The present disclosure relates to modular platforms.
In areas where there is pedestrian and vehicular traffic, particularly in publicly-accessible areas, it is common to have specific pedestrian pathways, such as walkways. Such walkways might include sidewalks, pedestrian or vehicular bridges, pedestrian and vehicle ramps, paved walkways through parks, patios, floor surfaces, balconies and the like. Such pedestrian walkways exist in public transit facilities (e.g., subway stations), light rapid transit, bus rapid transit, railway stations, and other locations where there is pedestrian traffic. In many types of pedestrian walkways, there is a requirement for pedestrians to be able to safely navigate such walkways and to remain on the walkways, especially where public transit vehicles are passing closely by. This is particularly important for mass transit platforms near, for example, subways, buses, or trains where there is a need for safe pedestrian walkways.
Besides specific pathways for pedestrians, there can be a need for pedestrians to be able to maintain good traction on pedestrian walkways in order to prevent slips and falls, particularly on outdoor surfaces that can be subject to inclement weather such as wind, rain, snow, or ice.
Additionally, it may be important for pedestrians to be able to determine the presence of platform edges so that the pedestrians do not accidentally walk off the edge of a platform, especially if a vehicle might be passing by. This may be especially important in mass transit situations, and particularly for subways or commuter trains, where the side of the subway or train is right at the edge of the platform. The need for making the presence of platform edges easy to determine may be of particular importance when making such facilities accessible and safe for blind or visually impaired persons.
Conventional concrete and wooden transit platforms may have a durability problem due to degradation by environmental chemicals such as salt, urea, acid rain, oils, and greases as well as stray electrical currents. This necessitates regular maintenance and periodic replacement of the platforms at considerable cost and service disruption to transit authorities. Steel and concrete are also susceptible to corrosive elements, such as water, salt water, and agents present in the environment like acid rain, road salts, or chemicals. Environmental exposure of concrete structures leads to pitting and spalling in concrete and thereby results in severe cracking and a significant decrease in strength in the concrete structure. Steel is likewise susceptible to corrosion, such as rust, by chemical attack. The rusting of steel weakens the steel, transferring tensile load to the concrete, thereby cracking the structure. The rusting of steel in standalone applications requires ongoing maintenance, and after a period of time corrosion can result in failure of the structure. The planned life of steel structures is likewise reduced by rust. Wood has been another long-time building material for bridges and other structures. Wood, like concrete and steel, is also susceptible to environmental attack, especially by rot from weather and termites. In such environments, wood encounters a drastic reduction in strength which compromises the integrity of the structure. Moreover, wood undergoes accelerated deterioration in structures in marine environments, and is susceptible to fire damage.
Concrete structures are typically constructed with the concrete poured in situ as well as using some preformed components pre-cast into structural components (e.g., supports) and transported to the site of the construction. Constructing such concrete structures in situ requires hauling building materials and heavy equipment and pouring and casting the components on site. This process often requires the use of cranes, which can be costly and difficult to use in the case of nearby overhead wires. The weight of concrete structures also increase the necessary foundational requirements, which can increase cost, complexity and time of construction. Consequently, this process of construction involves lengthy construction times and is generally costly, time consuming, subject to delay due to weather and environmental conditions, and disruptive to existing traffic patterns.
Pre-cast concrete structural components are extremely heavy and bulky. Therefore, these are typically costly and difficult to transport to the site of construction due in part to their bulkiness and heavy weight. Although construction time is shortened as compared to poured in situ, extensive time, with resulting delays, is still a factor. Construction with such pre-cast forms is particularly difficult, if not impossible, in areas with difficult access or where the working area is severely restricted due to adjoining tracks, buildings, or platforms. In typical pre-cast concrete construction, tolerances of plus or minus one-quarter inch or more are common, making precise installation and alignment difficult. Pre-cast components may also require the addition of a topping surface to create a finished, level surface.
There is a need for a lightweight structure to facilitate installation in areas with difficult access and/or restricted working areas. In addition, a lightweight structure eliminates the costly concrete foundations and steel support systems necessary to support conventional concrete platforms.
Therefore, an improved modular assembly, such as for a transit platform, is needed.
The present disclosure provides for a modular assembly. The modular assembly can include a plurality of base members made of a plastic material, each base member including a top surface and a bottom surface opposite of the top surface, the bottom surface defining channels. A plurality of support members can be provided, each of the plurality of support members may extend across the plurality of base members and disposed within the channels of the plurality of base members. A mounting bracket can be configured to mount each of the plurality of support members to a metal plate of a lower support structure, the metal plate being received by a clamp of the mounting bracket. Each of the plurality of base members can adjoin one another to form a horizontal platform for traffic.
