STRUCTURAL SUPPORT AND ASSEMBLY OF STRUCTURAL SUPPORTS

Abstract

A structural support includes a first side-wall, a second side-wall, a first planar wall, and a second planar wall. The structural support further includes internal walls that are disposed between the first side-wall and the second side wall, and extend from a first inner surface of the first planar wall to a second inner surface of the second planar wall. The first side-wall, the second side-wall, the first planar wall, and the second planar wall define connector components. The internal walls define a plurality of channels between the connector components.

Description

BACKGROUND

More and more often, building construction projects involve the construction and/or use of portable, or non-permanent, or quickly-assembled/disassembled buildings and enclosures, or other types of non-permanent structures (together referred to hereafter as “non-permanent buildings”) that include some type of roof or other overhead structure supported by a vertically extending frame. These non-permanent buildings are often designed to be: (1) suitable for housing activity by multiple persons, and (2) enclosed or modifiable to be enclosed so outside weather conditions do not impede the activities taking place inside. Further, an objective in designing these non-permanent buildings is often to build a structure that is functionally equivalent to a permanent building in that it: (1) is provided with (a) utility services including electricity, heat, air conditioning, water, drain, and waste, and (b) communication or data services such as interne, phone, and cable or other data transmission services; and (2) allows for other types of data transmission such as cellular data.

Many structural components of such non-permanent buildings are designed to be easily constructed to provide the basic functions noted above. However, these non-permanent buildings are more times than not supported by foundations recessed several feet into the ground, formed of concrete, include rebar, or are otherwise built and intended to support permanent structures. Thus, even though a majority of an overall structure of a non-permanent building may be built and removed quickly, the steps to form or otherwise provide a foundation before above-ground construction may commence are: time consuming; labor intensive; require special and expensive industrial equipment (e.g., cement mixers, overhead cranes, rebar cutters, etc.); require sleeving to provide conduits for power, data, and plumbing cables and pipes; and often cannot be immediately followed with additional same-day construction because materials (e.g., concrete) must dry and harden before trades may build from the newly installed foundational structure. Furthermore, once a non-permanent building that the foundation supports is no longer needed and is removed, the foundation remains and defines a footprint that is difficult and costly to remove. Even if there is some viable use for the foundation, such a scenario is less than optional because a design of a next structure built on the foundation will be limited by the spatial constraints of a footprint, the utilities that are compatible with conduit paths, and the types of equipment and scale of structure that may be supported by a load capacity of the foundation.

As a result, a need exists for structural components that may be constructed into foundations at a high speed, low cost, and with minimal requirements for labor and complex equipment in similar respects to the non-permanent buildings these foundations support.

SUMMARY

Systems or building designs for non-permanent buildings other than those of the present disclosure, such as some metal buildings having some, although a low, degree of mobility/portability, are traditionally designed individually to particular specifications. They often lack universal applicability to more than one, let alone several, construction projects (i.e., they are not considered “plug and play” types of construction projects). Furthermore, a cost and time required to engineer and produce these types of non-permanent building is higher and takes longer due to fabrication constraints, than non-permanent buildings incorporating the structural supports described herein. In contrast, structural supports of the present disclosure are: engineered to support and have directly erected thereon, different types of non-permanent buildings, such as different types of metal buildings; may be shipped anywhere; and may be installed by a novice with only a forklift.

Examples described herein include structural supports that may be quickly, easily, and cost effectively combined into assemblies that provide non-permanent foundations fully capable of supporting non-permanent buildings. In one example, the structural supports may be provided in standard sizes and have both male interconnecting component-ends, female interconnecting component-ends, and mixed male and female interconnecting component-ends. These ends are configured so that fabrication, connection, and individual and group installation are fast and simple. In turn, total foundation assembly and installation may be accomplished, in one example, in one or two days with as little equipment as a fork lift to move the structural supports, and a socket wrench to bolt interconnected (mated) opposing ends of adjacent supports together. In addition, a building customer's required plumbing and mechanical piping and conduit, as well as required electrical, data, phone, and/or fiber optic cable and conduits may be pre-installed in channels defined by internal walls of one or more of the structural supports.

