13 is to act as a bumper to support the permanent roof structure 1 onto the construction sub-assembly 44, when the construction sub-assembly 44 sits on last floor 34, during the time that the extensible load support means 6 are retracted into the permanent roof structure 1 to be reattached on the top portion of the temporary load supporting forms 35.
The adjustable hoisting means 13 comprise adjustment means 15 and 16 to adapt to normal construction variations. The end 17 is attached to the construction sub-assembly 44 with a positive fixation method, such as bolts and safety pins, not allowing separation if impacted by an interfering object. The length of the adjustable hoisting means 13 is specific to each application.
The adjustable hoisting means 13 allow the workers to adjust the height of the construction sub-assembly 44, as it is desired, at any stage of the construction work, using the extensible load support means 6 of the permanent roof structure 1. This allows the workers to work at the best ergonomic and most productive heights during the construction work, for example when assembling horizontal conduits of plumbing, ventilation conduits, and electrical wires. It also allows the operator of the permanent roof structure 1 to lift, once completed, the construction sub-assembly 44 to a pre-determined height to allow the installation of the permanent building columns or temporary load supporting forms 35 when building a concrete building structure.
Guiding Device
The permanent roof structure 1 must remain aligned and stable during vertical movement using a guiding device. The guiding device is a novel arrangement of some of the already known guiding elements such as scissors (not shown), lambdas 12 (see
The guiding device purpose is to counteract any external lateral forces that could potentially move the permanent roof structure 1 laterally if it was unguided. Such lateral forces include wind, seismic forces and others. When there is no construction work, the permanent roof structure 1 is attached to the building through positive fixation and the permanent roof structure 1 sits directly on the interface elements 11 that are then used as bumpers and anchor blocks.
Wall Enclosure
As shown in
The permanent retractable wall enclosure 18 can be self motorized or anchored on the last floor 34 and extend or retract following the movement of the permanent roof structure 1 driven by the extensible load support means 6. The permanent retractable wall enclosure comprises a wall either constructed with articulated rigid panels, such as shown in
The temporary wall enclosure as shown in
High Capacity Vertical Transportation Means
One or multiple high capacity vertical transportation means, such as a permanent dedicated high capacity freight elevator 24, internal or peripheral to the building, are accessible from the first basement or ground level and allow construction material and components to be transported efficiently to the construction zone 3. The building is equipped with an access ramp 39 that trucks 43 use to unload merchandises, materials and components at a dock 42 or a transfer deck 69 equipped with handling equipment such as a dock lift 41, jib cranes and other equipment. Materials and components are transported to a permanent high capacity freight elevator access 40 using standard material handling equipment such as forklift trucks (not shown).
The high capacity vertical transportation means,
As shown in
When adding a floor to the building, the effective stroke of the permanent vertical transportation mean 24 needs to be adjusted by adapting the control system such as changing a register in the program of the programmable logic controller (not shown), by extending the guide rails (not shown), by relocating the travel limit switches (not shown). To extend cables, it is possible to secure the cage 24 to the building structure 38 with pins or bumpers (not shown). The extra cable required has to be already available on an accumulation drum 26 (see
The high capacity vertical transportation means can be permanent, temporary, internal or peripheral to the building. An example of a concept for a temporary high capacity transportation means is shown in
The permanent roof structure 1 is equipped with a covered opening 2 offering sufficient clearance for the vertical movement required during the construction without interfering with the building structure 38.
The permanent vertical transportation mean 24 is also used post-construction to move occupant's goods or during renovation projects while a temporary system is removed once the construction is completed.
Construction and Extension of the Building Structure
The new construction system and method described here works well with conventional steel construction method having lightly adapted components and standard connections. The structural components are transported using the permanent vertical transportation mean 24 and material handling equipment, standard or specialized (not shown). The new construction system and method hereby can also use a specific column design where the column is made of at least two components assembled around the extensible load support mean 6. Finally, the new construction system and method works well with hybrid or concrete building structures where temporary load supporting forms 35 are used to support the construction sub-assembly 44 while the extensible load support mean 6 are retracted to be reattached on top of an open interface element 11 that allows concrete to flow through.