The present disclosure also provides for a method of installing a modular assembly. A plurality of base members made of a plastic composite material can be provided. Each base member may include a top surface and a bottom surface opposite of the top surface. The bottom surface can define channels. A plurality of support members can be provided. Each of the plurality of support members can extend across the plurality of base members and be disposed within the channels of the plurality of base members. A metal plate of a lower support structure can be clamped to the plurality of support members with a mounting bracket to form a horizontal platform for traffic.
The lower support structure can be formed by drilling a plurality of helical piles into soil. The plurality of helical piles can be cut to a desired height. Respective lower support surfaces of adjustable leveling mechanisms can be welded to each of the plurality of helical piles. Respective upper support surfaces of each of the adjustable leveling mechanisms can be fastened to an I-beam. The metal plate of the lower support structure can be formed from an upper flange of the I-beam
A plurality of fasteners can extend between the upper support surface and the lower support surface. A vertical height of each of the adjustable leveling mechanisms can adjust by moving a support element along the plurality of fasteners. The support element can support the upper support surface and/or the lower support surface. The upper support surface and the lower support surface can also include a plurality of elongated apertures that receive the plurality of fasteners. The plurality of fasteners can be laterally slidable along the apertures to adjust a horizontal position of the upper support surface relative to the lower support surface.
For a fuller understanding of the nature and objects of the disclosure, reference should be made to the following detailed description taken in conjunction with the accompanying drawings, in which:
Although claimed subject matter will be described in terms of certain embodiments, other embodiments, including embodiments that do not provide all of the benefits and features set forth herein, are also within the scope of this disclosure. Various structural, process step, and electronic changes may be made without departing from the scope of the disclosure.
A modular assembly for decks, panels, platforms, boardwalks, floors, and the like is provided. The modular assembly is mounted on supporting members. In particular, the modular assembly may be used with a transit platform, such as at a train, subway, or bus station.
The modular assembly disclosed herein is easier to assemble than a concrete platform. Compared to existing systems, the modular assembly is preformed, easy to install, and easy to remove or replace. The modular assembly can be assembled or replaced quickly, which minimizes disruptions. Assembly or replacement can be easily performed even in areas with difficult access and/or restricted working areas. The modular assembly may be made of a lightweight, strong, and durable material, such as a composite material.
Furthermore, safety is improved using the modular assembly disclosed herein. In many types of pedestrian walkways, there is a requirement for pedestrians to be able to safely navigate such walkways and to remain on the walkways, especially where public transit vehicles are passing nearby. This may be particularly important for mass transit platforms in public transit facilities. The modular assembly disclosed herein can provide warnings proximate the edges, slip-resistant surfaces, and/or heating systems to melt frost, snow and ice. The modular assembly may also include, or entirely comprise, photoluminescent materials to provide information to pedestrians and/or vehicle operators. For example, exit, safety, warning, and/or related indicators can be included in the surface of the assembly for the purposes of conveying information. Accidents, such as slips and falls, can be prevented and tactile wayfinding can be incorporated.
While illustrated as approximately rectangular, the base members 101 can be square, polygonal, or other shapes. In one specific embodiment, each base member 101 can have a 2 foot by 4 foot surface and a height of 7 inches.
The base members 101 may be lightweight and water-resistant. In some embodiments the base members 101 can be made of a composite, polymer plastic material, vinyl, rubber, urethane, ceramic, glass reinforced plastic, concrete, or similar materials.
The base member 101 may provide drainage due to their materials or shape. For example, the top surface of the base member 101 may be angled or the base member 101 may include drainage channels or drain pipes that extend through the base member 101.
The base members 101 can be resistant to salt, urea, acid rain, oils, greases, stray electrical currents, or other environment factors. Unlike wood, the base members 101 can be impervious to rot or termites.
The base members 101 each include two channels 106. Each of the support members 105 are configured to be disposed in one of the channels 106. The support members 105 may be made of a metal, such as a steel or aluminum. The support members 105 can also be made of a non-metal material, such as a composite material, like fiberglass. In alternative embodiments, the surface panel 112 can be formed of a non-composite material such as a tile, concrete, or the like. The support members 105 may be a tube, beam, or other structural element. The support members 105 may be fastened to the base members 101, such as using bolts or screws.
Besides or in conjunction with fasteners, the support members 105 may be clamped to the base members 101 using a mounting bracket or a clamping mechanism. In an example, the support member 105 is an I-beam and the base member 101 is provided with Z clip mounting bracket. The Z clip mounting bracket may be fabricated of stainless steel to resist corrosion.
A wiring raceway 109 is positioned on the support members 105. The wiring raceway 109 can include wires for a heating assembly in the base member 101, electrical lighting wiring, communications wiring, or other wiring.
