CROSS-REFERENCE TO RELATED APPLICATIONS N/A
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT N/A
REFERENCE TO MICROFICHE APPENDIX N/A
BACKGROUND OF THE INVENTION 1. Field of the Invention
This invention relates to the field of foundations to support structures or equipment.
2. Description of the Related Art
In August, 2005, Hurricane Katrina and its storm surge caused severe and catastrophic damage along the U.S. Gulf coast, particularly in Louisiana, Mississippi, and Alabama. Levees separating Lake Pontchartrain and several canals from New Orleans were breached a few days after the hurricane subsided, subsequently flooding the majority of the city and many areas of neighboring parishes for weeks. Severe wind damage was reported well inland. Hundreds of thousands of residences were destroyed. The storm is widely estimated to have been the costliest natural disaster in U.S. history. The rebuilding process is currently ongoing, and basic building materials and skilled labor in the region are in short supply, if available at all, making conventional building techniques very expensive and time consuming. Many thousands of residents are in need of housing that can be built quickly and efficiently while being able to withstand similar acts of nature in the future.
In many areas before the storm, such as in New Orleans, residential reinforced concrete foundations were constructed at or near grade or ground level as shown in FIGS. 1 and 2, by initially excavating and removing soil from the site; moving and placing select fill soil into the foundation area; compacting the fill soil in stages to create a soil foundation pad; digging channels to form interior and exterior grade beams; constructing and placing formwork for the exterior grade beams; driving wooden piles or pilings into the soil in numerous locations under the excavated exterior and interior grade beams; placing conduits for mechanical, electrical, or plumbing (MEP) lines horizontally and extending them vertically upward above grade; positioning reinforcing steel bars and/or stirrups for the grade beams and slab; pouring concrete to form the grade beams and slab, including around the ends or heads of the piles extending above grade; removing the formwork; and backfilling with soil around the exterior of the foundation. The top of the finished slab would typically be about six inches (15.2 cm) above the finished grade of soil immediately surrounding the foundation. The undersides of the slab and grade beams rest upon the fill soil for structural support.
Some problems with quality control at the site include having too much or too little water in the concrete; having poor quality exposed concrete surfaces due to inferior workmanship in constructing the forms; having incorrect placement of reinforcing steel, such as for example too little concrete cover; and having incorrect placement of MEP lines. After the foundation is poured, new MEP lines have to be placed under the foundation by boring a channel horizontally through the soil, then upwardly through the slab. The concrete slabs, as described above, would typically not be designed to support themselves if the fill soil they were poured upon were removed or washed away. All of the work would be done at the construction site, and most, if not all, of the materials would be obtained nearby. The existing conventional process is time consuming, requiring several different contractors, subcontractors, and tradesmen. Obstructions outside of the foundation area, such as trees, might have to be removed to make room for construction equipment and staging of materials. The construction of the complete structure itself is highly dependent upon the timely completion of the foundation, which could lead to difficulties if soil conditions delayed or hindered the foundation work. In large measure, the conventional foundations did not prevent the damage to the structures that occurred after and during the storm surge, and in many instances the foundations themselves were compromised by the storm surge that washed out the fill soil under the slabs. Moreover, even without hurricane conditions, conventional slabs on grade, as shown in FIGS. 1 and 2 and described above, are subject to uneven vertical movement (settlement or heave) caused by change in moisture content of the underlying soil and resulting expansion and contraction.
In apparent recognition that an occurrence, such as Katrina, could repeat itself, New Orleans area building officials are currently requiring that residences be built with the top of their finished foundation slabs at least three feet (0.92 m) above the highest elevation or crown of the street that is nearby, which is typically measured along the longitudinal centerline of the street. This requires that the top of the finished slab be over three feet above the finished grade level of the soil immediately surrounding the foundation, and sometimes as high as five or six feet above. Extensive amounts of fill soil would be required with conventional building techniques, as described above, to construct such foundations, and fill soil and skilled labor to place it are either unavailable or uneconomical. Conventional building techniques would also be very time consuming.
