The present disclosure relates, generally, to building construction. In particular, the present disclosure relates to a panelization system allowing for the ground assembly of suspended building components (e.g., I-beams and panels) and the placement of the assembled panel modules using a clamp attachment for the boom of a telehandler.
With the construction of taller and multi-level warehouses and distribution centers, material selection has shifted from concrete pre-cast and tilt wall products to insulated metal panels (IMPs). IMPs are exterior wall and roof panels often with steel skins and an insulating foam core, known for their superior thermal properties, spanning capabilities, and comparatively quick installation, that together save costs compared to other wall assemblies. Currently in the art, several workers must be hoisted to high elevations, where the workers precariously assemble IMP sections together and fasten them to the building using complex parapet assemblies and wall girts. These installation methods, however, present scheduling challenges for concurrent and following trades because access to work zones are not available until that portion of the IMP scope is complete.
Likewise, the conventional IMP construction process presents many safety risks and efficiency challenges. Workers are required to handle IMP products at dangerous heights, which increases falling hazards that may result in injuries or death. Assembly of the walls is a slow process as IMP planks are hoisted by crane a few at a time and then individually mounted. This conventional process restricts access to the jobsite and thus affects the scope of other trades and the overall building schedule.
Accordingly, there is a need for a system and method that reduces falling hazards by performing assembly at ground level, that allows for maneuvering of the assembled IMP into position, and that increases the scheduling efficiency of the construction. The system and method for assembling and installing insulated metal panels disclosed herein solves these problems and others.
In some embodiments, an IMP assembly system comprises a panel assembly table and a boom IMP attachment. The panel assembly table comprises a base frame, a track, a gantry movable along the track, a material deck movable along the track, a material lift arm coupled to the gantry and configured to collect IMP panel sections for placement on a panel frame. The panel assembly table may further comprise one or more panel jacks for lifting the panel module to allow access to an underside. The boom IMP attachment comprises a quick-coupler couplable to the boom of a telehandler, a swivel coupler column coupled to the swivel coupler, a first tilt linear actuator and a second tilt linear actuator configured to tilt the orientation of a panel module, a first hydraulic rotation linear actuator and a second hydraulic rotation linear actuator configured to rotate the orientation of the panel module, a hydraulic controller couplable to the telehandler, a jib frame, a plurality of jib arms, a first clamp header rail, a second clamp header rail opposite the first clamp header rail, and a plurality of clamp assemblies on each clamp header rail.
In some embodiments, the panel jacks support the panel frame while a panel module is being built, then lift the assembled panel module so the panel module can be accessed by the boom IMP attachment of the telehandler. The boom IMP attachment maneuvers the assembled panel module from the panel assembly table to a building for installation or to a crane for hoisting for installation. In some embodiments, the boom IMP attachment is capable of rotating the panel module one hundred and fifty degrees in horizontal position, and tilting the panel module one hundred and ten degrees to stand the panel module vertically, although not limited to these degrees.
The following descriptions depict only example embodiments and are not to be considered limiting in scope. Any reference herein to “the invention” is not intended to restrict or limit the invention to exact features or steps of any one or more of the exemplary embodiments disclosed in the present specification. References to “one embodiment,” “an embodiment,” “various embodiments,” and the like, may indicate that the embodiment(s) so described may include a particular feature, structure, or characteristic, but not every embodiment necessarily includes the particular feature, structure, or characteristic. Further, repeated use of the phrase “in one embodiment,” or “in an embodiment,” do not necessarily refer to the same embodiment, although they may.
Reference to the drawings is done throughout the disclosure using various numbers. The numbers used are for the convenience of the drafter only and the absence of numbers in an apparent sequence should not be considered limiting and does not imply that additional parts of that particular embodiment exist. Numbering patterns from one embodiment to the other need not imply that each embodiment has similar parts, although it may.
Accordingly, the particular arrangements disclosed are meant to be illustrative only and not limiting as to the scope of the invention, which is to be given the full breadth of the appended claims and any and all equivalents thereof. Although specific terms are employed herein, they are used in a generic and descriptive sense only and not for purposes of limitation. Unless otherwise expressly defined herein, such terms are intended to be given their broad, ordinary, and customary meaning not inconsistent with that applicable in the relevant industry and without restriction to any specific embodiment hereinafter described. As used herein, the article “a” is intended to include one or more items. When used herein to join a list of items, the term “or” denotes at least one of the items, but does not exclude a plurality of items of the list. For exemplary methods or processes, the sequence and/or arrangement of steps described herein are illustrative and not restrictive.
