FIELD OF ART
The present invention relates to prefabricated buildings made principally of steel. The present invention more particularly relates to a rapidly deployable prefabricated folding building that does not require a full-size concrete foundation pad for support.
BACKGROUND OF THE INVENTION
A number of prefabricated folding steel buildings have been invented by the present inventor, such as U.S. Pat. No. 9,222,250, which is incorporated herein by reference. Such buildings use sections each having two wall and two connecting roof panels, set side by side, and connected to form a building. There is a need for such buildings that do not require time-consuming surface preparation such as exact leveling and concrete pad production, and so can be more rapidly deployed for civil and military applications. There is yet a further need for a rapidly deployable building that may use only one piece of heavy equipment for erection. There is yet an even further need for a rapidly deployable building that is made of completely reusable components
SUMMARY OF THE INVENTION
Briefly described, the invention includes a fully recoverable and reusable modular steel footing and beam system that allows installation of the rapidly deployable prefabricated folding building system on a wide variety of substrates, including bare earth, existing asphalt, and existing concrete. The substrate may show some deviation from level and still be accommodated. The invention also includes three-part folding haunch and ridge braces allowing braces to ship attached to building panels resulting in minimal handling, reduced weights, and ability to install roof and walls separately. Roof weight is reduced and so can be handled with a forklift or telehandler, as the only heavy equipment needed to erect the building. Flashings are insulated, factory cut, and drilled for fasteners, in alignable pattern to fastener-receiving rivets installed in the corrugated siding and roofing. Fasteners and fastener installation locations are color coded.
DESCRIPTION OF THE FIGURES OF THE DRAWINGS
The present invention will hereinafter be described in conjunction with the following drawing figures, wherein like numerals denote like elements, and
FIG. 1 is a top perspective view illustrating an exemplary footing structure of an embodiment of the rapidly deployable prefabricated folding building, according to a preferred embodiment of the present invention.
FIG. 2 is a front exploded elevation view illustrating an exemplary embodiment of the rapidly deployable prefabricated folding building, according to a preferred embodiment of the present invention;
FIG. 3 is a perspective view illustrating an exemplary embodiment of a detail of the rapidly deployable prefabricated folding building of FIG. 2, according to a preferred embodiment of the present invention;
FIG. 4A is a perspective view illustrating an exemplary embodiment of a detail of the rapidly deployable prefabricated folding building of FIG. 2, according to a preferred embodiment of the present invention;
FIG. 4B is a perspective view illustrating an exemplary embodiment of a detail of the rapidly deployable prefabricated folding building of FIG. 2, according to a preferred embodiment of the present invention.
FIG. 4C is a top plan view illustrating an exemplary embodiment of a shim of the rapidly deployable prefabricated folding building of FIG. 2, according to a preferred embodiment of the present invention.
FIG. 5 is a front perspective exploded view illustrating the exemplary embodiment of the rapidly deployable prefabricated folding building of FIG. 2, according to a preferred embodiment of the present invention;
FIG. 6 is a front perspective view illustrating an exemplary detail of the exemplary embodiment of the rapidly deployable prefabricated folding building of FIG. 5, according to a preferred embodiment of the present invention;
FIG. 7 is a front perspective view illustrating an exemplary detail of the exemplary embodiment of the rapidly deployable prefabricated folding building of FIG. 5, according to a preferred embodiment of the present invention;
FIG. 8 is a front perspective view illustrating an exemplary detail of the exemplary embodiment of the rapidly deployable prefabricated folding building of FIG. 5, according to a preferred embodiment of the present invention;
FIG. 9 is a front perspective view illustrating an exemplary detail of the exemplary embodiment of the rapidly deployable prefabricated folding building of FIG. 5, according to a preferred embodiment of the present invention;
FIG. 10 is a front perspective view illustrating an exemplary detail of the exemplary embodiment of the rapidly deployable prefabricated folding building of FIG. 5, according to a preferred embodiment of the present invention;
FIG. 11 is a front elevation view illustrating an exemplary detail of the exemplary embodiment of the rapidly deployable prefabricated folding building of FIG. 5, according to a preferred embodiment of the present invention;
FIG. 12 is a front perspective view illustrating an exemplary detail of the exemplary embodiment of the rapidly deployable prefabricated folding building of FIG. 5, according to a preferred embodiment of the present invention; and
FIG. 13 is a diagrammatic view illustrating an exemplary embodiment of a fastener color coding scheme in the exemplary embodiment of the rapidly deployable prefabricated folding building of FIG. 5, according to a preferred embodiment of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
As used and defined herein, “upward,” “downward,” “top,” and “bottom,” as well as other words of relative positioning, refer to the building or part thereof in its operational orientation.