Foundation members below grade or ground level are often classified as shallow or deep, depending on the depth of the load-transfer member and the type of load transfer mechanism. Deep foundation members include driven piles and drilled shafts or piers. Piles are usually made from pressure treated timber, concrete, or steel, and are driven with large pile drivers or hydraulic hammers into the underlying soil. The principal load transfer mechanism for piles is skin friction along the length of the pile between the outside circumference of the pile and the soil. Drilled piers are typically made with reinforced concrete poured at the construction site after the shafts have been drilled into the underlying soil using large truck mounted rotary drills. The principal load transfer mechanism for drilled piers is bearing pressure of the soil on the bottom circular area of the pier along with significant skin friction if the piers are deep enough. Sometimes piers are belled at the bottom to increase the bearing area with the soil. Shallow foundation members include grade beams and footings, which are typically made of reinforced concrete, and typically only extend from one to three feet below grade. Shallow foundation members rely exclusively on bearing pressure with the soil as the load transfer mechanism. The required foundation member for a structure depends on the strength and compressibility of the soils at the site, the proposed loading conditions, and the project performance criteria, such as settlement limitations.
Elevated residences in the prior art have been constructed using driven piles. Instead of the piles only extending a foot or so above grade as shown in FIG. 2, the piles typically extend ten or so feet above grade. Residences in beach communities have been constructed on horizontal wooden framing that is assembled on such pressure treated timber or concrete piles to elevate them above potential rising flood waters. Residences constructed of wood in inland communities have been positioned a few feet above grade using pier and beam construction to separate the horizontal wooden framing from the soil, which can cause rotting and allow termite access. In such construction, the below grade foundation member is typically a drilled pier or a pad footing of reinforced concrete. The foundation member may have longitudinal reinforcing steel bars that extend upward above grade. Concrete masonry unit (CMU) blocks may be stacked on the pier or footing to elevate the horizontal wooden framing for the residence a few feet above grade. A common CMU block size is 7⅝″ wide, 15⅝″ long, and 7⅝″ high (19.4 cm×39.7 cm×19.4 cm). A CMU block typically has two holes extending from its bottom to its top. The blocks may be stacked so that the reinforcing bars may extend through the aligned holes. The bottoms and tops of the blocks are individually grouted together while they are stacked, similar to applying mortar to brick. Grout can be poured into the holes after the blocks are stacked and grouted together.
Although they are uncommon in residential foundation construction, cast in place structural slabs have been used to separate the slab from the vertical movement of the underlying soil due to changes in moisture content. The preparation for cast in place structural slabs is similar to that described above for FIGS. 1 and 2, except that before the reinforcing steel is placed, corrugated paper forms, known in the art as void forms, void boxes, or carton forms, are placed in the foundation area under where the grade beams and slab will be poured. Such void forms are manufactured by SureVoid Products, Inc. of Englewood, Colo., among others. The void forms are approximately six inches (15.2 cm) in height, and provide a temporary support platform for concrete placement until the grade beams and slab can set and support themselves across drilled piers or other foundation members. The void forms, lying under the concrete grade beams and slab after the concrete has been poured at the site, gradually absorb moisture, decompose, and lose their strength after the concrete has set, creating a void or space into which the soil can thereafter expand and contract without causing damage. The structural slab system, unlike the system shown in FIGS. 1 and 2, has to be designed to span between the foundation members, such as drilled piers, since the soil will not be available for support after the void forms decompose.
Precast concrete structural elements have been used for erecting low cost concrete structures, such as houses and buildings. Such structures are generally more economical and more easily erected than structures constructed with conventional building techniques. U.S. Pat. No. 4,328,651 to Gutierrez proposes a precast concrete footing box with notches for receipt of precast concrete grade beams (Col. 4, lns. 15-18) that have grooves for insertion of precast concrete wall panels. The non-elevated Gutierrez precast system appears to propose a cast-in-place floor system (Col. 4, lns. 51-52). Pub. No. U.S. 2003/0033773 A1 to Houpapa proposes a precast concrete foundation block with grooves for receipt of precast concrete wall sections. Houpapa proposes a conventional cast-in-place (in situ) concrete floor slab (¶'s 63, 64, 70 and 71). U.S. Pat. No. 3,706,168 to Pilish proposes a precast concrete footing block with slots for receipt of precast concrete wall panels. Pilish proposes that precast concrete floor panels rest upon inverted L-shaped steel channel members that are attached to the wall panels by nuts affixed to embedded studs in the wall panels (Col. 4, lns. 50-65).