It should be understood that the steps of any such processes or methods are not limited to being carried out in any particular sequence, arrangement, or with any particular graphics or interface. Indeed, the steps of the disclosed processes or methods generally may be carried out in various sequences and arrangements while still falling within the scope of the present invention.
The term “coupled” may mean that two or more elements are in direct physical contact. However, “coupled” may also mean that two or more elements are not in direct contact with each other, but yet still cooperate or interact with each other.
The terms “comprising,” “including,” “having,” and the like, as used with respect to embodiments, are synonymous, and are generally intended as “open” terms (e.g., the term “including” should be interpreted as “including, but not limited to,” the term “having” should be interpreted as “having at least,” the term “includes” should be interpreted as “includes, but is not limited to,” etc.).
While the term “IMP wall module” is used throughout the present disclosure to refer to an assembled wall panel prepared for installation, the term may also denote one or more insulated metal panels, panel assemblies, or wall segments comprising metal, wood, plastic, glass, combinations thereof, or alternative construction materials.
As previously discussed, there is a need for a system and method for assembling and installing insulated metal panels that reduces falling hazards by performing greater assembly at ground level, and that optimizes the building scheduling efficiency amongst other trades on the jobsite. The IMP assembly system disclosed herein solves these problems and others.
In order to reduce falling hazards and the amount of work done at elevations, the process begins by assembling and IMP at ground level. The construction of the IMP may begin long before material delivery or other building activities happen on-site in order to enable the IMP assembly system to avoid scheduling conflicts with other construction projects concurrently being built on site. Accordingly, in some embodiments, as shown in
The panel frame 116 may comprise a steel stud or tube substructure, such as frame members 113A-F (
Beneath each panel module 118 is at least one panel jack 120A-D, which may be positioned prior to assembly of the panel module 118, although they may also be positioned after assembly. As best shown in
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In some embodiments, the boom IMP attachment 126 is capable of rotating the panel module 118 one hundred and fifty degrees from a horizontal position, and tilting the panel module 118 degrees to stand the panel module 118 vertically. However, while specific degrees are provided, it will be appreciated that the present invention is not so limited, and the degrees may be more or less than the above.
Referring now to
The clamp slide 156 allows for the distance to be varied between the fixed jaw 150 and the movable jaw 152. The clamp slide 156 may be coupled to the piston 160 of the clamp linear actuator 158, such as by using a locking pin 163. The piston 160 may be controlled using hydraulics supplied to the clamp linear actuator 158 using hydraulic ports 168. This allows the operator of the telehandler 130 to decrease the distance, or increase the distance, between the fixed jaw 150 and movable jaw 152, as needed. For example, in some embodiments, as the hydraulic pressure is decreased, the piston 160 moves into the cylinder 162. Because the piston 160 is coupled to the movable jaw 152 via the clamp slide 156, both the clamp slide 156 and the movable jaw 152 coupled thereto move toward the fixed jaw 150.
The distance between the fixed jaw 150 and the movable jaw 152 may be further decreased or increased by selectively coupling the clamp slide 156 via locking pin apertures. In other words, a locking pin may be removed, the clamp slide 156 adjusted as needed, and then the locking pin may be re-inserted into the appropriate locking pin aperture. The locking pin may also pass through (or otherwise be coupled to) the piston 160. It will be appreciated that while referenced herein as fixed jaw 150, it is not required to be fixed (i.e., immovable). In other words, in an alternate embodiment, both the movable jaw 152 and the fixed jaw 150 would be movable and would approximate each other during hydraulic actuation. Further, while hydraulic systems are shown and described, the clamp assemblies 140A-L are not so limited. In other words, electronically controlled mechanisms may be used, including screw drives, a rack and pinion mechanism with an electric motor, or similar methods of linear actuation.
As best shown in
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As mentioned, boom IMP attachment 126 may tilt in relation to the boom 129 of the telehandler 130, tilting the panel module 118. The first tilt linear actuator 144A and the second tilt linear actuator 144B are configured to tilt the orientation of the panel module 118 to stand the panel module vertically, or substantially vertically. This allows the panel module 118 to be tilted from the initial position (e.g., horizontal) during assembly along the panel assembly table 102, parallel to the ground, to a final position (e.g., vertical) during installation along the exterior wall or façade of the building 176, perpendicular to the ground. Again, once the telehandler 130 has moved the panel module 118 from the panel assembly table 102 to the installation site, a crane 170 comprising a rigging assembly is coupled to an end of the panel module 118. Upon secure transfer to the crane 170, the boom IMP attachment 126 may be released from the panel module 118. To release the boom IMP attachment 126, the operator widens the clamping apertures 154, thereby releasing the panel module 118. It will be appreciated that the first and second hydraulic rotation cylinders 146A-B allow the jib frame 134 to rotate along an axis. Once the panel module 118 is positioned flush against the wall of the building 176 by the crane 170, workers may fasten the panel module 118 into place using bolts, welds, or other fasteners.