For buildings with hybrid or concrete structures, the re-bars 51 installation is complete around the extensible load support mean 6 without preventing it to be retracted further in the construction. The temporary load supporting forms 35 are circumscribing the re-bars assembly 51 sub-assembly with the specified clearance. Since the re-bars 51 and the interface elements 11 extend above the concrete surface, it is possible to have continuity in the concrete structure from bottom to top. The extensible load support means 6 are retracted back in the permanent roof structure 1 before the concrete is poured. The construction sub-assembly 44 is supported by the temporary load support means 35 that are also used as concrete forms to pour concrete. The temporary load supporting forms 35 are equipped with a top interface, herein a top support cap 35′, that is capable of supporting the construction sub-assembly 44 and provide the next attachment points for the base of the extensible load support means 6. The extensible load support means 6 retract inside the temporary load supporting forms 35 and are reattached on the top portion of the temporary load supporting forms 35.
Because of the light construction of the permanent roof structure 1, the extensible load support means 6 do not require to be positioned exactly in-line with the load bearing columns of the foundation 48 or the building best support points, unlike other known methods. The extensible load support means 6 are located either in-line with some identified supporting element 37 of the foundation 48 or close to the foundation 48 supporting element 37 or any point capable of supporting the extensible load support means 6 and total load that the extensible load support means 6 are supporting.
Extension of the Electrical and Communication Systems
Additional connectors, junction boxes and panels are installed to allow connection of new occupational floors to the existing electrical system. New cables can run all the way to the main panel in some cases and shielded bars are extended when adding a floor as the occupational need to do so arises. The access for electrical connections is set up on the last floor 34, ready for the next construction phase. A floor main disconnect is already installed on the last floor 34 and is closed once the electrical work has been completed in the construction zone 3 and the construction sub-assembly 44.
Extension of Main Conduits for Plumbing, Fire Protection, Ventilation . . .
The main conduits for water, fire protection, ventilation and sanitary drains typically reduce in size from floor to floor as it goes up in the building. The main conduits of the first floor, for example, must be designed adequately for the future needs and be able to sustain the demand when the number of floors increases. The main conduits are extended using extra sections of conduits. The ends of the conduits are equipped with valves, quick connecting devices, sealing caps or removable covers. Valves are necessary to allow the connection of a new network on a pressurized conduit without disturbing the operation of the existing portion. It is possible, when required, to elaborate a double network of conduits, temporary or permanent, in order to avoid service interruption to the occupied floors 4 under the construction zone 3.
Extension of the Occupants Elevator Shafts and Stroke
The occupants elevator drives and the mechanical room for elevators can be located in the basement, in the elevator shaft or above the elevators, on a frame similar to the frame 23 shown in
When extending the building as the occupational need to do so arises, the sequence and method for extending the elevator shaft 38, the guide rails, the cables, the relocation of the travel limit switches and all other components requiring to be extended follow the same principle than the one applicable for the permanent vertical transportation mean 24.
When adding a floor to the building, the effective stroke of the occupants elevators needs to be adjusted by adapting the control system such as changing a register in the program of the programmable logic controller (not shown), by extending the guide rails (not shown), by relocating the travel limit switches (not shown). To extend cables, it is possible to secure the cage 24 to the building structure 38 with pins or bumpers (not shown). The extra cable required has to be already available on an accumulation drum that is normally locked, but is released during the operation of lifting the occupants elevator drive mechanism. While the drive mechanism, or mechanical room, of the elevators is lifted by the extensible load support means 6 of the permanent roof structure 1, the accumulation drum releases the amount of cable required for the elevator cage additional stroke. From the beginning of the construction, the accumulation drum needs to store the cable required for the maximum stroke the elevator cage will ever do, otherwise the cable will need to be changed in the course of the construction.