The above discussed U.S. Pat. Nos. 4,328,651 and 3,706,168; and Pub. No. U.S. 2003/0033773 A1 are incorporated herein by reference for all purposes in their entirety.
A need exists for an economical elevated foundation slab system that can be constructed at the site with a minimal amount of labor and materials.
BRIEF SUMMARY OF THE INVENTION An elevated foundation slab system is disclosed that uses risers, transfer beams, cross beams, and slab panels that may be assembled together with minimal skilled labor. The components are modular, which allows different foundation slab area sizes and shapes to be constructed with the same components. A minimal number of components are used, which reduces inventory and makes manufacture and erection quicker and more efficient. The components may be made of conventionally reinforced concrete or other materials. The components may be pre-cast away from the construction site and are configured for economical transportation to the site. Quality control may be better maintained since the components do not have to be manufactured at the job site. The system may be positioned with shallow or deep foundation members, such as piles, piers, grade beams, or pads.
The system provides elevation above high water, and stability in high winds. A minimal amount of materials are needed at the construction site, and fill soil is not required. The relatively compact and lightweight components make transportation of the components possible with smaller or fewer trucks, and erection possible with smaller and easily maneuverable construction equipment (also transported by the trucks). These smaller trucks and construction equipment can maneuver around trees and other normally encountered obstructions at the site. Uneven vertical movement of the system from change in moisture content of the underlying soil or other factors is minimized since the system is elevated. However, if necessary, the system facilitates re-leveling with shims if uneven vertical movement occurs at any time after the system is built, or even during construction. Aesthetically pleasing architectural finishes, such as brick or stone facade, may be cast onto the exterior surface of the components, and/or painted to match the structure above. Openings or channels for mechanical, electrical, and plumbing (MEP) lines may be placed in the components before they are cast, so that the MEP lines can be made at the construction site, even after the slab system is assembled, since the system is elevated.
BRIEF DESCRIPTION OF THE DRAWINGS A better understanding of the present invention can be obtained with the following detailed descriptions of the various disclosed embodiments in the drawings:
FIG. 1 is a plan view of a prior art residential cast in place reinforced concrete foundation with grade beams and piles shown in phantom view.
FIG. 2 is a section view taken along line 2-2 of FIG. 1.
FIG. 3 is a cut away perspective view of the low elevated slab system (LESS) of the present invention, with some risers shown positioned on piles, transfer and cross beams assembled on risers, and slab panels assembled on the transfer and cross beams.
FIG. 4 is a plan view of the LESS of the present invention, illustrating risers (some shown partially in phantom view), transfer beams (some shown partially in phantom view), cross beams (one of which shown in phantom view), and slab panels (some shown cut away) assembled together.
FIG. 5 is a side elevation view of FIG. 4, illustrating risers, transfer beams, and slab panels (some shown in phantom view) assembled together.
FIG. 6 is a broken section view taken along line 6-6 of FIG. 4 with the openings of the risers shown in phantom view, and one side exterior riser shown positioned with a pile.
FIG. 7 is a section view taken along line 7-7 of FIG. 4 to better show an end exterior riser.
FIG. 8 is a section view taken along line 8-8 of FIG. 4 with the opening of an interior riser shown in phantom view.
FIG. 9 is a section view taken along line 9-9 of FIG. 8 to better show cross beams on an interior riser.
FIG. 10 is a plan view of corner and interior edge slab panels of the LESS that span between two beams, supported by a transfer beam.
FIG. 11 is a side elevation view of the slab panels of FIG. 10 of the LESS with one end cut away to illustrate a weld plate, and another weld plate shown at the other end in phantom view.
FIG. 12 is a plan view of exterior side and interior side slab panels of the LESS that span between two beams, without support by a transfer beam.
FIG. 12A is a plan view of exterior middle and interior middle slab panels of the LESS that span between two beams, without support by a transfer beam.