Structural supports and assemblies constructed therefrom according to the present disclosure, are different than other solutions. This is due, in part, to each structural support's capability to have a unique arrangement of standardized interconnecting components. In one example, all ends/sides of every structural support of an assembled foundation is capable of being configured with male, female, or both male and female (quick connect) interconnecting components. This enables groups of structural supports to be uniquely assembled into any configuration. Further, these unique configurations may be achieved without specialized components, or any type of tool or linkage not already provided or constituted by the standardized interconnecting components that each structural support has.

In one example, structural supports according to the present disclosure are easy to position, may be stacked for storage or transport, and may be transported using a variety of widely available vehicles or transport methods (large and small work trucks, oversized trucks, vehicles used by common commercial carriers, in containers moved by tractor trailers, or as freight, etc.). This versatility in transport and delivery options means that metal or other types of non-permanent buildings may be installed in remote areas. These are locations that were often not previously considered as building construction site options, even for temporary buildings, because installing a traditional foundation presented many difficulties with getting labor and concrete preparation and installation equipment in and out of those remote areas.

In yet another example, individual structural supports may each be constructed with internal walls or partitions that define channels that extend an entire or substantial portion of a length of each structural support. The channels may be used to house pre-wiring and pre-tubing for electrical, plumbing, and mechanical systems. As a result, the structural supports allow segments of a foundation to be pre-wired, assembled, dissembled, and moved upon need.

In addition, the non-permanent foundations described herein effectively eliminate the loss of use or missed opportunity costs to an original user that must leave behind a concrete or other type of foundation intended as a permanent installation. Furthermore, the real money costs associated with having to remove concrete or other types of foundations more suited to be permanent or long-term installations are also eliminated.

Both the foregoing general description and the following detailed description are exemplary and explanatory only and are not restrictive of the examples, as claimed.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 illustrates a perspective view of a structural support according to an aspect of the present disclosure.

FIG. 2 illustrates a perspective partially exploded view of a structural support, according to an aspect of the present disclosure.

FIGS. 3A and 3B illustrate perspective and sectional views of a structural support, the sectional view of FIG. 3B taken from a plane corresponding to section line 3B-3B as illustrated in FIG. 3A.

FIGS. 4A and 4B illustrate perspective and sectional views of a structural support, the sectional view of FIG. 4B taken from a plane corresponding to section line 4B-4B as illustrated in FIG. 4A.

FIGS. 5A and 5B illustrate perspective and sectional views of a structural support, the sectional view of FIG. 5B taken from a plane corresponding to section line 5B-5B as illustrated in FIG. 5A.

FIGS. 6A and 6B illustrate perspective and sectional views of a structural support, the sectional view of FIG. 6B taken from a plane corresponding to section line 6B-6B as illustrated in FIG. 6A.

FIG. 7 illustrates a perspective view of an exemplary assembly of structural supports.

FIG. 8 illustrates a perspective view of a non-permanent building including an exemplary assembly of exemplary structural supports, according to as aspect of the present disclosure.

FIG. 9 illustrates a perspective view of a partially constructed non-permanent building including an exemplary assembly of exemplary structural supports, according to as aspect of the present disclosure.

FIG. 10 is a closeup of a portion of FIG. 9 identified as detail 10.

DESCRIPTION OF THE EXAMPLES

Reference will now be made in detail to the present examples, including examples illustrated in the accompanying drawings. Wherever possible, the same reference numbers will be used throughout the drawings to refer to the same or like parts.

FIG. 1 illustrates a perspective view of a structural support 100 according to an aspect of the present disclosure. The structural support 100 includes a first planar wall 110, a second planar wall 120, internal walls 130 that extend from a first inner surface 312 (see FIG. 3B) of the first planar wall 110 to a second internal surface (see FIG. 3B) of the second planar wall 120, a first side wall 140, and a second sidewall 150. The first and second side walls 140, 150 respectively define first and second connector components 160, 170 that are configured to receive third and fourth connector components 180, 190. The internal walls 130 define channels 135 that extend over a longitude of the of the structural support 100. The internal walls 130 disposed closest to each of the first and second side walls 140, 150 are partitioned to define second connector slot sub-components configured to receive the third connector components 180 extending in a direction orthogonal to the longitude of the structural support 100.

