Patent Application
20230383523
Conventional construction is typically 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.
Traditional building construction continues to be more and more expensive and more and more complex. Changing codes, changing environments, and new technology have all made the construction of a building more complex than it was 10 or more years ago. In addition, trade labor availability is being reduced significantly. As more and more craftsmen retire, fewer and fewer younger workers may be choosing the construction industry as a career, leaving the construction industry largely lacking in skilled and able men and women to do the growing amount of construction work.
The construction industry is increasingly using modular construction techniques to improve efficiency. Modular construction techniques may include pre-manufacturing complete volumetric units (e.g., a stackable module) or one or more building components, such as wall panels, floor panels, and/or ceiling panels, offsite (e.g., in a factory or manufacturing facility), delivering the pre-manufactured modules or components to a building construction site, and assembling the pre-manufactured modules or components at the building construction site.
While modular construction techniques provide certain advantages over traditional construction techniques, challenges continue to exist in being able meet housing and other building demands in communities. For example, the construction industry, whether using modular construction techniques or traditional construction techniques, needs to be able to address issues such as reducing construction costs and construction waste, reducing time-to-build, providing building designs that efficiently use space, and other challenges brought on by increasing demands for affordable housing and other building needs.
Implementations of this application relate to a floor-ceiling corridor panel that may be used in construction of a building or edifice. Various aspects are disclosed herein.
In one aspect, pre-manufactured floor-ceiling corridor panel for a multi-story building having load bearing walls is disclosed. The floor-ceiling corridor panel can comprise: a plurality of parallel metal studs; an end member affixed to an end of the studs; a peripheral angle at least partially surrounding the floor-ceiling corridor panel and having a horizontal section and a vertical section, wherein the horizontal section of the peripheral angle is configured to be placed on top of a corridor support member of a utility wall of the building, and wherein the vertical section of the peripheral angle is affixed to the end member; wherein the horizontal section of the peripheral angle is formed with first holes for alignment with second holes formed in the corridor support members.
In some implementations, the pre-manufactured floor-ceiling corridor panel further comprising a plurality of ceiling layers affixed to transverse edges of the plurality of metal studs.
In some implementations, the plurality of ceiling layers comprises at least two layers of board material and at least one layer of sheet metal, and wherein one layer of the at least to layers of board material form a corridor ceiling.
In some implementations, the pre-manufactured floor-ceiling corridor panel further comprising a plurality of floor layers affixed to transverse edges of the plurality of metal studs.
In some implementations, the plurality of floor layers comprises at least two layers of board material, at least one layer of foam, and at least one layer of sheet metal.
In some implementations, one layer of the at least two layers of board material form a corridor floor.
In some implementations, the at least one layer of foam is at least two-inches thick and formed of high-density foam material.
In some implementations, the end member and peripheral angle define an interior of the floor-ceiling corridor panel, and wherein sheet metal further defining the interior of the floor-ceiling corridor panel is configured to receive, disperse, and absorb drag forces transmitted in a direction of the plurality of parallel metal studs and received from an adjacent horizontal diaphragm.
In some implementations, the adjacent horizontal diaphragm is formed within an interior of a pre-manufactured floor-ceiling panel having a floor surface, a ceiling surface, and a longitudinal edge arranged perpendicular to the end member of the pre-manufactured floor-ceiling corridor panel.
In some implementations, the adjacent horizontal diaphragm comprises at least one drag anchor welded therein and configured to transmit force through internal members of an adjacent load bearing wall and toward the peripheral angle.
In some implementations, the peripheral angle is formed of at least ¼ inch thick hot rolled steel.
In some implementations, the peripheral angle is configured to mate and fixedly attach to a corner linking brace panel at distal ends of the pre-manufactured floor-ceiling corridor panel.
In some implementations, the corner linking brace panel comprises at least two lengths of hollow structural steel welded to a transverse angle of steel.
In some implementations, the corner linking brace panel further comprises another length of hollow structural steel welded to distal ends of the at least two lengths of hollow structural steel.