FIG. 12B is a side elevation view of the slab panels of FIG. 12A of the LESS, with one end cut away to illustrate a weld plate and other weld plates shown at the other end in phantom view.
FIG. 13 is a side elevation view of a cross beam of the LESS for positioning with the slab panels of FIGS. 10, 12, and 12A, which cross beam spans between the side exterior riser of FIG. 28, interior riser of FIG. 34, extension exterior riser of FIG. 37, and/or extension interior riser.
FIG. 14 is a plan view of the cross beam of FIG. 13 with one end cut away to illustrate two weld plates, and two other weld plates shown at the other end in phantom view.
FIG. 15 is an elevation end view of the cross beam of FIG. 13.
FIG. 16 is a plan view of the end transfer beam for positioning with the corner slab panel of FIG. 10, exterior side slab panel of FIG. 12, exterior middle slab panel of FIG. 12A, extension corner slab panel, and/or extension side slab panel of the LESS, which end transfer beam spans between the corner riser, end exterior riser, and/or extension exterior riser of FIGS. 25, 31 and 37, respectively.
FIG. 17 is a side elevation view of the end transfer beam of FIG. 16.
FIG. 18 is an elevational end view of the end transfer beam of FIG. 17.
FIG. 19 is a plan view of a corner transfer beam for positioning with the corner slab panel of FIG. 10, which corner transfer beam spans between the corner riser, side exterior riser, and/or extension exterior riser of FIGS. 25, 28 and 37, respectively.
FIG. 20 is a side elevation view of the corner transfer beam of FIG. 19.
FIG. 21 is an end elevation view of the corner transfer beam of FIG. 20.
FIG. 22 is a plan view of a non-corner transfer beam for positioning with an interior edge slab panel of FIG. 10, which non-corner transfer beam spans between side exterior risers of FIG. 28, extension exterior risers of FIG. 37, and/or extension interior risers.
FIG. 23 is a side elevation view of the non-corner transfer beam of FIG. 22.
FIG. 24 is an end elevation view of the non-corner transfer beam of FIG. 23.
FIG. 25 is a front elevation view of the corner riser of the LESS, partially cut away to show the opening, with the remainder of the opening shown in phantom view.
FIG. 26 is a side elevation view of the corner riser of FIG. 25 with the opening shown in phantom view.
FIG. 27 is a plan view of the corner riser of FIG. 25.
FIG. 28 is a front elevation view of the side exterior riser for positioning with the cross beam of FIG. 13 and the corner and/or non-corner transfer beams of FIGS. 19-24, with the riser opening shown in phantom view.
FIG. 29 is a side elevation view of the side exterior riser of FIG. 28.
FIG. 30 is a plan view of the side exterior riser of FIG. 28.
FIG. 31 is a front elevation view of the end exterior riser, as shown assembled in FIG. 7, positioned with the end transfer beam of FIG. 16.
FIG. 32 is a side elevation view of the end exterior riser of FIG. 31.
FIG. 33 is a plan view of the end exterior riser of FIG. 31.
FIG. 34 is a front elevation view of an interior riser for positioning with the cross beam of FIG. 13.
FIG. 35 is a side elevation view of the interior riser of FIG. 34.
FIG. 36 is a plan view of the interior riser of FIG. 35.
FIG. 37 is a front elevation view of an extension exterior riser for interconnecting up to four beams of the LESS, with its opening shown in phantom view.
FIG. 38 is a side elevation view of the extension exterior riser of FIG. 37.
FIG. 39 is a plan view of the extension exterior riser of FIG. 38.
FIG. 40 is an elevational view in cut away section of a riser of the LESS with a pile with the riser partially cut away to show concrete placed in the opening and recess of the riser.
FIG. 41 is an elevational view of a riser of the LESS with a drilled bell bottom pier shown in broken view with reinforcing steel extending upwardly therefrom with the riser partially cut away to show concrete placed in the opening and recess of the riser.
FIG. 42 is an elevational view of a riser of the LESS with a pad on two piles with the riser partially cut away to show concrete placed in the opening and recess of the riser and the remainder of the riser shown with an architectural finish.
