SAFE ROOM II

Abstract

A protective shelter and methods for manufacturing are disclosed. A protective shelter includes a room having a plurality of sides and a roof to form an enclosed space where the sides and roof of the shelter are reinforced with a plurality of reinforcing rods and the reinforcing rods of the sides are connected to the reinforcing rods of the roof, at least one opening in one of the sides for a door to provide access to the enclosed space of the room, at least four channel base rails that have a pair of top edges, a channel bottom defined between the pair of top edges, a first end and a second end and where the base rails are incorporated into the bottom portions of each side of the room, a plurality of vertical dead bolt anchors welded to the channel bottoms of the base rails and a lower end of at least one of the reinforcing rods of the sides is wired to an upper end of one of the plurality of vertical dead bolt anchors.

Description

BACKGROUND OF THE INVENTION

1. Field of the Invention

The invention relates to a room to serve as a storm shelter for protecting an occupant against dangerous winds from hurricanes or tornadoes. More particularly, the invention relates to a prefabricated storm shelter that is incorporated into the design of a home or can be installed after home construction, and will be able to withstand significant wind velocities.

2. Description of the Related Art

For dangerous storms such as hurricanes and tornadoes, safe emergency shelters protect persons and property from harm and destruction. Hurricanes and tornadoes have been recorded with wind speeds of over 250 mph and tornadoes are capable of staying on the ground for over one hour. Flying debris can cause much injury and destruction. It is not uncommon that people are killed during these dangerous storms as well as causing millions of dollars in property damage. Regardless of catastrophic damages that occur from hurricanes and tornadoes, relatively little protection against them is provided because of variously prohibitive problems with present protection alternatives. In general, almost all building construction codes (and testing thereof) are to reduce damage to the buildings but not to save human lives. Thus, there exists a need for storm shelters.

When hurricane type warnings are issued, some homeowners choose not to evacuate, but instead choose to stay in their residence and wait for the hurricane to dissipate in power and hoping the hurricane will move into a different area. When tornado type warnings are issued, there is usually very little time for individuals and families to go to community shelters. Also many community shelters do not allow for pets. The National Tornado Forum has announced an effort to encourage more people to build “safe rooms” (emergency shelters). The Federal Emergency Management Agency (FEMA) and the Federal National Mortgage Association (Fannie Mae) have programs and financing in place to encourage people to place their families in a “safe room” or shelters. Evacuation that takes place in densely populated areas themselves can be dangerous due to traffic and weather.

It is desired to have a low-cost prefabricated shelter that is incorporated into the construction of a home and able to withstand significant wind velocities and other catastrophic damages that occur from powerful storms, such as hurricanes and tornadoes.

BRIEF SUMMARY OF THE INVENTION

Embodiments of the present invention address deficiencies of the art in respect to protective shelters. A protective shelter includes a room having a plurality of sides and a roof to form an enclosed space where the sides and roof of the shelter are reinforced with a plurality of reinforcing rods and the reinforcing rods of the sides are connected to the reinforcing rods of the roof The protective shelter further includes at least one opening in one of the sides for a door to provide access to the enclosed space of the room at least four channel base rails that have a pair of top edges, a channel bottom defined between the pair of top edges, a first end and a second end and where the base rails are incorporated into the bottom portions of each side of the room. The protective shelter further can include a plurality of vertical dead bolt anchors welded to the channel bottoms of the base rails and a lower end of at least one of the reinforcing rods of the sides is wired to an upper end of one of the plurality of vertical dead bolt anchors. The protective shelter yet further can include a plurality of column supports each having a top portion and a bottom portion that is tied into and part of a house foundation, where the base rails are fixedly attached to the top portions of the column supports by a retaining plate and the bottom portions of the column supports join the shelter into the foundation of a home, where concrete poured to cover the supports above the top edges of the base rails forms a floor slab of the shelter. Alternatively, the protective shelter can be detached from the house and serve as a separate wind event shelter.