Piles can be used to anchor the structures into the ground and support the structure above the ground. In one embodiment, conventional foundation piles can be used, where a precast concrete pile or steel beam is driven into a soil bed. In other embodiments, a screw pile may be used to produce a deep foundation that can be installed quickly with minimal noise and vibration. For example, screw piles may be efficiently wound into the ground. This can provide for an efficient means of installation and coupled with their mechanism of dispersing load, may provide effective in-ground performance in a range of soils, including earthquake zones with liquefaction potential. Using this technique, the structures may be above a body of water. The ground may also include artificial supporting fillers, such as concrete. Such structures include buildings, bridges, ramps, decks, panels, platforms, and boardwalks.
Piles can also be installed by pre-drilling a hole in a soil bed using an auger and lowering a pre-molded pile into the hole. A hybrid system also exists between the driving and drilling methods whereby an open ended pile is driven into a soil bed, after which point the soil inside the pile is augured out and concrete is poured in the cavity formed therein. Cast-and-hole methods as well as caissons may also be used, specifically where there are concerns for preserving nearby buildings against the problems discussed above. A pile also can be attached to a drill head which is substantially larger than the diameter of the pile itself. The pile is turned together with the drill head by a drilling rig to create a passage in the soil bed through which the pile may pass. A conduit is provided through the center of the pile for water or grout to be pumped down and out the tip of the drill head to either float away debris or anchor the pile in its final resting place in the soil bed.
The base member 101 can include a coating that is configured to seal the heater assembly 108 between the deck module 107 and the surface panel 112. This can prevent moisture from impairing operation of the heater assembly 108. The coating may be continuous around the entire base member 101 where the deck module 107 and surface panel 112 meet. Seals or other devices also can be used to prevent the impact of moisture.
In an embodiment, the heater assembly 108 is in direct contact with the surface panel 112 to maximize heat transfer. In another embodiment, an adhesive or filler between the heater assembly 108 and the surface panel 112 is used to provide improved heat transfer.
The deck module 107 may be configured to direct heat toward the surface panel 112. This will preferentially direct heat from the heater assembly 108 toward the surface panel 112. A reflective surface and/or insulation may be used to direct heat away from the deck module 107.
In a particular embodiment, pre-molded insulation or foamed insulation can fill the open spaces of the base member 101, such as between the various internal cross support members of the deck module 107 or in other locations. The insulation precludes heat from the heater assembly 108 from escaping downwardly through the base member 101, thereby allowing for more efficient heating of the surface panel 112. The insulation can be either a low density type of foam or a high density type of foam (e.g., a structural foam) to provide additional structural support. Furthermore, a ceramic layer, can be placed between the surface panel 112 and the deck module 107.
The surface panel 112 on top of the base member 101 may be made a suitable material such as a composite, polymer plastic material, vinyl, rubber, urethane, ceramic, glass reinforced plastic, concrete, or similar materials. The surface panel 112 may include visual indicators or designs (e.g. arrows, warnings, symbols, etc.), and/or graphics (text, logos, advertisements, etc.) thereon. The surface panel 112 may also include or be made of a luminescent material.
The surface panel 112 on top of the base member 101 may include any suitable polymer plastic material or fiber glass type material, and can includes a heat conductive polymer material and/or a heat retentive polymer material. The surface panel 112 may also include a fire retardant. The surface panel 112 may be made according to known composite manufacturing methods, such as being made as a sheet molded compound (SMC), bulk molding composite (BMC), wet compression molding, injection molding, or the like. The heat conductive polymer material allows for quick conduction of heat from the heater assembly 108 through the surface panel 112 and to the exposed surface of the surface panel 112 to permit quick melting of snow and ice. The heat retentive polymer material can retain heat within the heater assembly 108 once the electrical power to the heater assembly 108 has been turned off, thereby allowing for a longer cycle time until electrical power needs to be applied again to retain sufficient heat to melt snow and ice. It is also possible to include small stones, or the like, in the polymer material in order to preclude wearing of the surface panel 112. It should be noted that small stones, aluminum oxide, silica sand, or the like, cannot be included if the surface panel 112 is formed via a compression molding method. It should also be noted that fillers such as the heat conductive polymer material and the heat retentive polymer material may degrade the UV resistance of the resin used to form the surface panel 112. Accordingly, a UV resistant coating can be sprayed on top of the surface panel 112.
A slip-resistant coating may be added to the surface panel 112. The slip resistant coating can be of a non-slip monolithic walking surface. The slip-resistant coating can be resistant to the effects of ultraviolet radiation, temperature changes, and/or corrosive elements such as acids, alkalis, salts, phosphates, organic chemicals, and solvents such as mineral spirits, or gasoline. It also may be sufficiently hard to protect against abrasion, chipping, scratching, or marring. Alternatively, or additionally, an additional structure may be attached to the surface panel, or serve as the surface panel. For example, a concrete layer (e.g. paver) or tile (e.g. porcelain) can be added to the surface panel 112.