FIG. 43 is an elevational view of a riser of the LESS with a grade beam with reinforcing steel extending upwardly therefrom with the riser partially cut away to show concrete placed in the opening and recess of the riser.
FIG. 44 is an elevational view of a riser of the LESS with a pile using an alternative of steel reinforcing bars extending laterally through both the riser and the pile.
FIG. 45 is an elevational assembled view of the end exterior riser, end transfer beam, and a cut away exterior middle slab panel together, with concrete in the opening of the riser, and two shims positioned between the end exterior riser and the bottom of the end transfer beam for leveling the LESS.
FIG. 46 is a section view taken along line 46-46 of FIG. 4 to better show a corner riser, end transfer beam and corner transfer beam assembled together, with concrete in the opening of the riser and two shims positioned between the corner riser and bottom of the end transfer beam for leveling the LESS.
FIG. 47 is a section view taken along line 47-47 of FIG. 4 to better show an interior riser, cross beam and slab panels assembled together, with concrete in the opening of the riser and shims positioned between the cross beam and the bottom of the slab panels for leveling the LESS.
FIG. 48 is a cut away perspective view of the LESS of the present invention, illustrating transfer and cross beams assembled with two extension exterior risers of FIG. 37 of the LESS, an isolated extension interior riser, and slab panels positioned on the transfer and cross beams.
DETAILED DESCRIPTION OF THE INVENTION Generally, the present invention involves a system and method for the construction of an elevated foundation slab system using a minimal number of modular components. The system includes risers (C1, C2, C3, C4, C5A, C5B, C6), transfer beams (B1, B2, B3, B4, B5, B7, B8), cross beams B6, and slab panels (P1, P2, P3, P4, P5, P6, P7, P8). Foundation slab areas of different sizes and shapes may be created with the same components. It is contemplated that the finished slab elevation H1 as measured from the bottom of the risers (C1, C2, C3, C4, C5A, C5B, C6) may preferably be six feet (1.8 m). However, other heights are contemplated as well.
As shown in FIGS. 40-44 and discussed below, risers (C1, C2, C3, C4, C5A, C5B, C6) may be positioned over shallow or deep foundation members, such as for example one or more piles, one or more drilled piers, a grade beam, or a cap or pad. As shown in FIGS. 3, 4 and 48 and discussed below, cross B6 and transfer (B1, B2, B3, B4, B5, B7, B8) beams may be positioned on risers (C1, C2, C3, C4, C5A, C5B, C6) that are configured to receive them. Cross beams B6 have a rectangular cross sectional area, and typically are positioned to span over interior risers C4 placed in the interior of the foundation area. Transfer beams (B1, B2, B3, B4, B5, B7, B8) have an L-shaped cross sectional area (a smaller rectangle over a larger rectangle with a common exterior side ES). The exterior sides ES of transfer beams (B1, B2, B3, B4, B5, B7, B8) have a greater height than their interior sides IS, which creates ledges (9, 13, 15) on their interior sides IS. Transfer beams (B1, B2, B3, B4, B5, B7, B8) are placed around the perimeter of the foundation area with their interior sides IS on the interior.
Slab panels (P1, P2, P3, P4, P5, P6, P7, P8), which have a rectangular shape in plan view and uniform thickness TH, may be positioned on top of cross beams B6 and/or on the ledges (9, 13, 15) of transfer beams (B1, B2, B3, B4, B5, B7, B8) that are configured to receive them. Channels or openings for mechanical, electrical, and plumbing (MEP) lines may be pre-cast into slab panels (P1, P2, P3, P4, P5, P6, P7, P8) or other components, or alternatively placed at the construction site, such as by cutting or drilling. Because slab panels (P1, P2, P3, P4, P5, P6, P7, P8) are elevated, critical path accommodation for installation of MEP lines after erection of the foundation slab does not present a problem as it does with a conventional cast in place slab on grade foundation, as shown in FIGS. 1 and 2.