In another embodiment of the invention, a method of manufacturing a protective shelter can be provided. The method can include p providing an inner mold core, forming a channel frame that encloses the inner mold core by joining four channel base rails in a rectangular configuration, the channel frame defining four sides of the protective shelter, welding a plurality of vertical dead bolt anchors into at least one channel bottom of the four channel base rails of the channel frame, wiring a lower end of at least one of a plurality of reinforcing rods of the sides to an upper end of one of the plurality of vertical dead bolt anchors to form a wired joint, positioning an outer surrounding mold shell to form a mold, and pouring concrete into the mold containing the channel frame to form the four walls and roof of the shelter.

Additional aspects of the invention will be set forth in part in the description which follows, and in part will be obvious from the description, or may be learned by practice of the invention. The aspects of the invention will be realized and attained by means of the elements and combinations particularly pointed out in the appended claims. It is to be understood that both the foregoing general description and the following detailed description are exemplary and explanatory only and are not restrictive of the invention, as claimed.

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS

The accompanying drawings, which are incorporated in and constitute part of this specification, illustrate embodiments of the invention and together with the description, serve to explain the principles of the invention. The embodiments illustrated herein are presently preferred, it being understood, however, that the invention is not limited to the precise arrangements and instrumentalities shown, wherein:

FIG. 1 is perspective view showing a partial cross section through the shelter of the present invention;

FIG. 2 is a plan view of the bottom rebar floor of the shelter of the present invention;

FIG. 3 is a cross section of the channel frame base rails of the present invention;

FIG. 4 is an enlarged corner view of the present invention;

FIG. 5 is a plan view of a support for the shelter of the present invention; is a perspective view of the shelter of the present invention in a modular form; and,

FIG. 6 is an enlarged cross section view of a support for the shelter being a Sonotube or pier foundation.

DETAILED DESCRIPTION OF THE INVENTION

Embodiments of the present invention address deficiencies of the art in respect to protective shelters. A protective shelter includes a room having a plurality of sides and a roof to form an enclosed space where the sides and roof of the shelter are reinforced with a plurality of reinforcing rods and the reinforcing rods of the sides are connected to the reinforcing rods of the roof. The protective shelter further includes at least one opening in one of the sides for a door to provide access to the enclosed space of the room at least four channel base rails that have a pair of top edges, a channel bottom defined between the pair of top edges, a first end and a second end and where the base rails are incorporated into the bottom portions of each side of the room. The protective shelter further can include a plurality of vertical dead bolt anchors welded to the channel bottoms of the base rails and a lower end of at least one of the reinforcing rods of the sides is wired to an upper end of one of the plurality of vertical dead bolt anchors. The protective shelter yet further can include a plurality of column supports each having a top portion and a bottom portion that is tied into and part of a house foundation, where the base rails are fixedly attached to the top portions of the column supports by a retaining plate and the bottom portions of the column supports join the shelter into the foundation of a home, where concrete poured to cover the supports above the top edges of the base rails forms a floor slab of the shelter. In another embodiment, the protective shelter can have its own foundation. Then concrete is poured to cover the supports above the top edges of the base rails and forms a floor slab of the shelter. Alternatively, the protective shelter can be detached from the house and serve as a separate wind event shelter.

With reference now to the drawings in which like elements are denoted with the same numeral throughout the several views, and in particular with reference to FIG. 1, a prefabricated protective shelter or “safe room” 10 is depicted. By prefabricated, it is meant that the complete shelter is pre-cast from reinforced concrete by pouring concrete or a structural equivalent into a cavity defined by an inner mold core and an outer surrounding mold shell. The prefabricated shelter can then be shipped to a desired location. Shelter 10 is shown as rectangular in shape and is comprised of a front wall 12, a back wall (not shown), a left side wall 14 and a right side wall (not shown) and a roof 16. Other shapes and configurations of shelter 10 are possible as well, in accordance with alternative embodiments of the present invention. Other size and dimensional characteristics are also contemplated and within the scope of the invention, as shelter 10 may be specifically configured to fit within a home requiring different configurations.

The walls 12, 14 and roof 16 are preferably made from a durable material, preferably reinforced concrete. Any other suitable material that satisfies requirements set by regulatory bodies for “safe rooms” may also be used to pre-cast the walls and roof. At least one wall, such as front wall 12 has at least one opening 18 for a door through which entry into an enclosed space 19 within shelter 10 is possible. Opening 18 may also be located in other preferred locations on shelter 10.