In another aspect, a multi-story building is disclosed. The building can comprise: one or more levels formed from prefabricated interior panels, prefabricated exterior panels, and prefabricated floor-ceiling panels, the one or more levels being substantially parallel to a ground plane defined by a foundation; and a floor-ceiling corridor panel arranged adjacent to at least one of the prefabricated exterior panels, the floor-ceiling corridor panel comprising: a plurality of parallel metal studs; an end member affixed to distal ends of the plurality of parallel metal studs; a peripheral angle at least partially surrounding the floor-ceiling corridor panel and having a horizontal section and a vertical section, wherein the horizontal section of the peripheral angle is configured to be placed on top of a corridor support member of a utility wall of the building, and wherein the vertical section of the peripheral angle is affixed to the end member; wherein the horizontal section of the peripheral angle is formed with first holes for alignment with second holes formed in the corridor support members.
In some implementations, the floor-ceiling corridor panel further comprises a plurality of ceiling layers affixed to transverse edges of the plurality of metal studs.
In some implementations, the plurality of ceiling layers comprises at least two layers of board material and at least one layer of sheet metal, and wherein one layer of the at least to layers of board material form a corridor ceiling.
In some implementations, the floor-ceiling corridor panel further comprises a plurality of floor layers affixed to transverse edges of the plurality of metal studs, and wherein the plurality of floor layers comprises at least two layers of board material, at least one layer of foam, and at least one layer of sheet metal.
In some implementations, the end member and peripheral angle define an interior of the floor-ceiling corridor panel, and wherein sheet metal further defining the interior of the floor-ceiling corridor panel is configured to receive, disperse, and absorb drag forces transmitted in a direction of the plurality of parallel metal studs and received from an adjacent horizontal diaphragm.
In some implementations, the adjacent horizontal diaphragm is formed within an interior of at least one of the prefabricated interior panels, wherein the at least one of the prefabricated interior panels having a floor surface, a ceiling surface, and a longitudinal edge arranged perpendicular to the end member of the pre-manufactured floor-ceiling corridor panel.
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 embodiments described in the detailed description, drawings, and claims are not meant to be limiting. Other embodiments may be utilized, and other changes may be made, without departing from the spirit or scope of the subject matter presented herein. 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 contemplated herein.
As used herein, the term “longitudinal” refers to a relative direction, generally in the direction of a major length of a component; however, longitudinal may refer to any length if the component is square. As used herein, the term “transverse” refers to a relative direction that is substantially orthogonal to a longitudinal reference direction; however, lateral may refer to any direction that crosses a longitudinal direction in some examples where oblique members are arranged proximal longitudinal members. It should be readily understood that as both terms “longitudinal” and “lateral” are relative to a frame of reference, they may be used interchangeably depending upon a particular frame of reference, depending upon a desired final placement, and/or depending upon a specific context in which the two terms are used.
This disclosure is drawn, inter alia, to methods, systems, products, devices, and/or apparatuses generally related to pre-manufactured floor-ceiling corridor panels that may be used in multi-story buildings having load bearing walls and other building parts (e.g., stair and elevator modules, podium level steel transfer structures, etc.), such as a low-rise or mid-rise building. The floor-ceiling corridor panels are structural in that they are able to absorb and/or transfer lateral and/or vertical loads, for example, from a horizontal diaphragm and/or other structural components of a multi-story building.
Traditionally, buildings are constructed using a metallic (e.g., steel, aluminum, etc.) structural frame that is designed to resist vertical and lateral loads. Thus, the structural frame can be thought of as a skeletal structure of a multi-story building, wherein the structural frame provides structural support for the building by absorbing vertical loads due to the weight of multiple stories and lateral loads such as due to wind or earthquakes, as well as providing the framing for various walls, floors, ceilings, and other components that can be affixed to the structural frame during the course of constructing the building. However, manufacturing and assembling such a traditional and extensive structural frame can be time consuming and costly in terms of labor and material. For instance, an affordable housing crisis or other community needs may dictate that buildings with good structural integrity be built quickly and economically.