Risers are designated as C1, C2, C3, C4, C5A, C5B, or C6 as shown in FIGS. 25-39 and/or described below depending on their positions along the exterior or in the interior of the foundation area. Each riser (C1, C2, C3, C4, C5A, C5B, C6) has a different top and/or weld plate configuration, which dictates the beams (B1, B2, B3, B4, B5, B6, B7, B8) with which it may be assembled. Transfer beams are designated as B1, B2, B3, B4, B5, B7, or B8 as shown in FIGS. 16-24 and/or described below depending on their positions in and around the foundation area, their lengths, and the locations of their weld plates. The slab panels are designated as P1, P2, P3, P4, P5, P6, P7, or P8 as shown in FIGS. 10-12B and/or described below depending on their positions in the foundation area, their lengths, and the locations of their weld plates.
Although the preferred method of manufacture is to pre-cast the components away from the construction site, it is also contemplated that all or some of the components may be cast at the construction site. Although the preferred material for all components is concrete conventionally reinforced longitudinally with steel bars R and transversely with steel stirrups T, other materials are contemplated as well, including plain concrete, prestressed concrete, post-tensioned concrete, and all types of composites as are known in the art. All types and strengths of concrete as are known in the art are contemplated. All types and strengths of reinforcing materials as are known in the art are contemplated, including steel. It is contemplated that the different precasting materials and reinforcing materials could be used in any combination, such as for example, a reinforced concrete riser (C1, C2, C3, C4, C5A, C5B, C6) with a prestressed concrete transfer beam (B1, B2, B3, B4, B5, B7, B8). Although the preferred use of the system and method is for elevated residential foundation slab systems, it is also contemplated that the system and method may be used for elevated foundation slab systems for any type of structure or equipment, such as for example industrial buildings, commercial buildings, and industrial equipment.
A residential structure with AERODWELL™ wall and ceiling panels manufactured by Hanson Pipe & Precast Inc. of Dallas, Tex. may be erected above the LESS of the present invention. AERODWELL™ wall and ceiling panels eliminate the need for framing, insulation, exterior sheathing, and sheet rocking. They reduce construction delays and costs. AERODWELL™ wall panels may be positioned upon the tops 3 of the transfer beams (B1, B2, B3, B4, B5, B7, B8). The entire construction process for a dried-in structure with AERODWELL™ wall and ceiling panels erected above the LESS can be completed in just three days. During production, openings for doors, windows, electrical conduits, telephone, and television wires may be cast into the ceiling panels, and exterior finishes may be customized by overlaying brick, stucco, siding or stone. It should be understood that other types of residential structures may be erected above the LESS as well.
As discussed above in detail, FIGS. 1 and 2 show a prior art residential slab on grade foundation placed over wooden piles A. After some excavation is completed and the soil is hauled away, piles A are driven into the underlying soil, and select fill soil is transported to the site, placed over the area, and compacted in stages to form a foundation pad F. The channels for the exterior E and interior I grade beams are dug, and formwork G used on the exterior grade beams E is typically built at the site with wood. After the reinforcing steel (R, T) is placed, the concrete is then poured for the grade beams (E, I) and slab S.
FIGS. 3-5 show an elevated foundation slab system of the present invention in which slab panels (P1, P2, P3, P4, P5, P6) are positioned on the cross beams B6 and/or transfer beams (B1, B2, B3, B4, B5) that are configured to receive them, as will be discussed below, and which beams (B1, B2, B3, B4, B5, B6) are positioned on the risers (C1, C2, C3, C4) that are configured to receive them, which will also be discussed below. Some of the risers (C1, C2, C3, C4) are positioned on piles A. The slab panels (P1, P2, P3, P4, P5, P6) may be attached or connected with each other and/or the transfer beams (B1, B2, B3, B4, B5) with steel plates Y at the locations where their respective weld plates align, as will also be discussed below.
Corner risers C1 with ledges 24 for receipt of transfer beams (B1, B2, B3, B4) are positioned at the four corners of the rectangular foundation area. Side exterior risers C2 that have grooves 47 for receipt of cross beams B6 and ledges (52, 54) for receipt of transfer beams (B3, B4, B5) are positioned along the perimeter of the foundation area on two parallel sides. End exterior risers C3 that have ledges 60 for receipt of transfer beams (B1, B2) are positioned along the perimeter of the foundation area on the other two parallel sides. Interior risers C4 are positioned in the interior of the foundation area for receipt of cross beams B6. Risers (C1, C2, C3, C4) divide the foundation area into four bays: two exterior bays shown as EB and two interior bays shown as IB.