FIG. 2 illustrates a perspective partially exploded view of a structural support 200, according to an aspect of the present disclosure. In one example, third connector components 280 are provided as adaptors, each adaptor having a rectangular shaped body 282 and third connector apertures 284 extending through the body 282. The third connector apertures 282 being sized, in one example, to permit fourth connector components 290 to pass through the third connector components 280 and engage with aperture sub-components 262, 272 of the first or second connector components 260, 270 of the structural supports 200.

FIGS. 3A and 3B illustrate perspective and sectional views of a structural support 300. The sectional view of FIG. 3B is taken from a plane corresponding to section line 3B-3B as illustrated in FIG. 3A. In FIG. 3B, a second connector slot sub-component 374 of the structural support 300 that is shown, does not include a third connector positioned therein. Accordingly, portions of channels 335A, 335B, that would normally be blocked from view by a third connector are visible, and include a partitioned wall 332 and a distal end 304 of a first channel 335A the structural support 300. The distal end 304, like a proximal end 302 shown in FIG. 3A, may include a first connector with a first connector slot sub-component. The first channel 311 defined by the partitioned wall 332, a first side wall 340, and a second inner surface 322, extends from the proximal end 302 to the distal end 304. Likewise, a second channel 335B defined by the partitioned wall 332, an internal wall 330, and the second inner surface 322, also extends from the proximal end 302 to the distal end 304.

The partitioned wall 332 illustrated in FIG. 3B is substantially similar to the internal wall 330. The exception being provision of three gaps in the partitioned wall; each gap corresponding to a second connector slot sub-component 374 of a second connector component 370, which are shown in FIG. 3A. Turning back to FIG. 3B, first aperture sub-components 372A are defined within portions of a first planar wall 310 of the structural support 300 that correspond to the second connector slot sub-components 374. On the other hand, second aperture sub-components 372B are defined within portions of a second planar wall 320 of the structural support 300 that correspond to the second connector slot sub-components 374. As explained with reference to FIGS. 4A and 4B, these first and second connector slot sub-components receive fourth connector components 390 to secure third connector components 480 to (a) the second connector components 370, and (b) the structural support 300.

With the third connector components 480 secured to the structural support 300 illustrated in FIG. 3A, the structural support 300 can be attached to another structural support (not shown) along the first side wall 340. This other structural support may receive, in respective second connector slot sub-components 370, portions of the third connector components 480 extending from/through the first side wall 340 of the structural support 300. With additional fourth connector components 390, the third connector components 480, and thus the structural support 300, may be secured to the other structural support. Interactions between second, third, and fourth connectors 370, 480, 390 are described in more detail with references to FIGS. 4A and 4B.

FIGS. 4A and 4B illustrate perspective and sectional views of the structural support 300. The sectional view of FIG. 4B is taken from a plane corresponding to section line 4B-4B as illustrated in FIG. 4A. As shown, the structural support 300 includes three second connector components 370A, B, C defined by, among other structures, a first side wall 340. For one of the second connector components 370A, no third connector component 480 is inserted into a second connector slot sub-component 374 thereof. On the other hand, third connector components 480 are positioned within the other second connector components 370B, 370C. However, only the third connector component 480 provided closest to the distal end 302 of the structural support 300 is secured thereto by fourth connector components 390.

As shown in FIG. 4B, a third connector component 480 is received in the second connector component 370B provided in a middle portion of the structural support 300, but is not secured to thereto by the fourth connector components 390. However, in viewing FIG. 4B, it is clear each third aperture 484 defined in a portion of the third connector component 480 inserted into the structural support 300, can be aligned with a respective pair of first and second aperture subcomponents 372A, 372B. Together, each combination of aligned apertures can receive a fourth connector component 390, which in one example, can include a threaded end corresponding to a threaded wall defining a respective second aperture sub-component 372B.