Therefore, various embodiments disclosed herein provide structural components to construct a building, for example, load bearing walls and other building parts such that the reliance upon a traditional structural frame can be reduced or eliminated, while at the same time enabling the building to meet lateral and vertical loading requirements. The load bearing walls can be pre-manufactured demising walls, end walls, shear walls, or other vertical walls, at least some of which are constructed and arranged so as to provide the structural support for the building in a manner that is sufficient to enable the building to handle vertical and lateral loads. The other building parts, such as floor panels and corridor panels and their accompanying components, in combination with the load bearing walls and coupling linkages between them, also enhance the structural integrity for the building (e.g., for handling or transferring loads), improve acoustical performance, and increase fire safety.
The building may be a multi-story low-rise building or a multi-story mid-rise building in some embodiments. Each story of the building can include a single unit or multiple units. For instance, a particular unit may be living space, office space, retail space, storage space, or other human-occupied space or otherwise usable space in the building. In the context of living space, as an example, each story of the building may include multiple units to respectively accommodate multiple tenants.
The use of the pre-manufactured load bearing walls and other pre-manufactured parts enables the building to be constructed with a shorter time-to-build and at a lower cost (relative to a building that is constructed using a traditional structural frame), and without sacrificing the structural integrity of the building. Moreover, the floor-ceiling panels of the building may be made thinner relative to conventional floor-ceiling panels, thereby enabling the building to have more stories per vertical foot compared to a traditional building. Thus, the building is able to provide more usable space (e.g., living space) as opposed to a traditional building that occupies the same footprint. In other cases, the thinner floor-ceiling panels provide more space between the floor and ceiling of each unit, which may be desirable for some occupants that prefer living spaces with “high ceilings.”
In some embodiments, the material composition of an entire module, as well as the wall, ceiling, and floor panels, may include steel. In some embodiments, the material composition may include aluminum. In still other embodiments, the wall, ceiling, and floor panels may be made from a variety of building suitable materials ranging from metals and/or metal alloys, composite materials, glass mat, gypsum, fiber cement, magnesium oxide, to wood and wood polymer composites (WPC), wood based products (lignin), other organic building materials (bamboo) to organic polymers (plastics), to hybrid materials, earthen materials such as ceramics, or any other suitable materials or combinations thereof. In some embodiments, cement, grout, or other pourable or moldable building materials may also be used. In other embodiments, any combination of suitable building material may be combined by using one building material for some elements of the entire module, as well as the wall, ceiling and floor panels, and other building materials for other elements of the entire module, as well as the wall, ceiling, and floor panels. Selection of any material may be made from a reference of material options (such as those provided for in the International Building Code), or selected based on the knowledge of those of ordinary skill in the art when determining load bearing requirements for the structures to be built. Larger and/or taller structures may have greater physical strength requirements than smaller and/or shorter buildings. Adjustments in building materials to accommodate size of structure, load, and environmental stresses can determine optimal economical choices of building materials used for components in an entire module, as well as the wall, ceiling, and floor panels described herein. Availability of various building materials in different parts of the world may also affect selection of materials for building the system described herein. Adoption of the International Building Code or similar code may also affect choice of materials.
Any reference herein to “metal” includes any construction grade metals or metal alloys as may be suitable for fabrication and/or construction of the entire module, as well as wall, ceiling, and floor panels, and/or other components thereof described herein. Any reference to “wood” includes wood, wood laminated products, wood pressed products, wood polymer composites (WPCs), bamboo or bamboo related products, lignin products and any plant derived product, whether chemically treated, refined, processed or simply harvested from a plant. Any reference herein to “concrete” or “grout” includes any construction grade curable composite that includes cement, water, and a granular aggregate. Granular aggregates may include sand, gravel, polymers, ash and/or other minerals.
The building 10 may be a multi-story building with one or more units (e.g., living, office, or other spaces) in each story. In the example of
The ground floor level L1 may contain living spaces, office spaces, retail spaces, storage spaces parking, storage, common areas (such as a lobby), etc. or combination thereof. Levels L2-L6 may also contain living spaces, office spaces, retail spaces, storage spaces, common areas, etc. or combination thereof. Such spaces may be defined by discrete units, separated from each other and from corridors or common areas by interior demising walls and utility walls (not shown in
Each end of the building 10 includes an end wall 12. One or more panels that make up the end wall 12 may span a single story in height, or may span multiple stories (e.g., two or more stories) in height. Any of the sides of the building 10 may include a window wall 14 that accommodates a window 16, such as window(s) for unit(s). One or more panels that make up the window wall 14 may span a single story in height. Some parts of the building 10 may include an end wall without windows (e.g., not a window wall), such as an end wall 18, which may be comprised of a panel that spans one story of the building 10.