FIG. 1 is an exemplary illustration of an embodiment of the present invention wherein concrete walls 12, 14 and roof 16 of shelter 10 are reinforced. A plurality of connected reinforcing rods 22 and 24 are utilized in a grid-like fashion for the construction of shelter 10 thereby fortifying roof 16. It is known that because of extreme differences in pressure between the inside of a house and the outside low pressure area of a hurricane or tornado that there may be an outward push of pressure from the house. The plurality of connected reinforcing rods 22 and 24 enable roof 16 to withstand these pressure differences and maintain its integrity with shelter 10. Near the bottom portion of shelter 10, a plurality of vertical dead bolt anchors (DBAs) 60 are welded into the channel bottom of each base rail at various distances to provide anchoring of the plurality of connected reinforcing rods 22 and 24. In general, a plurality of reinforcing rods 22 is attached at one end to one of the vertical dead bolt anchors 60 and extends substantially the length of at least one side of walls and for a length into roof 16. In an embodiment, many of the side and roof reinforcing rods 22 and 24 are replaced by welded wire mesh (WWM). For example, welded wire mesh can be used for replacing the traditional “cut & bend” of side and roof reinforcing rods 22 and 24, e.g., steel thermo-mechanical treated bars. The welded wire mesh can be an electric fusion welded prefabricated reinforcement consisting of a series of parallel longitudinal wires with accurate spacing welded to cross wires at the required spacing. Machines are used to produce the mesh with precise dimensional control. In embodiments, two sheets of the welded wire mesh are placed in each of the four sidewalls and the roof. Each of the lower portions of the sheets of welded wire mesh (WWM) in the four sidewalls can be attached to the upper ends of the plurality of vertical dead bolt anchors (DBAs) 60 by wire at wiring joints 62. The forming of wiring joints 62 can be according to local code, ASTM standards and/or FEMA specifications. The upper ends of the welded wire mesh (WWM) in the four sidewalls further can be attached (tied) to the horizontal reinforcing bars located at the top of the sidewalls that join with the roof. Furthermore, the side ends of the welded wire mesh (WWM) in the four sidewalls further can be attached (tied) to the vertical reinforcing bars located along the side edges of the sidewalls that join with the roof to form the corners of the protective shelter. The use of welded wire mesh (WWM) in place of individual reinforcing rods advantageously provides up to a seventy-five percent savings on labor costs.

In accordance with an embodiment of the present invention, at least two channeled base rails 20, preferably taking the form of substantially C-shaped channels, are incorporated into the base of shelter 10. Each base rail 20 has a pair of top edges and a channel bottom section defined between the pair of top edges. During the construction of shelter 10, each base rail 20 is fixedly incorporated into the bottom portions of at least two walls of shelter 10. For example, as detailed in FIG. 1, base rails 20 are incorporated into front wall 12, rear wall and the four corners of shelter 10. In other embodiments, four channel base rails are incorporated into the base of shelter 10. During the construction of shelter 10, each base rail 20 is fixedly incorporated into the bottom portions of each of the four walls of shelter 10. For example as detailed in FIGS.1 and 2, the base rails 20 are incorporated into front wall 12, rear wall, both sidewalls 14 and the four corners of shelter 10. FIG. 1 further illustrates that a corner of shelter 10 can include multiple reinforcing rods positioned adjacent to each other. For example, FIG. 1 illustrates a corner 58 with three reinforcing rods adjacent to each other. As discussed in more detail in a later section, a plurality of vertical dead bolt anchors (DBAs) 60 are welded into the channel bottom of each base rail at various distances to provide anchoring of the plurality of connected reinforcing rods 22 and 24. For example, vertical dead bolt anchors (DBAs) 60 can be spaced twelve inches, on center, in the channel bottoms of base rails 20 but then be spaced six inches, on center, at the corners formed by joining two base rails 20. The lower ends of the plurality of connected reinforcing rods 22 and/or 24 can be attached to the upper ends of the plurality of vertical dead bolt anchors (DBAs) 60 by wire at wiring joints 62. The forming of wiring joints 62 can be according to local code, ASTM standards and/or FEMA specifications.