FIGS. 5A and 5B illustrate perspective and sectional views of the structural support. The sectional view of FIG. 5B is taken from a plane corresponding to section line 5B-5B as illustrated in FIG. 5A. More specifically, FIG. 5B shows a sectional view of the first channel 335A that is: (a) defined by the partitioned wall 332, the first side wall 340, and the second inner surface 322, and (b) extends from the proximal end 302 to the distal end 304 of the structural support 300.

As illustrated in FIG. 5B, first connector components 560 are provided at the proximal and distal ends 302, 304 of the structural support 300. Like the second connector components 370, the first connector components 560 include pairs of first and second aperture sub-components 562A, 562B that are defined in the first and second planar walls 310, 320. As shown, these pairs of aperture sub-components 562A, 562B are provided along a longitudinal axis of the structural support. While the first connector components 560 are provided within the first channel 335A and the second channel 335B which is defined by the inner wall 330, it will be understood that any of the channels defined by pairs internal walls 330 may include first connector components 560.

With third connector components 480 secured to first connector components 560 at the proximal end 302, the structural support 300 can be attached to another structural support along said proximal end 302. This other structural support may receive, in respective first connector slot sub-components 564, portions of third connector components 480 extending from/through the proximal end 302 of the structural support 300. With additional fourth connector components 309, these third connector components 480, and thus the structural support 300, may be secured to first connector components 560 of the other structural support.

FIGS. 6A and 6B illustrate perspective and sectional views of a structural support 300. The sectional view of FIG. 6B is taken from a plane corresponding to section line 6B-6B as illustrated in FIG. 6A. FIG. 6B is particularly useful for appreciating the structure of channels for a structural support according to the present disclosure. As illustrated, the structural support 300 may include two first channels 335A, two second channels 335B, and a group of third channels 635 provided between the second channels 335B.

Each first channel 335A may defined by respective side and partitioned walls 340, 332. Further, each first channel 335A may include first connector components 560 and a portion of each second connector component 370 (i.e., one pair of first and second aperture sub-components 372A, 372B) defined by a respective group of side, partitioned, and internal walls 340, 332, 330. Each second channel 335B may be defined by respective partitioned and internal walls 332, 330. Further, each second channel 335B may include a portion of each second connector component 370 (i.e., one pair of first and second aperture sub-components 372A, 372B) defined by a respective group of side, partitioned, and internal walls 340, 332, 330.

Any of third channels 635 may be used to house pre-wiring and pre-tubing for electrical, plumbing, and mechanical systems. In addition, depending on a size (e.g., length) of third connector components 480 used, the second channels 335B may also be utilized to house pre-wiring and pre-tubing. As a result, the structural supports 300 can provide segments of a foundation that are pre-wired or pre-tubed, and make overall construction of a non-permanent building, including various electrical, mechanical, and data focused systems quicker, easier, and more efficient.

FIG. 7 illustrates a perspective view of an exemplary non-permanent foundation assembly 700 (“foundation assembly 700”) constructed of exemplary structural supports 710, according to an aspect of the present disclosure. More specifically, FIG. 7 shows a group of structural supports 710 that have been interconnected together using third connector components as described herein, to be assembled into a singular body that may serve as a foundation for a non-permanent building.

In another example, structural supports 710 may be designed with anchoring systems rated for any wind speed requirement for a pre-engineered building, such as a non-permanent metal building. As assembled into a foundation, the anchoring systems provided on the individual structural supports 710 may be strategically used to allow the foundation to be anchored into the ground to a level of security that would be required for any weather condition.