The unit(s) in each story may be formed using either an entire pre-manufactured module or from one or more pre-manufactured floor-ceiling panels and wall panels (not shown in
The sides of interior walls that face the interior space (e.g., living space) of the building 10 may be covered by a finish panel, such as wall paneling, for decorative and/or functional purposes. Analogously, the sides of floor-ceiling panels that face the interior space (e.g., living space) of the building 10 may also be covered with laminate flooring, finish panels, tile, painted/textured sheetrock, etc. for decorative and/or functional purposes. For exterior walls such as end walls and window walls, the sides of these walls facing the outside environment may be covered with waterproofing membranes, tiles, glass, or other material for decorative and/or functional purposes.
According to various implementations, the building 10 is constructed using load bearing walls (such as demising walls, end walls, etc.). In this manner, such walls are able to support vertical loads, as well as lateral loads. Because these walls are load bearing components, the building 10 can eliminate or reduce the use of an extensive steel structural frame in at least some of the levels. For instance, a steel structural frame (e.g., made of an array of beams and columns to which each and every floor-ceiling panel and wall are directly attached) may be absent in levels L2-L6. A steel structural frame may be used in level L1 and/or further structural reinforcement may be given to load bearing walls that are used in level L1 alternatively or in addition to a structural frame, so as to provide structural integrity at ground level.
The building 10, having six levels L1-L6, is defined in some jurisdictions as a mid-rise building (e.g., buildings having five to 12 levels). Buildings having four levels and under are defined in some jurisdictions as a low-rise building. The various embodiments of the load bearing walls described herein may be used in low-rise and mid-rise buildings. Such low-rise and mid-rise buildings may have various fire ratings, with a 2-hour fire rating for mid-rise buildings of six stories or more and a 1-hour fire rating for buildings of five stories or less being examples for some of the buildings that use the load bearing walls described herein.
In some embodiments, the load bearing walls and other building parts described herein (in the absence of a structural frame, or with a reduced amount thereof) may be used for buildings that have a greater number of stories than a typical low-rise or mid-rise building. In such embodiments, the load bearing walls and/or other building parts described herein may be implemented with additional and/or modified structural components, so as to account for the increased load associated with the greater number of stories.
For purposes of example and illustration, some buildings described herein will have a generally rectangular footprint, and will be assumed to be a low-rise building having at most five stories (levels), and it is understood that the various implementations described herein may be used for buildings with other numbers of stories. The features disclosed herein may be adapted to construct buildings having other shapes, sizes, heights, configurations, number of stories, etc., or any other building where load bearing walls and the other building parts described herein are used in the absence of extensive structural frames on at least some stories. In some embodiments, the various operations of a construction sequence may be performed in a different order, omitted, supplemented with other operations, modified, combined, performed in parallel, etc., relative to what is shown and described herein.
Generally, construction of mid-rise buildings may include a podium level foundation created on-site, through skilled labor including welding, riveting, and other joining, as well as through complex construction and surveying techniques, including complex structural framing built on-site prior to traditionally constructing units into this traditional structural framing.
In some embodiments, the load bearing walls and other building parts described herein (in the absence of a structural frame, or with a reduced amount thereof) may be used for buildings that have a greater number of stories than a typical low-rise or mid-rise building. In such embodiments, the load bearing walls and/or other building parts described herein may be implemented with additional and/or modified structural components, so as to account for the increased load associated with the greater number of stories.
To describe a construction sequence to arrive at the partially constructed building 20 in
Next in the construction sequence, pre-manufactured stair and elevator modules 30 and 31 may be built on the foundation 24, and positioned such that the elevator portions of the modules 30 and 31 that will contain the elevator shaft are superimposed over the elevator pit(s) 28. The modules 30 and 31 according to various embodiments may be two stories in height, and there may be one or more of these modules per building, with two modules 30 and 31 shown by way of example in
Each of the modules 30 and 31 may be comprised of vertical columns made of steel, and horizontal beams spanning between the columns and also made of steel. Thus, the columns and the beams form a structural frame.