For traction type drives, the extensible occupants elevator comprises a traction disk or pulley 59, a synchronization drum 58 used only during extension, a cable holding means 57, a cable accumulation means 56, a governor device 60 with its specific governor accumulation means 61, a passenger cabin 63 and a counterweight 62. All the drive components can be mounted on a displaceable frame 23 such as shown in
A similar procedure can be used for an elevator pit drive as shown in
Extension of Stairs
The stairs wells and the elevator shaft always extend higher than the last floor constructed 34. Both are extended as floors are added. The stairs provide access to the last floor constructed 34 and the permanent vertical transportation mean 24 can access the last floor constructed 34 as well in order to start the construction of the next floor as occupational need to do so arises.
Location of the Building Systems Machinery
The description disclosed hereby assumes that the building heating, air conditioning, water treatment and other units are installed mostly at the lower and intermediate levels. If the units are installed on the permanent roof structure 1, the lifting capacity of the extensible load support mean 6 and the driving means 9 are modified accordingly and further adaptation will be required to the conduits network to avoid service interruptions to the occupied floors.
Example of Construction Process Possible with the New Construction System
Each subsequent floor construction typically starts at step 9 of the above construction process.
The construction process can also be adapted to specific project or building requirements. For example, a divided permanent roof structure 1 as shown in
The Table below lists the differences between the features of the disclosed construction system and method of the present invention versus the existing or traditional method of construction.
It is within the ambit of the present invention to cover any obvious modifications of the preferred embodiment descried herein provided such modifications fall within the scope of he appended claims.
The present application is a National Phase of International application No. PCT/CA2010/000161, filed Feb. 5, 2010, which claims priority on U.S. provisional patent application no. 61/150,813 filed on Feb. 9, 2009.
Filing Document | Filing Date | Country | Kind | 371c Date |
---|---|---|---|---|
PCT/CA2010/000161 | 2/5/2010 | WO | 00 | 8/4/2011 |
Publishing Document | Publishing Date | Country | Kind |
---|---|---|---|
WO2010/088771 | 8/12/2010 | WO | A |
Number | Name | Date | Kind |
---|---|---|---|
2160446 | Stalfort | May 1939 | A |
3036816 | Stubbs et al. | May 1962 | A |
3579935 | Regan et al. | May 1971 | A |
3692446 | Vanderklaauw | Sep 1972 | A |
3726053 | Filipek et al. | Apr 1973 | A |
3828513 | Vanderklaauw | Aug 1974 | A |
3974618 | Cortina | Aug 1976 | A |
4301630 | Burkland | Nov 1981 | A |
4691485 | Nagy et al. | Sep 1987 | A |
4832315 | Vanderklaauw | May 1989 | A |
4980999 | Terenzoni | Jan 1991 | A |
5088263 | Horii et al. | Feb 1992 | A |
5327690 | Saito | Jul 1994 | A |
5371993 | Saito | Dec 1994 | A |
5417018 | Matsumoto et al. | May 1995 | A |
5528877 | Franklin | Jun 1996 | A |
5575591 | Vanderklaauw | Nov 1996 | A |
5839239 | Jang | Nov 1998 | A |
5970680 | Powers | Oct 1999 | A |
6082058 | Deng | Jul 2000 | A |
6260311 | Vladikovic | Jul 2001 | B1 |
6379085 | Vanderklaauw | Apr 2002 | B1 |
7818942 | Nakamitsu et al. | Oct 2010 | B2 |
20030136062 | Gunthardt | Jul 2003 | A1 |
Number | Date | Country |
---|---|---|
2632884 | Jun 2007 | CA |
Entry |
---|
PCT—International Search Report. |
Number | Date | Country | |
---|---|---|---|
20110289862 A1 | Dec 2011 | US |
Number | Date | Country | |
---|---|---|---|
61150813 | Feb 2009 | US |