FIG. 8 illustrates a perspective view of an enclosed non-permanent building 800 including an exemplary foundation assembly 810 of exemplary structural supports , according to as aspect of the present disclosure. In one example, the enclosed non-permanent building 800 include the foundation assembly 810, a frame (not shown, see FIG. 9) attached to the foundation assembly 810, and walls 820 attached to the frame 920. The foundation assembly 810 can be provided as one large skid of interconnected skids in the form of the structural supports. In one example, with the frame 920 attached to the foundation assembly 810, and the wall attached to the frame 920, the non-permanent building 800 may be moved from one location to another on a jobsite, or from one jobsite to another jobsite, as a single structure carried by a two or more fork lifts utilizing the channels to mount the non-permanent building thereon.

The structural supports illustrated in FIG. 8, as well as any of the structural supports described herein, may be fabricated and manufactured using simple, fast, easily repeatable, and efficient processes. In one example, any of structural supports according to the present disclosure may be fabricated from structural steel, and may be hot-dipped and galvanized to prevent steel rot.

Further, structural supports described herein may be both produced individually or pre-assembled in sections of multiple supports, and transported to jobsites with only minimal lead times. A builder may order and receive delivery of a specified number of structural supports for a construction project within a relatively small window of time. More importantly, the builder may time delivery so that window of time is overlapped by short-term rental period for equipment that may be used to move the structural supports around a construction site, such as forklifts. Normally, these types of equipment are being used, but not optimally utilized (e.g., have periods of downtime), during their respective short-term rental periods for other tasks at the beginning of a project when a foundation is normally installed.

FIG. 9 illustrates a perspective view of an open non-permanent building 900 including an exemplary foundation assembly 910 of exemplary structural supports , according to as aspect of the present disclosure. The open non-permanent building 900 includes a frame 920 attached to foundation assembly 900. FIG. 10 illustrates a connection between a leg 930 of the frame 920, and a structural support of the foundation assembly 900. It will be understood that such a frame may be attached to the exemplary foundation assembly 900 using connectors such as the fourth connector components previously described. Any such connector component, including the fourth connector components may be provided with a bolt, hex-bolt, threaded fastener, nut and bolt combination, screw fastener, and the like.

In terms of installing a foundation such as the foundation assembly 900, or other foundation assemblies described herein—change orders or other situations that arise during certain types of projects, for example design-build projects, may require some level of ad-hoc provisioning of material, equipment, and labor that is costly and may derail and overall project schedule. However, in coupling transportability with short lead times for fabrication, the structural supports may be delivered in a matter of weeks. Further, once delivered, they may be erected in a day with little effort and labor. Thus, the structural supports of the present disclosure may enable builders and project managers to address unforeseen issues during early build out stages without losing labor man hours or getting significantly off-schedule.

Other features of, or provided by, the structural supports according to the present disclosure include their being considered, under certain building and other regulatory codes, a “mobile building” or a tool, and thus, obviating the need for storm water retention that may be required for code compliance in some areas. Using forklifts and channels defined by the supports, a non-permanent building, for example a metal building, may be moved in its entirety, and places in another location where it is needed. The supports provide for a portability of entire non-permanent building, with little labor, effort, and minimal coordination. Such metal buildings become more of an option to customers wanting a port-able building that may be reused in different locations.

Other examples of the disclosure will be apparent to those skilled in the art from consideration of the specification and practice of the examples disclosed herein. Though some of the described methods have been presented as a series of steps, it should be appreciated that one or more steps may occur simultaneously, in an overlapping fashion, or in a different order. The order of steps presented are only illustrative of the possibilities and those steps may be executed or performed in any suitable fashion. Moreover, the various features of the examples described here are not mutually exclusive. Rather any feature of any example described herein may be incorporated into any other suitable example. It is intended that the specification and examples be considered as exemplary only, with a true scope and spirit of the disclosure being indicated by the following claims.

Claims

1. A structural support comprising: a first side-wall;a second side-wall;a first planar wall;a second planar wall;internal walls disposed between the first side-wall and the second side wall, and extending from a first inner surface of the first planar wall to a second inner surface of the second planar wall,wherein the first side-wall, the second side-wall, the first planar wall, and the second planar wall define connector components; andwherein the internal walls define a plurality of channels between the connector components.

2. The structural support of claim 1, wherein each of the connector components is configured to receive more than one other type of connector component in a single interconnection.