The modules 30 and 31 of various embodiments are positioned at specific locations of the foundation 24, depending upon any desired implementation of a final building. In the example of
Next in the construction sequence, braced frames are installed on the foundation 24 in relation to the modules 30 and 31. For example, braced frames 32 and 34 are arranged perpendicularly around and in close proximity to the module 30, such that the module 30 is nested by the braced frames 32 and 34. With respect to the module 31, braced frames 36 and 38 are also arranged perpendicularly but spaced away from the module 31 by a greater distance.
The braced frames 32-38 may be arranged on the foundation 24 in any suitable location and orientation, dependent on factors such as the footprint or configuration of the building 20, source of lateral and/or vertical loads, location/orientation for optimal stabilization, etc. Any suitable number of braced frames may be provided at the ground level. The braced frames may further vary in configuration. The example of
According to various embodiments, the modules 30 and 31 are used as erection aids that guide the positioning and orientation of the braced frames 32-38. For instance, the modules 30 and 31 are installed first, and then the braced frames 32-38 are arranged relative to the location of the modules 30 and 31. The braced frames may be directly welded (or otherwise attached/connected) to the modules, or may be linked to the module(s) over a distance via linking beams or other structural framing. In this manner, the modules 30 and 31 stabilize the braced frames 32-38, and the braced frames 32-38 can operate to also absorb vertical and lateral loads from the building 20 and/or transfer such load(s) to the modules 30 and 31 via their linking connections.
The next phase of the construction sequence involves the erection of a steel transfer structure 40 (e.g., a podium structure) at ground level. The steel transfer structure 40 comprises a steel frame that receives and transfers load to the foundation 24. The steel transfer structure 40 may have vertical members 42 (columns) having a height that spans one story, girders 44 that join pairs of columns 42, and beams 46 that perpendicularly join pairs of girders 44.
After completion of the steel transfer structure 40, the next phase of the construction sequence involves the placement/installation of the floor-ceiling panels 22 over consecutive beams 46, and more specifically, hanging the floor-ceiling panels 22 onto the beams 46. A floor deck comprised of floor-ceiling panels 22 thus results after such installation.
Afterwards, load bearing walls 50 (e.g., demising and end walls) are installed by being positioned over the beams 46, and utility walls 52 are then installed by being hung onto the load bearing walls 50.
Next, corner linking brace panels (see
According to the examples depicted in
For example, during construction, floor-ceiling panels 104 are installed as described above. Thereafter, load bearing wall panels 106 (e.g., interior demising walls and/or exterior end walls) are installed. Subsequently, the utility wall panels 108 are installed. Having the anticipated corridor defined by this installation, the corner linking brace panel 103 may then be installed. Although not illustrated here in
Accordingly, floor-ceiling corridor panels 102 may be “hung” or placed onto the support members of both the utility walls 108 and the corner linking brace panel 103. The floor-ceiling corridor panels 102 are supported on the support members through angle members 110. Additional support members 114 may also be arranged to at least partially support the angle members 110. The additional support members 114 are also referred to as “corridor beams,” “corridor linking beams,” and/or “corridor composite beams” herein, depending upon the context of a particular installation.
The angle members 110 at least partially surround the periphery of each floor-ceiling corridor panel 102, and have several through holes 112 defined there-through. These angle members 110 abut directly against the support members and fasteners (e.g., self-tapping or thread-forming bolts and/or other fasteners) are placed to fixedly attach and support the floor-ceiling corridor panels.
Additionally, each utility wall 108 may include a corridor support member 181 defined along a longitudinal axis thereof. The corridor support member 181 may be formed of metal, such as hollow structural steel (HSS) of other stock. The corridor support member 181 may include threaded holes, captive fasteners, or fastener holes defined thereon arranged to match fastener holes 112.
Following hanging of the floor-ceiling corridor panels 102, fasteners may be passed through each angle member 110, through holes 112, and into a respective corridor support member 161 and/or 181. Furthermore, fasteners may be passed through each angle member 110, through holes 112, and into additional support members 114. In this manner, each corridor panel 102 may be fixedly attached to the adjacent building components thereby forming a useable, safe, and efficient corridor. This corridor, and subsequent corridors formed above/below, may at least temporarily function to allow construction crews access about the building 20 for construction and finishing purposes.