To facilitate transporting shelter 10, roof 16 may be provided with a plurality of “lifting eyes” 26 as seen in FIG. 1. Each lifting eye 26 acts as an anchor for a crane or other suitable piece of equipment to hoist shelter 10 onto a truck or position shelter 10 on a footing at a construction site.

In accordance with an embodiment of the present invention, optional openings 27, 28, 29 or 30 may also be provided through roof 16. For example, opening 27 is designed to permit a FEMA air vent. Opening 28 is designed to permit heating, ventilation and air conditioning (HVAC) ductwork to be installed within shelter 10. Opening 29 can be designed to permit electrical conduits to be installed within the enclosed space 19 of shelter 10. It is contemplated that a single opening could accommodate HVAC and electrical conduits may be preferred for certain applications. Opening 30 can be cast to provide an area in which a hinged escape door is provided and serves as an additional exit route in case opening 18 is blocked by debris resulting from the effects of a tornado, hurricane or other hazard. Other openings may also be designed to permit the installation of plumbing inside shelter 10. The openings 18 and 30 can include reinforcing bars along all or some of the edges of the opening. For example, as illustrated in FIG. 1, opening 18 has two reinforcement bars 54 at all the edges of the opening 18 and one diagonal reinforcement bar 56 at the top corners of the opening. Similarly opening 30 has two reinforcement bars 50 at all the edges of the opening 30 and one diagonal reinforcement bar 52 at the corners of the opening.

FIG. 2 is a plan view of the bottom rebar floor of the shelter of the present invention. As illustrated, a floor bottom of a channel frame formed by four connected base rails 20 can be positioned on a concrete pad 72 (not shown) which is flush with the outer edge of the channel frame. In embodiments, the concrete pad 72 may extend from beneath the channel frame 20, for example for approximately six inches along two sides of the channel frame. In embodiments, the channel frame can vary from seven to thirteen feet in width while having an inside depth of six feet four inches to a maximum of twelve feet four inches. The channel frame can include a plurality of horizontal headed studs 64 attached to the inner sidewall of the base rails 20. In embodiments, the horizontal headed studs can be ⅝×8 headed studs and have a length of one foot. The plurality of horizontal headed studs 64 can be deployed at various positions throughout the channel frame. For example, horizontal headed studs 64 typically can be deployed at two foot intervals. A welded wire fabric (WWF) and/or a welded wire mesh (WWM) 70 can be tied to the horizontal headed studs 64 before pouring the finished floor of shelter 10.

FIG. 3 is an exemplary illustration of a cross section of a channel base rail of an embodiment of the present invention. As illustrated in FIG. 3, the channel base rail 20 rests on support 72, e.g., an eight inch thick concrete pad. A vertical dead bolt anchor 60 can be welded to the channel bottom portion of channel base rail 20 and which is shown as encased by a concrete wall 78 of shelter 10. In accordance with an embodiment, vertical dead bolt anchor 60 can be a number #5 DBA, with a length of twenty-four inches. FIG. 3 further illustrates a horizontal headed stud 64 attached to the inner sidewall of the base rails 20 and which is shown as encased by the top of finished floor 74 at concrete wall 78. The finished floor can vary in thickness, for example as shown in FIG. 3, the thickness is shown to be four inches, while the thickness of the concrete pad 72 is shown to be eight inches. The concrete pad 72 ends flush with the concrete wall 78 and adjoins the base-bed soil 80.

FIG. 4 is an exemplary illustration of an enlarged corner view of an embodiment of the present invention. As illustrated in FIG. 4, a corner of two intersecting channel base rails 20 rests on support 72, e.g., an eight inch thick concrete pad. A retaining plate 84, e.g., an eight inch by eight inch by one-half inch steel plate, can be welded to the inside of channel base rails 20. The retaining plate 84 has at least one drilled hole 85 that provides for insertion of at least one fastener 106 (see FIG. 6) to secure a corner of a channel frame formed by two connected base rails 20 to a support.