FIG. 1 is a top perspective view illustrating an exemplary footing structure 100 of an embodiment of the rapidly deployable prefabricated folding building 200 (see FIG. 2), according to a preferred embodiment of the present invention. In operation, bearing plate 102 (one of three labeled) rests on the ground or other supporting surface such as, without limitation, asphalt, concrete, natural stone, ice, or hard pan desert. Depending on the characteristics of the supporting substrate, bearing plates 102 may vary in size and anchors 108 may vary in type and depth. Anchor adapter plates 104 (one of six labeled) are fastened to bearing plates 102 with fasteners 106 (one of twenty-four labeled) which are preferably bolts with lock washers. Anchor adapter plates 104 secure the ground anchors 108 (one of six labeled) to the bearing plates 102. A drive shaft 110 of the ground anchor 108 extends above the anchor adapter plate 104 so that, with the anchor adapter plate removed, drive shaft 110 can be coupled to a motorized drive to remove the anchor 108. Responsive to various substrates, various types of anchors 108 may be used. For non-limiting example, on a concrete substrate, concrete anchors, as are known in the art, may be used. Those of skill in the art, enlightened by this disclosure, will be able to select appropriate anchors for various substrates.
Building attachment plate 112 is fixed to bearing plate 102 via vertical steel plates 128 (one of many labeled) and is T-shaped with the corners 136 (one of six labeled) of the “T” used to receive connecting beams 114 (one of two labeled) at adjustable heights. The stem 122 of the “T” is used to support two adjacent columns 302 and 1102 (see FIGS. 3 and 11) of adjacent wall panels 308 and 1114 (see FIG. 11). The crossbar 124 of the “T” has opposing ends 130 and 132 and each has two bolt holes 134 (one of twelve labeled) corresponding to bolt holes 314 and 316 (one each of six labeled) in each rafter footing 312 (see FIG. 3). It is the bolting of the rafter footing 312 to the building attachment plate 112 that secures the wall panel 308 (see FIG. 3) to the steel bearing plate 102.
Connecting beams 114 are preferably steel I-beams with closed, slotted 138 ends 116. There are four slotted 138 ends 116 on each connecting beam, two at each end, separated by the web of the I-beam. The illustrated height 126 of the building attachment plate 112 is approximately the minimum, as tools must be used under the building attachment plate 112 to secure the aforementioned bolts. The greater the height 126, the greater the deviation from level the substrate may be. Bolt holes 118 and 120 are proximate the top of a plate 128 and correspond to the top of the slots 138 in ends 116 of the connecting beams 114. Plate 128 is the side of the stem 122 of the building attachment plate 112. Thus, the end of the connecting beam 114 can be adjusted upward by the height of the slot 138 to maintain a constant level of the connecting beams 114 against varying terrain. Increasing height 126 would enable additional bolt holes 118 and 120 at higher level on plate 128, thereby enabling adaptation to even more uneven terrain in various embodiments.
In various embodiments, various numbers of bearing plates 102 and connecting beams 114 may be configured and arranged in parallel linear spaced-apart arrays, with no arbitrary upper limit on the number, to make a building of any desired length. In a particular embodiment, a rapidly deployable prefabricated folding building 200 may be supported on more than one substrate. For example, a portion of the rapidly deployable prefabricated folding building 200 may be supported on concrete and then extend onto bare earth. The advantages of this steel bearing plate 102 and connecting beam 114 system include: providing a level arrangement of connecting beams 114 on non-level ground; providing various anchoring options for various substrates; requiring no significant excavation; requiring no concrete, being fully recoverable and reusable; and being adaptable to multiple substrates under one rapidly deployable prefabricated folding building 200.
FIG. 2 is a front exploded elevation view illustrating a first exemplary embodiment of the rapidly deployable prefabricated folding building 200, according to a preferred embodiment of the present invention. Rapidly deployable prefabricated folding building 200 is shown in an exemplary late step of construction with the bearing plates 102 installed and the rafters 206 and 210 and walls connected as a four-panel section 238 and suspended in air using a large forklift (not shown) or the like. Three-part haunch braces 216, 218 and 234; and 230, 232, and 236 are not connected, allowing columns 202 and 214 to rotate freely from the ends 204 and 212, respectively, of rafters 206 and 210, respectively. In the illustrated configuration, it is easy to align the bottom ends of columns 202 and 214 with their respective building attachment plates 112. After the columns are attached, via pre-drilled aligned fastener holes, the three-part haunch braces 216, 218 and 234; and 230, 232, and 236 are connected and bolted.