Furthermore, drag forces, shear forces, and/or loads may be distributed throughout the partially constructed building and into the fixedly attached floor-ceiling corridor panels 102. For example,
As will become apparent throughout the description of the remaining figures, drag anchors in unison with the internal structure of the floor-ceiling corridor panels 102, as well as intervening elements, provide a relatively sturdy manner in which forces can be transmitted and absorbed, and function to stabilize the building, in addition to increasing fire safety and other technical benefits. Hereinafter, a more detailed discussion of the structure of each floor-ceiling corridor panel 102 is provided.
The floor-ceiling corridor panel 102 may include a first layer of board 202 and a second layer of board 204 affixed onto the first layer of board 202. The first layer of board 202 and the second layer of board 204 may comprise gypsum board, glass fiber mat gypsum board, or any suitable board material. The first layer of board 202 and the second layer of board 204 may generally extend the full length and width of the floor-ceiling corridor panel 102.
The floor-ceiling corridor panel 102 may also comprise a first sheet metal layer 206 affixed onto the second layer of board 204. The sheet metal layer 206 may be formed of relatively light gauge material. In one implementation, the sheet metal layer 206 is a 22-gauge steel sheet. The sheet metal layer 206 may generally extend the full length and width of the floor-ceiling corridor panel 102.
The floor-ceiling corridor panel 102 may further comprise a plurality of metal studs 208 that are arranged transversely across portions of the sheet metal layer 206. Each stud of the metal studs 208 may be spaced approximately 16-inches from one another, in some implementations. Furthermore, each stud of the metal studs 208 may be formed of c-channel steel, or another steel stock.
The floor-ceiling corridor panel 102 further comprises a second sheet metal layer 210 affixed onto the plurality of metal studs 208. The sheet metal layer 210 may be formed of relatively light gauge material. In one implementation, the sheet metal layer 210 is a 22-gauge steel sheet. The sheet metal layer 210 may generally extend the full length and width of the floor-ceiling corridor panel 102.
According to one implementation, sheet metal screws are used to attach both of the first sheet metal layer 206 and the second sheet metal layer 210 to the plurality of metal studs 208. In some implementations, at least one of the first sheet metal layer 206 and the second sheet metal layer 210 are at least partially welded to one or more of the plurality of metal studs 208. In some implementations, a combination of fasteners and welding may be used to attach sheet metal layers to the plurality of metal studs 208.
The floor-ceiling corridor panel 102 further comprises a third layer of board 212 affixed onto the second sheet metal layer 210. The floor-ceiling corridor panel 102 may also include a layer of foam 214 affixed onto the third layer of board. Additionally, the floor-ceiling corridor panel 102 may further include a fourth layer of board 216 affixed onto the layer of foam 214. The third layer of board 212 and the fourth layer of board 216 may comprise fiber cement board, medium density overlay (MDO) board, Magnesium oxide (MgO) board, or any suitable board material. The third layer of board 212 and the fourth layer of board 216 may generally extend the full length and width of the floor-ceiling corridor panel 102. The layer of foam 214 may comprise a 2-inch thick layer of high density foam or polystyrene, in some implementations.
Further defining the interior 200 of the floor-ceiling corridor panel 102, longitudinal metal tracks 218 may extend the length of the floor-ceiling corridor panel 102 (see
Somewhat similarly, transverse end studs 208′ may be arranged at either distal end of the floor-ceiling corridor panel 102 (see
As briefly described above, each floor-ceiling corridor panel 102 may be surrounded by angle 110 and fixedly attached to corridor support members 181 of adjacent utility wall panels 108.
In one implementation, the cantilever boxes 182 are attached to the internal support members 184 with fasteners 183. However, welded connections are also applicable. The particular number of cantilever boxes 182 may be based upon an overall design of an associated building 20. Additionally, although described as “boxes,” L-brackets and/or other bracket designs may be used alternatively or in combination with the illustrated boxes.