Selective heating of the individual base members 101 is possible. For example, base members 101 under a roof may not be heated as much as those not under a roof that may be exposed to snow. In a modular assembly 100, some base members 101 may be heated (sequentially or simultaneously) while other base members 101 are not heated. Selective heating of the base members 101 can also be performed based on one or more sensors embedded within and/or attached to the assembly. Alternatively or additionally, one or more sensors may be located remote from the assembly 100 for the purposes of making a determination to selectively heat base members 100. For example, the one or more sensors can include moisture, temperature, wind, pressure, or the like. Based on information from the one or more sensors (e.g. a determination of snow, ice, or similar precipitation), a controller can be used to automatically heat one or more of the base members 101. This can save on heating costs or can focus heating on areas prone to snow or ice.
Selective heating of the modular assembly 100 also is possible. The timing, duration, and extent of heating can vary for a particular modular assembly 100 placement or design.
Selective heating may use a controller in electrical communication with one or more heater assemblies 108. The controller can be configured to activate, deactivate, and/or change heat settings for individual heaters in the structure assembly 100. The controller can be activated and monitored remotely by Wi-Fi internet communications or cellular network.
The base members 101 can include interlocking mechanisms to fix adjoining base members 101. In one example, the interlocking mechanisms can be tongue and groove designs or other designs. For example, as seen in
Interlocking mechanisms, such as using one or more tongue and grooves on an edge of a base member 101, can be configured to enable a modular assembly 100 with a surface that includes a non-constant grade. For example, the modular assembly 100 of
Parts of the base members 101 can be made by a compression molding process or method, such as sheet molded compound (SMC) or wet compression molding. Parts of the base members 101 also can be made by pultrusion, hand lay-up, or other suitable methods including resin transfer molding (RTM), vacuum curing and filament winding, automated layup methods, or other methods.
Embodiments of the modular assembly disclosed herein can be assembled in the field or prefabricated. A prefabricated modular assembly may the provided with multiple base members attached to a support member. Thus, a prefabricated base member unit may be provided.
A leveling mechanism 125 can be provided to account for differences in height between the lower support structure (e.g. helical pile) and the support members 105 and/or I-beam. In one example, the leveling mechanism 125 is a threaded connection element of a bearing plate, which allows for in-field adjustment of the height of the helical pile.
As shown in
The leveling mechanism 125 may be used to accommodate spatial differences between the lower support structure 126 (e.g. helical pile) and the support members 105 and/or I-beam. For example, the leveling mechanism 125 may be used to accommodate spatial differences across the longitudinal axis X, lateral axis Y, and/or vertical axis Z. The leveling mechanism 125 may also be used to accommodate rotational differences (e.g. yaw) between the lower support structure 126 and the support members 105. This can be particularly advantageous for situations where the lower support structure 126 cannot precisely be positioned to an acceptable level of accuracy. For example, piles (e.g. a helical pile) can quickly and efficiently produce a lower support structure 126, but positional accuracy of the piles can be difficult to ensure in the field. The leveling mechanisms 125 described herein can accommodate for spatial inaccuracies in an efficient manner. For example, the leveling mechanisms 125 can be adjusted quickly and easily on-site, without the need for more costly or difficult assembly procedures.
The I-beam 148 can be fastened via fasteners 147 to the upper support surface 142 of a leveling mechanism 125. The leveling mechanism can include a lower support surface 143 fixed (e.g. via welding) to a lower support structure 126. The lower support structure can include a pile, such a 4″ in diameter pier.
Variations in design are possible due to the flexibility and relative low cost of tooling used in the manufacturing process. Panel size, length, width, thickness, color, ribbing, and surface profiles can be modified to suit specific project requirements. Drainage details also can be modified to suit specific project requirements.
The embodiments of the modular assembly disclosed herein can solve the problem of durability and premature breakdown of concrete and wood platforms due to degradation. The light weight of the modular assembly facilitates ease of installation in areas which have difficult access and work windows. The modular assembly also solves the problem of dealing with heavy concrete platforms which necessitate the use of costly foundations and steel support systems. These benefits apply to both new and retrofit construction requirements. Reduced maintenance and long life cycles are achieved. The modular assembly can be assembled faster than prior art platforms, and can avoid or significantly reduce welding of component parts.
Although the present disclosure has been described with respect to one or more particular embodiments, it will be understood that other embodiments of the present disclosure may be made without departing from the spirit and scope of the present disclosure.
This application claims priority to U.S. Provisional Application No. 62/503,574, filed on May 9, 2017, the entire disclosure of which is incorporated herein by reference.
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Number | Date | Country | |
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20180327979 A1 | Nov 2018 | US |
Number | Date | Country | |
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62503574 | May 2017 | US |