Three-part ridge brace 220, 228, and 226 is shown in its assembled configuration. Ridge brace arms 220 and 226 are held in horizontal position by supports 222 and 224, respectively, during and after assembly. Five-hole ridge plate 208 pivotally connects rafters 206 and 210 in folded configuration during storage and shipping and rigidly connects rafters 206 and 210 at the deployed angle after assembly. Supports 222 and 224 are preferably stowable filaments, such as, without limitation, cable or chain.
FIG. 3 is a perspective view illustrating an exemplary embodiment of a detail of the rapidly deployable prefabricated folding building 200 of FIG. 2, according to a preferred embodiment of the present invention. A wall panel 308 of a four-panel section 238 is shown supported by connecting beam 114 and connected to building attachment plates 112 via bolts through footing plates 312 having bolt holes 314 and 316 corresponding to bolt holes 134 in the building attachment plate 112. Wall panel 308 includes columns 202 and 302 with a sheet 304 of material extending there between. Sheet 304 may be a composite material that includes insulation, penetration resistant materials, and structurally supportive materials. Columns 202 and 302 are C-channel steel with supportive cross strips 306 (one of five labeled) at points for bolting wall panels together side-by-side. Bolt holes 310 (one of five labeled) align to similar holes in the web of the C-channel. Note that each column 202 and 302 take up only half of the width of the stem of each T-shaped building attachment plate 112.
FIG. 4A is a perspective view illustrating an exemplary embodiment of a detail of the rapidly deployable prefabricated folding building 200 of FIG. 2, according to a preferred embodiment of the present invention. The slots 138 in the ends of connecting beams 114 can receive bolts into vertical plates 128 of building attachment plates 112 to raise the connecting beams relative to building attachment plate 112 by different amounts at each end, thereby keeping the connecting beam 114 level on un-level substrate. Preferably, shims 408 (see FIGS. 4B and 4C), shaped like the footing plate of the column 202, are used at cavities 404 and 406. In a particular embodiment, the height of building attachment plates 112 can be increased to accommodate a higher slope of the substrate.
FIG. 4B is a perspective view illustrating an exemplary embodiment of a detail of the rapidly deployable prefabricated folding building 200 of FIG. 2, according to a preferred embodiment of the present invention. Shims 408 are shaped like the footing plate 312 of the rafter 302 and has bolt holes 410 and 412 to accommodate connection of the footing plate 312 through the shims 408 to the building attachment plate 112. Preferably, shims 408 are a stack of thin plates that can be stacked according to the needed height in each case. A wedge may be used to finish the shim 408.
FIG. 4C is a top plan view illustrating an exemplary embodiment of a shim 408 of the rapidly deployable prefabricated folding building 200 of FIG. 2, according to a preferred embodiment of the present invention. Shim 408 has the shape of a footing plate of column 202 with bolt holes 410 and 412 to accommodate connection of the footing plate 312 through the shims 408 to the building attachment plate 112 and, thereby, to bearing plate 102.
FIG. 5 is a front perspective exploded view illustrating a second exemplary embodiment of the rapidly deployable prefabricated folding building 500, according to a preferred embodiment of the present invention. The subject matter discussed in regard to FIGS. 1, 3, and 4A-4C apply equally to rapidly deployable prefabricated folding building 500. Bearing plates 102 are preferably arranged in parallel spaced apart linear arrays, as shown, for rapidly deployable prefabricated folding buildings 200 and 500. In a particular embodiment, additional parallel spaced apart linear arrays of bearing plates may be used to provide support for “lean to” walls. Exemplary preliminary steps of a preferred second method of construction are illustrated in FIG. 5. First the roof panels 510 and 512 are unfolded and five-hole ridge plates 208 and 606 (see FIG. 6) are fully attached and tightened. Second, the three-part ridge brace 220, 228, 226 is assembled, as is a similar three-part ridge brace 620, 628, 626 for the rafters 602 and 604 (see FIG. 6). Wall panels 308 and 508 are set upon, and attached to, building attachment plates 112 using traditional tilt-up installation and braced with temporary kick braces 502 (one of four labeled). Temporary kick brace 502 extends between an attachment point on column 514 and a footing 504 which is adapted to the substrate in a manner similar to adapting bearing plates 102 and anchors 108. Each wall panel 308 and 508 gets two temporary kick braces 502, one for each column 202, 302, 214, and 514. The roof 516 is then lowered to proximity with the tops of the wall panels 308 and 508 and lower ends of rafters 206 and 210 are attached to columns 202 and 214, respectively, using bolts. Lower ends of rafters 602 and 604 (see FIG. 6) are connected to top ends of columns 302 and 514, respectively, using bolts. Haunch braces 216, 218, 234; 230, 232, 236; and 822, 824, 826 (see FIG. 8), on both sides, are then connected and bolted, completing installation of a section 238.