FIGS. 5 and 6 are an exemplary illustration of an embodiment of the present invention wherein shelter 10 is sustained on a plurality of supports 100. In its preferred form, support 100 is in the form of a round column, e.g., an eighteen inch Sonotube, but can also take the shape of a square, e.g., a twelve inch square concrete pier or any other suitable configuration. In accordance with an embodiment of the present invention, a plurality of supports 100 are placed at predetermined locations when the home is built, preferably in the building foundation, i.e. a footer, so that a plurality of reinforcing rods 102 and 104 are used to secure supports 100. Support 100 can be manufactured from poured concrete or any other suitable material that is capable of supporting shelter 10 and withstanding the wind loads. Shelter 10 is placed on supports 100 such that base rails 20 are resting on the top portion of supports 100. Base rails 20 are fixedly attached to supports 100, preferably through the use of the retaining plate 84 and at least one fastener 106. An adhesive can be used in conjunction with fastener 108 to provide additional strength to fastener 108. As an example, a ¾ inch Simpson Strong-Bolt wedge anchor or equivalent and an epoxy adhesive can be used to secure base rails 20 to support 100.

In accordance with an embodiment of the present invention, shelter 10 generally can be installed at an existing home site as follows. First, a plurality of supports 100, preferably at least four, are fixedly attached adjacent to the preexisting foundation of the home. Next, shelter 10 is placed on supports 100 so that base rails 20 are fixedly attached to supports 100, by the use of retaining plates 84 and fasteners 106. A secondary floor slab is then poured around shelter 10 so that the concrete covers the supports 100 and the retaining plate 84, and above the top edges of base rails 20 to form the floor of the shelter. In this fashion, shelter 10 becomes incorporated and anchored into the foundation and floor slab of the home, thus being able to withstand significant wind velocities and other catastrophic damages that occur from hurricanes and tornadoes.

In accordance with an embodiment of the present invention, a method of manufacture for a protective shelter is described. An inner mold core can be provided. A channel frame can be formed to enclose the inner mold core by joining four channel base rails in a rectangular configuration at the base of the inner mold core. A plurality of vertical dead bolt anchors 60 can be welded, on center, into the channel bottom of the base rails 20. Next, a plurality of connected reinforcing rods 22 and/or 24 or a sheet of welded wire mesh (WWM) can be attached to the upper ends of the plurality of vertical dead bolt anchors 60 by wire at wiring joints 62. The outer surrounding mold shell can be positioned to form a mold. Finally, reinforced concrete can be poured in the mold to form the four walls and roof of shelter 10. By executing the above described method each and every fastener, joint and or connection is encased in concrete.

When not protecting individuals from catastrophic damages that occur from tornadoes, hurricanes, and other hazards, it is envisioned that the shelter can serve other purposes. The protective shelter can be dry walled and finished as any other room in the home and used accordingly. For example, the shelter can be used as a storage room, a walk-in closet, a vault, a hobby room, a sewing room or a wine storage room.

In summary, certain embodiments of the present invention comprise prefabricated protective shelters, also known as safe rooms that are able to withstand significant wind velocities and other catastrophic damages that occur from hurricanes and tornadoes. The protective shelters are incorporated into the foundation of a home. This is accomplished by first fixedly attaching the shelters to a plurality of supports which are part of the foundation and then pouring concrete to cover the supports up to the top edges of the base rails of the shelters thus incorporating the shelters into the foundation of the home.

While the invention has been described with reference to certain embodiments, it will be understood by those skilled in the art that various changes may be made and equivalents may be substituted without departing from the scope of the invention. In addition, many modifications may be made to adapt a particular situation or material to the teachings of the invention without departing from its scope. Therefore, it is intended that the invention not be limited to the particular embodiment disclosed, but that the invention will include all embodiments falling within the scope of the appended claims. The invention has been described with respect to certain preferred embodiments, but the invention is not limited only to the particular constructions disclosed and shown in the drawings as examples, and also comprises the subject matter and such reasonable modifications or equivalents as are encompassed within the scope of the appended claims.