As forces are applied to the utility wall panel 108 from, for example, edifices 40 or other portions of the building 20, the internal support members 184 transfer these forces across the cantilever boxes 182, into the longitudinal corridor support members 181, and further into the interior 200 of the floor-ceiling corridor panel 102. Additionally, forces may be transmitted in the longitudinal direction along the corridor support members 181 and interconnections there-between. Forces are transferred to sheet steel layers top and bottom of studs via connection to 218 and 110.
As described above, installation of the floor-ceiling corridor panel 102 into a portion of an anticipated corridor requires, at least, installation of one or more utility wall panels 108, load bearing walls 106, and or additional support members 114. Each floor-ceiling corridor panel 102 may hang on associated support members and be fixedly attached on-site with minimal/reduced labor. In addition to the floor-ceiling corridor panel 102, a corner linking brace panel 103 may be pre-installed prior to hanging a floor-ceiling corridor panel 102 near a corner condition (see 103,
For example, and without limitation, plates 137 may be welded to distal ends of the third length of HSS 134, of the corner linking brace panel 103, intended to be mated and fixedly attached to a bracing frame (e.g., see
Floor-ceiling corridor panels 102 have been described herein that receive, transfer, and/or absorb forces and drag transmitted through horizontal diaphragms formed from floor-ceiling panels 104, as well as lateral forces (e.g., see
As will become apparent throughout the description of the remaining figures, drag anchors 301 in unison with the internal structural studs 300 of the floor-ceiling panels 104, the floor-ceiling corridor panels 102, as well as intervening elements, provide a relatively sturdy manner in which forces can be transmitted and absorbed, and function to stabilize the building, in addition to increasing fire safety and other technical benefits.
Each drag anchor 301 or the at least two drag anchors, is fixedly attached to distal ends of the associated internal studs 300. In some implementations, each drag anchor is welded to an internal stud 300, distal end. Furthermore, each drag anchor 301 may be fixedly attached through fasteners, to an adjacent load bearing wall panel 106. Each adjacent load bearing wall panel 106 includes internal support members configured to receive force transmitted through an adjacent drag anchors 301. Each internal support member of the load bearing wall panel 106 is configured to transmit the force received from each drag anchor 301 to a longitudinal corridor support member 161. Finally, each longitudinal corridor support member 161 is arranged to transmit force in both the longitudinal direction and the orthogonal direction (i.e., force vector may be a sum of both vectors and disperse within the interior 200 of the floor-ceiling corridor panel 102, see
The drag anchors 301 may be relatively sturdy welded anchor assemblies formed as described below.
The drag anchor 301 further includes at least one plate washer section (only a single section is shown), labeled 314, and arranged to abut the fold line 311 and upper and lower edges of the body panels 310 and 312. In one implementation, a single plate washer is used as illustrated. In some implementations, more than one plate washer section is used. The plate washer sections 314 are fastened onto the body panel 312 with a bolt, in some implementations. The plate washer section 314 comprises a through-hole that is aligned to an underlying through hole 316 formed in the body panel 312. The plate washer sections 314 may be square in at least one implementation. The plate washer sections 314 may be formed of the same or similar material as the second body panel 312. The plate washer sections may be formed of the same, lesser, or greater thickness as the second body panel 312. The plate washer sections 314 may be cut or die-cut from a blank of plate steel, in some implementations.
The second body panel 312 may comprise an edge 322 that is welded to an end-cap of the internal stud 300. The first body panel 310 may comprise an edge 324 that is welded to the body of the internal stud 300. The second body panel 312 may receive fasteners 326 inserted from an exterior of the floor-ceiling panel 104, through a peripheral c-channel of the floor-ceiling panel, and be threaded therein.
The rigid steel member 336 is bolted to plate 332 with fasteners 334. The rigid steel member 336 and plate 332 transmit the received force to longitudinal corridor support member 161. The longitudinal corridor support member 161 transmits the force received from the rigid steel member 336 and plate 332 to angle 110. The 336, 332, 334 connection is used to transfer lateral loads along 336 from knife plates at respective ends of end walls. Connection 336 to 161 can be made by welds similar to 336 and 330.