FIG. 6 is a front perspective view illustrating an exemplary detail of the exemplary embodiment of the rapidly deployable prefabricated folding building 500 of FIG. 5, according to a preferred embodiment of the present invention. FIG. 6 illustrates details an early step in assembly of the roof 516. Five-hole ridge plates 208 and 606 have been fully attached and tightened. During folded storage and transportation, two of the holes in each five-hole ridge plate 208 and 606 have bolts and three holes are empty. In use, four holes of the five-hole ridge plates 208 and 606 have bolts, and the top center hole is used for lifting and for securing safety lines for roof workers.
Left ridge brace arm 620 and ridge brace coupling sleeve 628 are shown in stowed position. Right ridge brace arm 626 is deployed from stowed position by rotating about pivot 606 and is suspended for coupling alignment by support 624, which is preferably a cable, chain, or similar strong and flexible filament. Support 624 is attached to rafter 604 and to right ridge brace arm 626 and is stowed with right ridge brace arm 626 for transportation and storage.
FIG. 7 is a front perspective view illustrating an exemplary detail of the exemplary embodiment of the rapidly deployable prefabricated folding building 500 of FIG. 5, according to a preferred embodiment of the present invention. Left ridge brace arm 620 is deployed and is suspended for coupling alignment by support 622, which is preferably a cable, chain, or similar strong and flexible filament. Support 622 is attached to rafter 602 and to left ridge brace arm 620 and is stowed with left ridge brace arm 620 for transportation and storage. As deployed, ridge brace coupling sleeve 628 encloses free ends of left and right ridge brace arms 620 and 626 and is bolted in place through holes 708 and 710 and corresponding holes in left and right ridge brace arms 620 and 626. The bolts used to secure ridge brace coupling sleeves 628 and 228 are preferably color-coded to correspond to colors applied proximate the appropriate bolt holes. The under sides 702 and 704 of roof panels 510 and 512 are visible in this view. Gap 706 between roof panel 510 and 512 will be covered with flashing, as discussed further below.
FIG. 8 is a front perspective view illustrating an exemplary detail of the exemplary embodiment of the rapidly deployable prefabricated folding building 500 of FIG. 5, according to a preferred embodiment of the present invention. Attachment flange 802 extends from rafter 602 and bolts to the top of column 302 through flange bolt hole 816 and a corresponding pivot bolt hole (similar to pivot bolt hole 828) in the column 302. Attachment flange 818 (barely visible) is similarly configured to column 202 and pivot bolt hole 828. Haunch brace column arm 216 is shown in a stowed configuration with haunch brace coupling sleeve 228. Haunch brace column arm 216 is secured at a first end by pivot 804 and at the opposing end by another means, which may be a bolt through bolt hole 820 and a corresponding hole (not visible in this view) in column 302, a bundle tie, twine, clamp, or similar restraints. Haunch brace coupling sleeve 228 has bolt holes 810 and 812 for securing free ends of haunch brace column arm 822 and haunch brace rafter arm 824. Haunch brace rafter arm 824 is secured at a first end by pivot 806 and at a distal end by another means, which may be a bolt through bolt hole 808 and a corresponding hole (not visible) in rafter 602, a bundle tie, twine, clamp, or similar restraints. Crossbar 814 tops wall panel 308. The bolts used to make a pivotal connection between the rafters 206 and 602 and between the columns 202 and 302, respectively, are preferably color-coded to correspond to colors applied proximate the appropriate bolt holes. Once the feet 312 of the wall panels 308 and 508 (see FIGS. 3 and 5) are secured to the building attachment plates 112, the pivot bolts are tightened to prevent further pivoting.