3. The structural support of claim 2, wherein each of the connector components defines an aperture sub-component configured to fasten the structural support to at least one of the more than one other type of connector.

4. The structural support of claim 2, wherein the more than one other type of connector component includes: one connector component provided as an adaptor having a body that defines a plurality of apertures; andanother connector component provided as a bolt sized to extend through the apertures of the body of the adaptor.

5. The structural support of claim 1, wherein the connector components includes: first connector components that extend along a longitude of the structural support from respective longitudinal ends of thereof; andsecond connector components that include slot sub-components defined by respective openings in the first and second side walls.

6. The structural support of claim 1, wherein the channels are configured to receive planar extensions for raising and moving the structural support to a predetermined location.

7. The structural support of claim 1, wherein the structural support is a first structural support, and wherein the connector components are configured to connect the first structural support to a second structural support at one of the first side wall and the second side wall.

8. The structural support of claim 7, wherein the connector components are configured to connect the first structural support to a third structural support at one of a first longitudinal end and a second longitudinal end of the first structural support.

9. An assembly suitable for supporting a building, the assembly comprising: structural supports interconnected in a configuration corresponding to footprint of the building, each structural supporting including: a first side-wall, a second side-wall, a first planar wall, and a second planar wall (together “first and second walls”), the first and second walls defining first and second connector components; andinternal walls disposed between the first side-wall and the second side wall, and extending from a first inner surface of the first planar wall to a second inner surface of the second planar wall, the internal walls defining a plurality of channels between the connector components;third connector components configured to be received by the first and second connector components; andfourth connector component configured to be received by the third connector components and be secured to aperture sub-components of the first and second connector components.

10. The assembly of claim 9, wherein the channels are configured to receive planar extensions for raising and moving the assembly to a predetermined location.

11. The assembly of claim 9, wherein each of the first and second connector components is configured to receive at least one third connector component and at least one fourth connector component.

12. The assembly of claim 9, wherein each of the first and second connector components define an aperture sub-component configured to fasten a respective structural support to at least one third connector component and at least one fourth connector component.

13. The assembly of claim 9, wherein at least one of the third connector components includes an adaptor having a body, and wherein the body defines at least one aperture.

14. The assembly of claim 14, wherein at least one of the fourth connector components includes a bolt sized to extend through the at least one aperture.

15. The assembly of claim 9, wherein at least one of the first connector components extends along a longitude of respective structural support from respective longitudinal ends of thereof.

16. The assembly of claim 15, wherein at least one of the second connector components includes slot sub-components defined by openings in respective first and second side walls of the respective structural support.

17. A method of assembling a foundation assembly, the method comprising: providing a first structural support;providing a second structural support;positioning a third connector component within a first connector slot sub-component of a first connector component of the first structural support;aligning a first third connector aperture with: a first aperture sub-component defined by a first planar wall of the first structural support, anda second aperture sub-component defined by a second planar wall of the first structural support;positioning a fourth connector component through the first aperture sub-component and the third connector aperture and securing the fourth connector component to a wall that defines the second aperture sub-component; andpositioning the third connector component within a first connector slot sub-component of a first connector component of the second structural support.

18. The method of claim 17, further comprising: aligning a second third connector aperture with: a first aperture sub-component defined by a first planar wall of the second structural support, anda second aperture sub-component defined by a second planar wall of the second structural support; andpositioning a fourth connector component through the first aperture sub-component and the third connector aperture and securing the fourth connector component to a wall that defines the second aperture sub-component.

19. The method of claim 18, further comprising: positioning another third connector component within a second connector slot sub-component of a second connector component of the first structural support;aligning another first third connector aperture with another first aperture sub-component defined by the first planar wall, and another second aperture sub-component defined by the second planar wall of the first structural support; andpositioning another fourth connector component through the other first aperture sub-component and the other third connector aperture and securing the other fourth connector another second aperture sub-component.

20. The method of claim 19, further comprising positioning the other third connector component within a second connector slot sub-component of a second connector component of a third structural support.