The angle 110 transmits and disperses the received force into the upper and lower steel sheets defining the interior 200 of the floor-ceiling corridor panel 102, along the longitudinal direction about the floor-ceiling corridor panel, along the lateral direction across, transversely, the floor-ceiling corridor panel 102, and across any additional support members (e.g., support member 114 and/or corner linking brace 103, if installed).
As described above, floor-ceiling corridor panels and drag anchors have been provided. The floor-ceiling corridor panels and drag anchors, when used to fabricate a multi-story building having pre-fabricated load bearing walls, work to transmit and/or absorb drag, lateral, and vertical forces.
The present disclosure is not to be limited in terms of the particular embodiments described in this application, which are intended as illustrations of various aspects. Many modifications and embodiments can be made without departing from its spirit and scope. Functionally equivalent methods and apparatuses within the scope of the disclosure, in addition to those enumerated herein, are possible from the foregoing descriptions. Such modifications and embodiments 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. This disclosure is not limited to particular methods, which can, of course, vary. The terminology used herein is for the purpose of describing particular embodiments only, and is not intended to be limiting.
With respect to the use of substantially any plural and/or singular terms herein, the terms can be translated 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.
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.).
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 embodiments 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, 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.). 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, the disclosure is also thereby described in terms of any individual member or subgroup of members of the Markush group.
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. 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, 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. Such depicted architectures are merely embodiments, and 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 embodiments of operably couplable include but are not limited to physically mateable and/or physically interacting components.
While various aspects and embodiments have been disclosed herein, other aspects and embodiments are possible. The various aspects and embodiments disclosed herein are for purposes of illustration and are not intended to be limiting.
The present application is a non-provisional application that claims priority under 35 U.S.C. § 119(e) and/or under PCT Article 8 to U.S. Provisional Patent Application No. 63/104,239, filed on October 22, 38, and entitled “LOAD BEARING WALLS FOR A BUILDING” and to U.S. Provisional Patent Application No. 63/178,515, filed on April 22, 221, and entitled “LOW-MID RISE BUILDING HAVING LOAD BEARING WALLS, UTILITY WALLS, AND A CORRIDOR SYSTEM, AND OTHER ACCOMPANYING STRUCTURE, AND METHOD TO CONSTRUCT THE BUILDING.” The entire contents of U.S. Provisional Patent Application Nos. 63/104,239 and 63/178,515 are hereby incorporated by reference herein. The present application is related in subject matter to each of the following co-pending applications, each of which shares a common filing date of Oct. 21, 2021, entitled “MULTI-STORY BUILDING HAVING LOAD BEARING WALLS AND METHOD TO CONSTRUCT THE BUILDING” (docket no. SLP-US-927287-03-US-PCT), “MULTI-STORY BUILDING HAVING PODIUM LEVEL STEEL TRANSFER STRUCTURE” (docket no. SLP-US-927288-03-US-PCT), “PRE-MANUFACTURED FLOOR-CEILING PANEL FOR A MULTI-STORY BUILDING HAVING LOAD BEARING WALLS” (docket no. SLP-US-927289-03-US-PCT), “PRE-MANUFACTURED UTILITY WALL FOR A MULTI-STORY BUILDING HAVING LOAD BEARING WALLS” (docket no. SLP-US-927291-03-US-PCT), “PRE-MANUFACTURED LOAD BEARING WALLS FOR A MULTI-STORY BUILDING” (docket no. SLP-US-927290-03-US-PCT), “MULTI-STORY BUILDING HAVING PREFABRICATED STAIR AND ELEVATOR MODULES” (docket no. SLP-US-927293-03-US-PCT), and “PRE-MANUFACTURED FLOOR-CEILING DRAG ANCHOR FOR A MULTI-STORY BUILDING HAVING LOAD BEARING WALLS” (docket no. SLP-US-927294-03-US-PCT), all of which are hereby incorporated by reference herein, in their respective entireties.
| Filing Document | Filing Date | Country | Kind |
|---|---|---|---|
| PCT/US2021/056080 | 10/21/2021 | WO |
| Number | Date | Country | |
|---|---|---|---|
| 63178515 | Apr 2021 | US | |
| 63104239 | Oct 2020 | US |
