In the construction of multi-story commercial and industrial buildings, it is common to erect a structural steel frame for the building after the concrete footers and foundation has been poured. The steel frame defines the vertical spaces for the stairwell and elevator shafts. Typically, prefabricated steel stairways with steps and a horizontal landing for each floor are installed as the structural steel frame for the building is erected, and each steel stairway and each landing are secured by bolts or welding to steel frame members for the building. After corrugated steel floor panels are installed over the horizontal beams of the steel frame, concrete is pumped onto the steel floor panels to form each concrete floor for the building. If the steel stairway has step pans and a landing pan, concrete is manually poured into the steel pans forming the steps of the stairway and also into the steel pan forming the landing for the stairway halfway between adjacent floors. After all of the floors and stairways and landings are formed, vertical metal studding is usually installed onto the steel frame members defining the stairwell space for the building and around the stairways and landings to define the stairwell shaft. The stairwell shaft is then lined with drywall or other fire resistant sheets, and handrails are installed for the steps for each floor so that the stairwell is essentially completed except for final finishing.
It has been proposed to form a staircase or a stairwell tower for a multi-story house or building by precasting modular staircase or stairwell components or units and then assembling or stacking the units to form a staircase or stairwell for the building. For example, U.S. Pat. No. 3,755,974, No. 3,830,026, No. 3,980,155, No. 4,248,020 and No. 5,377,778 disclose various preformed staircase or stairway modules, which may be formed of precast concrete, and with each module extending a full story of the multi-story house or building. After the modules are stacked, they form a stairway or stairwell system.
The present invention is directed to the construction of a modular stairwell tower which is preferably constructed prior to erecting the steel frame members for a multi-story building having a number of floors. The tower includes a series of precast concrete stairwell units arranged in a stack with the number of stairwell units corresponding to twice the number of floors in the building. Each of the stairwell units includes a precast concrete tower section having vertical opposite side walls and vertical opposite end walls defining an open bottom and an open top. The walls of each tower section have a vertical height generally equal to one half the vertical distance between two successive floors of the building, and each stairwell unit includes a preformed or precast inclined stairway connected to one of the side walls of the corresponding tower section. A preformed or precast horizontal platform is located adjacent an upper end of the inclined stairway in each tower section and is connected to the side walls and one of the end walls to form a stairway landing.
Each of the stairwell units is horizontally oriented one hundred eighty degrees relative to each adjacent stairwell unit in the stack, and one of the walls of each alternate stairwell unit in the stack defines a doorway opening. Anchor members project into and are embedded in upper and lower portions of the walls of each of the stairwell units, and the anchor members in the lower portions of the bottom stairwell unit are rigidly connected, such as by welded plates, to anchor members embedded in a concrete support floor or base for the stairwell tower. Anchor members in the upper portions of the walls are rigidly connected, such as by welded plates, to the anchor members in the lower portions of the walls of the adjacent stairwell unit thereabove.
The modular stairwell tower of the invention provides for efficiently precasting the stairwell units away from the building site and for conveniently erecting or stacking the stairwell units with a crane. Structural steel frame members for the building may be subsequently attached to the erected stairwell tower, thereby providing stability and rigidity for the steel frame members as they are being erected. This attachment eliminates the need for a significant number of steel frame members used for bracing the steel frame as it is being erected. The modular stairwell tower of the invention also provides for convenient and safe access to all floors of the building as it is being constructed, thereby providing protection to the steel frame erection crew. The modular precast concrete stairwell tower further provides for fire rating without the need for dry wall or masonry and may be prime finished at the precasting facility or factory. In addition, fire line stand pipes may be installed within the stairwell tower to provide for fire protection during construction of the building. The construction of the stairwell tower prior to erecting the steel frame members for the building also enables workers to move tools and materials from floor to floor quickly and conveniently, thereby providing a savings in labor for constructing the building. The construction of the modular stairwell tower before erecting the frame members further eliminates the need for ladders and scaffolding and temporary railings during erection of the steel frame, further enhancing the safety aspect of the overall construction process.