Claims

1. A protective shelter comprising: a room having a plurality of sides and a roof to form an enclosed space, wherein the sides and roof of the shelter are reinforced with a plurality of reinforcing rods and the reinforcing rods of the sides are connected to the reinforcing rods of the roof;at least one opening in one of the sides for a door, wherein the door provides access to the enclosed space of the room;at least four channel base rails, wherein each base rail has a pair of top edges, a channel bottom defined between the pair of top edges, a first end and a second end and the base rails are incorporated into the bottom portions of each side of the room,a plurality of vertical dead bolt anchors welded to the channel bottoms inside the pair of top edges of the base rails and extending upward in a vertical direction, wherein a lower end of at least one of the reinforcing rods of the sides is wired to an upper end of one of the plurality of vertical dead bolt anchors;a plurality of column supports each having a top portion and a bottom portion that is tied into and part of a house foundation, wherein the base rails are fixedly attached to the top portions of the column supports by a retaining plate and the bottom portions of the column supports join the shelter into the foundation of a home, andwherein concrete poured to cover the supports above the top edges of the base rails forms a floor slab of the shelter.

2. The protective shelter of claim 1, wherein a portion of the reinforcing rods of the sides of the shelter comprise welded wire mesh.

3. The protective shelter of claim 1, wherein a portion of the reinforcing rods of the roof of the shelter comprise welded wire mesh.

4. The protective shelter of claim 1, wherein the poured concrete joins the shelter into a foundation of a home

5. The protective shelter of claim 1, wherein the shelter is made from a durable material.

6. The protective shelter of claim 5, wherein the durable material is steel-reinforced concrete.

7. The protective shelter of claim 1, wherein at least one fastener secures each base rail to the supports, thereby securing the entire shelter.

8. The protective shelter of claim 7, wherein the at least one fastener is a wedge anchor.

9. A method of manufacturing a protective shelter, the method comprising: providing an inner mold core;forming a channel frame that encloses the inner mold core by joining four channel base rails in a rectangular configuration, the channel frame defining four sides of the protective shelter;welding a plurality of vertical dead bolt anchors into at least one channel bottom of the four channel base rails of the channel frame;wiring a lower end of at least one of a plurality of reinforcing rods of the sides to an upper end of one of the plurality of vertical dead bolt anchors to form a wiring joint;positioning an outer surrounding mold shell to form a mold; and,pouring concrete into the mold containing the channel frame to form the four walls and roof of the shelter.

10. The method of claim 9, further comprising removing the protective shelter from the mold.

11. The method of claim 9, further comprising tying a bottom portion of a sheet of welded wire mesh to the upper end of one of the plurality of vertical dead bolt anchors and tying a side end of the welded wire mesh to a corner reinforcing rod.

12. A method of incorporating and anchoring a protective shelter to an existing home, the method comprising: constructing a protective shelter, wherein the shelter comprises a room having a plurality of sides and a roof to form an enclosed space, wherein the sides and roof of the shelter are reinforced with a plurality of reinforcing rods and the reinforcing rods of the sides are connected to the reinforcing rods of the roof;at least one opening in one of the sides for a door, wherein the door provides access to the enclosed space of the room;at least four channel base rails, wherein each base rail has a pair of top edges, a channel bottom defined between the pair of top edges, a first end and a second end and the base rails are incorporated into the bottom portions of each side of the room,a plurality of vertical dead bolt anchors welded to the channel bottoms of the base rails and wherein a lower end of at least one of the reinforcing rods of the sides is wired to an upper end of one of the plurality of vertical dead bolt anchors; and,a plurality of column supports each having a top portion and a bottom portion that is tied into and part of the house foundation, wherein the base rails are fixedly attached to the top portions of the column supports by a retaining plate and the bottom portions of the column supports join the shelter into the foundation of a home;placing a plurality of supports in a predetermined location of the home attached to a home foundation;placing the at least four base rails of the protective shelter on the plurality of supports;securing the at least four base rails to the supports; andpouring concrete to form a floor slab, wherein the concrete is poured to cover the supports above the top edges of the base rails to form a base of the shelter and a floor slab for the home.