The left end of end transfer beam B1 as viewed from its interior side IS is positioned with end exterior riser C3, and the right end of end transfer beam B1 is positioned with corner riser C1. As will be discussed below, end transfer beams B1 and B2 are mirror images of each other. The left end of end transfer beam B2 as viewed from its interior side IS is positioned with corner riser C1, and the right end of end transfer beam B2 is positioned with end exterior riser C3.
The left end of corner transfer beam B3 as viewed from its interior side IS is positioned with side exterior riser C2, and the right end of corner transfer beam B3 is positioned with corner riser C1. As will be discussed below, corner transfer beams B3 and B4 are mirror images of each other. The left end of corner transfer beam B4 as viewed from its interior side IS is positioned with corner riser C1, and the right end of corner transfer beam B4 is positioned with side exterior riser C2. The ends of non-corner transfer beams B5 are positioned on side exterior risers C2, and the ends of cross beams B6 are positioned on side exterior risers C2 and interior risers C4.
Corner slab panel P1 may be positioned at the four corners of the foundation area as partially shown in FIGS. 3 and 4. Corner slab panel P1 shown in FIG. 3 spans between end transfer beam B2 and cross beam B6. One side of corner slab panel P1 is also positioned on corner transfer beam B3. Corner slab panel P1 may be connected with interior edge slab panel P3 and transfer beams (B2, B3) with plates Y that may be welded where the respective weld plates (PL1, PL3, PL7, PL10) of the components align. It is contemplated that metal plate Y may be six inches wide, six inches long, and ⅜ inches thick (15.2 cm×15.2 cm×1.0 cm). However, other dimensions are contemplated as well. It is contemplated that plate Y may preferably be steel. Corner slab panel P1 shown in FIG. 4 spans between end transfer beam B1 and cross beam B6. One side of corner slab panel P1 is also positioned on corner transfer beam B4. Corner slab panel P1 may be connected with interior edge slab panel P3 and transfer beams (B1, B4) with plates Y that may be welded where the respective weld plates (PL1, PL3, PL7, PL10) of the components align. As can now be understood, corner slab panel P1 shown in FIG. 3 has been rotated 180° for placement in FIG. 4. As shown in FIG. 48, it is contemplated that corner slab panels P1 may also be positioned in the same manner as shown in FIGS. 3 and 4 in all four corners of the foundation area in the exterior bays EB.
As shown in FIGS. 3 and 4, exterior side slab panel P2 spans between cross beam B6 and either end transfer beam B1 or B2. Unlike corner slab panel P1, exterior side slab panel P2 does not have a third side positioned on a transfer beam (B1, B2, B3, B4). Unlike exterior middle slab panel P5, which will be discussed below, exterior side slab panel P2 is not positioned over an end exterior C3 or interior C4 riser. Exterior side slab panel P2 may be connected with interior side slab panel P4 with plates Y that may be welded where the respective weld plates PL1 of the slab panels (P2, P4) align. As shown in FIG. 48, it is contemplated that exterior side slab panels P2 may also be positioned in the same manner as they are shown in FIGS. 3 and 4 at the opposite side of the foundation area in the exterior bays EB.
As shown in FIGS. 3 and 4, exterior middle slab panel P5 spans between cross beam B6 and either end transfer beam B1 or B2. Unlike corner slab panel P1, exterior middle slab panel P5 does not have a third side positioned on a transfer beam (B1, B2, B3, B4). Unlike exterior side slab panel P2, exterior middle slab panel P5 is positioned over an end exterior C3 or interior C4 riser. Exterior middle slab panel P5 may be connected with interior middle slab panel P6 with plates Y that may be welded where the respective weld plates PL1 of the slab panels (P5, P6) align. As shown in FIG. 48, it is contemplated that exterior middle slab panels P5 may also be positioned in the same manner as they are shown in FIGS. 3 and 4 at the opposite side of the foundation area to complete the slab system in the exterior bays EB.