Other features and advantages of the invention will be apparent from the following description, the accompanying drawings and the appended claims.
In accordance with the present invention, one or more precast concrete modular stairwell towers 25 are constructed in accordance with the invention, and each tower 25 includes a vertical stack of precast reinforced concrete stairwell modules or units 30 and 30′. Each stairwell unit includes a rectangular precast reinforced concrete box-like tower section 35 and 35′ formed by opposite side walls 38 and opposite end walls 42 defining an open top and an open bottom. The primary difference between the tower sections 35 and 35′ is that alternate tower sections 35 have full doorway openings 44 (
The height of the side walls 38 and end walls 42 of the tower sections 35 and 35′, is substantially equal to one half the vertical distance between two adjacent floors of the building 20. For example, the vertical height of the walls 38 and 42 may be approximately seven feet for a distance between floors of about fourteen feet. Each tower section 35 and 35′ has an overall length within the range of 18 feet to 25 feet and preferably about 21.5 feet, and an overall width within the range of 9 feet to 12 feet and preferably about 10.5 feet.
Referring to
The stairway 50 and platform 55 in each stairwell unit 30 and 30′ has conventional steel reinforcing mats or bars, commonly referred to as rebars. As shown in
As shown in
Referring to
After the first or bottom precast concrete stairwell unit 30 is positioned on the base pad 95 (
Referring to
After the second stairwell unit 30′ is rigidly connected to the first stairwell unit 30, as shown in
Since each of the precast concrete stairwell units 30 and 30′ has substantially the same construction except for the doorway openings 44 and 46, and the height of each stairwell unit is essentially one half the vertical distance between two adjacent floors, each of the stairwell units 30′ is rotated or horizontally oriented by 180 degrees with respect to the adjacent stairwell unit 30 therebelow. This requires that the embedded anchor members 105 within the upper and lower portions of the walls 38 and 42 of each stairwell unit be uniformly and precisely located so that all of the anchor members are vertically aligned and can be welded together to form a rigid and high strength stairwell tower 25. As shown in
As mentioned above, it is desirable to construct or erect each of the modular stairwell towers 25 before the steel framing or frame members are erected for the building 20. In this manner, each of the towers 25 may serve as a rigid anchor for the steel frame members, thereby eliminating the need for a significant number of diagonal steel bracing members and shear members. Thus referring to
Referring to
From the drawings and the above description, it is apparent that a modular stairwell tower 25 and its method of construction in accordance with the invention provides desirable features and advantages. For example, by first constructing one or more of the stairwell towers at a building construction site, each tower provides the construction workers with convenient and safe access to all floors of the building during construction, and thereby provides protection for the erection crew for the steel frame as well as for the construction for the concrete floors. The tower also eliminates the need for temporary ladders and scaffolding and temporary railings while erecting the steel frame. Each of the stairwell units 30 and 30′ may also be economically produced at a remote precast facility where bad weather does not stop production. Furthermore, if the stairwell tower or towers are first erected and completed prior to erecting the steel frame for the building, the steel frame members may be anchored to the tower or towers, thereby eliminating the need for many diagonal bracing frame members and shear wall bracing frame members within the building. The steel workers may also use each stairwell tower for conveniently moving their tools and materials from floor to floor during erection of the steel frame for the building. The mounting of each stairway railing within each stairwell unit before stacking the units also substantially simplifies the installation of a railing system. After each stairwell tower is completed, fire line stand pipes may be installed within the tower and connected to a water supply to facilitate fire protection during construction of the building.
While the method and form of modular tower herein described constitutes a preferred embodiment of the invention, it is to be understood that the invention is not limited to the precise method and tower described, and that changes may be made therein without departing from the scope and spirit of the invention as defined in the appended claims. For example, it is within the scope of the invention to provide each stairwell unit with a fabricated metal stairway and landing platform which are secured to the tower walls of each stairwell unit in the event that a precast concrete stairway and landing platform are not desired or required. Also, each of the stairwell units may have an oval configuration with rounded end walls instead of a rectangular configuration as shown in the drawings.