FIG. 9 is a front perspective view illustrating an exemplary detail of the exemplary embodiment of the rapidly deployable prefabricated folding building 500 of FIG. 5, according to a preferred embodiment of the present invention. Three-part haunch brace 822, 824, 826 is shown deployed and secured. Haunch brace column arm 822 has rotated about pivot 804 to align with haunch brace rafter arm 824 which has rotated about pivot 806. Haunch brace coupling sleeve 826 has been translated to enclose ends of haunch brace column arm 822 and haunch brace rafter arm 824 and has been secured by bolts through bolt holes 812 and 810 and a corresponding bolt hole in haunch brace column arm 822 (obscured by haunch brace coupling sleeve 826) and bolt hole 808 in haunch brace rafter arm 824, respectively.
FIG. 10 is a front perspective view illustrating an exemplary detail of the exemplary embodiment of the rapidly deployable prefabricated folding building 500 of FIG. 5, according to a preferred embodiment of the present invention. Three-part haunch brace 216, 228, 226 is shown just before haunch brace coupling sleeve 228 is moved into assembled position. Second three-part haunch brace 822, 824, 826 is shown in a similar position. Second haunch brace column arm 822 has rotated about pivot 804 (seen from the rear side) into alignment with second haunch rafter arm 824, which has rotated into coupling alignment about pivot 1018. Second haunch brace coupling sleeve 234 has bolt hole 1008 for alignment to bolt hole 1028 in second haunch brace rafter arm 1026 and bolt hole 1012 for alignment to a bolt hole in second haunch brace column arm, which hole is not visible in this view. The bolts used to secure haunch brace coupling sleeves 234 and 826 are preferably color-coded to correspond to colors applied proximate the appropriate bolt holes.
FIG. 11 is a front perspective diagrammatic view illustrating an exemplary detail of the exemplary embodiment of the rapidly deployable prefabricated folding building 200 of FIG. 2, according to a preferred embodiment of the present invention. An advantage of the present invention is that the factory prepared insulated flashing 1108 has pre-drilled screw holes 1112 (one of many illustrated) that align with threaded rivets 1116 (one of many illustrated) in holes 1206 (see FIG. 12) in the corrugated metal siding panels 1104 and 1106 to receive screws 1110 (one of many illustrated). The flashing 1108 is shown covering an exterior seam 1118 between two columns 302 and 1102 of adjacent wall panels 308 and 1114, respectively. Similar flashing 1108 is used for rafter seams and ridge covering. The screws used to secure flashing 1108 are preferably color-coded to correspond to colors applied proximate the appropriate screw holes 1112. All flashing 1108 is factory cut to the correct length. Insulation (not shown), preferably closed-cell foam insulation, is adhered to the inside of the flashing 1108. Another advantage of the present invention is that the flashing 1108 is reusable. The entire rapidly deployable prefabricated folding building 200 can be non-destructively disassembled, transported, and reassembled at a new location.
FIG. 12 is a front elevation view illustrating an exemplary detail of the exemplary embodiment of the rapidly deployable prefabricated folding building 500 of FIG. 5, according to a preferred embodiment of the present invention. FIG. 12 illustrates a detail of FIG. 11. Threaded portion 1204 of screw 1110 extends through gasket washer 1202, then through a pre-drilled color-coded hole 1112 in flashing 1108, then into threaded rivet 1116 factory installed in a pre-drilled hole 1206 in corrugated siding 1106.
FIG. 13 is a diagrammatic view illustrating an exemplary embodiment of a fastener color coding scheme in the exemplary embodiment of the rapidly deployable prefabricated folding building 500 of FIG. 5, according to a preferred embodiment of the present invention. Flashing 1108 has a screw hole 1112 surrounded by an annular area of applied surface colorant 1302, such as, without limitation, paint, ink, or stain, as indicated by cross hatching. Screw 1110 has surface colorant 1304, which is the same color as colorant 1302, applied to the sides of the screw head, as indicated by cross hatching. Screw 1110 has surface colorant 1306, which is the same color as colorant 1302, applied to the top of the screw head, as indicated by cross hatching. It is preferred to make the extent of the applied surface colorant 1302 greater than the extent of the screw head 1110 in order to make quality control inspection easy. In various embodiments, various patterns for applying colorants 1302, 1304, and 1306 may be employed. For non-limiting example, applying the colorants 1302, 1304, and 1306 not as a complete covering, but in small patches of corresponding shapes for the benefit of the colorblind, may be appropriate in some embodiments.
There only difference between rapidly deployable prefabricated folding building 500 and rapidly deployable prefabricated folding building 200 is the construction sequence: the end product is the same. FIG. 2 shows that the novel footing system 100 works with the existing construction method, while FIG. 5 shows that the novel footing system 100 works with the new rapid construction method, as well.
Patent Grant
10260211