In some embodiments, a method of using an IMP assembly system 100 comprises coupling the quick-coupler 132 of a boom IMP attachment 126 to a telehandler 130. The boom IMP attachment 126 is then positioned beneath a panel module 118 that is formed from panel sections 114 fastened to a panel frame 116 (e.g., studs, beams). Each of the clamp assemblies 140A-L are positioned beneath the panel frame 116 such that the fixed jaw 150 and movable jaw 152 of each clamp assembly 140A-L are on opposite sides of a frame member 113A-F (
In some embodiments, a crane rigging assembly (comprising crane cables 172 and the spreader bar 174) is coupled to an end of the panel module 118. Once coupled to the crane 170, the boom IMP attachment 126 may be released from the panel module 118. To release the boom IMP attachment 126, the operator opens the clamping aperture to release the frame members 113A-F therein.
The panel frame 116 distributes the weight of the panel module 118 across the boom of the telehandler 130. While frame members 113A-F are shown and described throughout as beams or studs, it will be appreciated that the invention is not so limited. In other words, in addition to grasping frame members 113A-F, the boom IMP attachment 126 can be adapted to handle groups of open web steel joists, I-beams, or other structural members in the same manner. In some applications, such as single-story building and other comparatively short warehouses, the telehandler 130 may position the panel module 118 directly into position along the exterior façade of the building 176 without the assistance of a crane 170. This avenue further reduces risk (cranes have inherit risks) and project costs by removing the costs associated with a crane 170. In other words, the telehandler 130 may position the panel module 118 for securing directly to a building 176, which is not possible in the prior art.
Moreover, it will be appreciated, that assembling the panel module 118 at ground level, rather than multiple stories within the air, minimizes falling hazards, improving worker safety and reducing fatigue caused from working within a harness suspended above the ground. For example, iron workers benefit from reduced aerial time while incorporating steel components such as the panel frame 116 into the panel module 118. Likewise, all material may be better controlled in an ergonomic manner, reducing fatigue and other injury risks. Additional efficiency gains through more productive workflow translate into shorter durations for the overall IMP project scope, closing the building perimeter faster. Another schedule advantage can be achieved in onsite logistics, as most assemblies can be completed away from the building perimeter, improving access for multiple trades and crews, thereby optimizing material staging. The IMP assembly system 100 also contributes to a more simplified perimeter wall system design, removing complex parapet assemblies and wall girts that often affect multiple finishing scopes and present sequencing challenges throughout the construction process. Accordingly, the system and method for installing insulated metal panels disclosed herein solves these problems and others, overcoming the prior art.
It will be appreciated that systems and methods according to certain embodiments of the present disclosure may include, incorporate, or otherwise comprise properties or features (e.g., components, members, elements, parts, and/or portions) described in other embodiments. Accordingly, the various features of certain embodiments can be compatible with, combined with, included in, and/or incorporated into other embodiments of the present disclosure. Thus, disclosure of certain features relative to a specific embodiment of the present disclosure should not be construed as limiting application or inclusion of said features to the specific embodiment unless so stated. Rather, it will be appreciated that other embodiments can also include said features, members, elements, parts, and/or portions without necessarily departing from the scope of the present disclosure.
Moreover, unless a feature is described as requiring another feature in combination therewith, any feature herein may be combined with any other feature of a same or different embodiment disclosed herein. Furthermore, various well-known aspects of illustrative systems, methods, apparatus, and the like are not described herein in particular detail in order to avoid obscuring aspects of the example embodiments. Such aspects are, however, also contemplated herein.
Exemplary embodiments are described above. No element, act, or instruction used in this description should be construed as important, necessary, critical, or essential unless explicitly described as such. Although only a few of the exemplary embodiments have been described in detail herein, those skilled in the art will readily appreciate that many modifications are possible in these exemplary embodiments without materially departing from the novel teachings and advantages herein. Accordingly, all such modifications are intended to be included within the scope of this invention.
This application claims the benefit of U.S. Provisional Application Ser. No. 63292787, filed on Dec. 22, 2021, which is incorporated herein by reference.
Number | Date | Country | |
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63292787 | Dec 2021 | US |