As shown in FIGS. 3 and 4, interior edge slab panel P3 spans between cross beams B6. A side of interior edge slab panel P3 is also positioned on non-corner transfer beam B5. Interior edge slab panel P3 may be connected with corner P1 and interior edge P3 slab panels and side transfer beam B5 with plates Y that may be welded where the respective weld plates (PL1, PL3, PL13) of the components align. As shown in FIG. 48, it is contemplated that interior edge slab panels P3 may also be positioned in the same manner as they are shown in FIGS. 3 and 4 in the interior bays IB. One side of each interior edge slab panel P3 may be positioned on each non-corner transfer beam B5.
As partially shown in FIGS. 3 and 4, interior side slab panel P4 spans between cross beams B6. Unlike side slab panel P3, a side of interior side slab panel P4 is not positioned on non-corner transfer beam B5. Unlike interior middle slab panel P6, which will be discussed below, interior side slab panel P4 is not positioned over an interior riser C4. Interior side slab panel P4 may be connected with exterior side P2 and interior side P4 slab panels with plates Y that may be welded where the respective weld plates PL1 of the components align. As partially shown in FIG. 48, it is contemplated that interior side slab panels P4 may also be positioned in the same manner as they are shown in FIGS. 3 and 4 in the interior bays IB of the foundation area.
As partially shown in FIGS. 3 and 4, interior middle slab panel P6 spans between cross beams B6. Unlike side slab panel P3, a side of interior middle slab panel P6 is not positioned on non-corner transfer beam B5. Unlike interior side slab panel P4, interior middle slab panel P6 is positioned over an interior riser C4. Interior middle slab panel P6 may be connected with exterior middle P5 and interior middle P6 slab panels with plates Y that may be welded where the respective weld plates PL1 of the components align. As shown in FIG. 48, it is contemplated that interior middle slab panels P6 may also be positioned in the same manner as they are shown in FIGS. 3 and 4 to complete the foundation slab system in the interior bays IB.
It is contemplated that the preferred length, width, and height dimensions in FIGS. 4 and 5 are shown in TABLE 1 below. However, other dimensions are contemplated as well. It should now be understood that even though only four bays (EB, IB) are shown in FIGS. 3-5, foundation areas of much greater plan area may be created with the same components. For example, it is contemplated that length L may be made greater by creating three or more interior bays IB with the same types and sizes of components. It is also contemplated that width W may be made greater using the same types and sizes of components, such as for example using additional end exterior risers C3. As can now be understood, walls panels WL, including but not limited to AERODWELL™ wall panels, may be positioned upon the tops 3 of transfer beams (B1, B2, B3, B4, B5, B7, B8) after the LESS is constructed, as shown in FIGS. 3, 4, and 48, unlike slab panels (P1, P2, P3, P4, P5, P6, P7, P8), which were positioned on ledges (9, 13, 15) of transfer beams (B1, B2, B3, B4, B5, B7, B8) that were configured to receive them. It should be understood that such wall panels WL may have architectural exterior surface finishes, such as CMU block, face brick, or wood sheathing.
TABLE 1
Dimension English System Metric System
L 49′-5″ 15.1 m
L1 2′-5″ .7 m
L2 9′-1″ 2.77 m
L3 9′-7″ 2.9 m
L4 48′-0″ 14.6 m
L5 12′-0″ 3.65 m
W 24′-0″ 7.3 m
W1 12′-0″ 3.65 m
H1 6′-0″ 1.8 m
H2 4′-4½″ 1.3 m
FIG. 6 shows two cross beams B6 each positioned with one end in one of ledges (96, 97) on interior riser C4, and the other end in the groove 47 on side exterior riser C2. An L-shaped bent plate or angle J3 may be used to weld one end of cross beam B6 with exterior side riser C2 where their respective weld plates (PL6, PL21) align. It is contemplated that the angle J3 and all other similar angles identified hereafter may be steel. It should be understood that although welding is the preferred method of connection of angle J3 and all other angles, other methods are contemplated as well for angle J3 and all other angles, such as for example bolting. Likewise, angle J1 may be used to attach the two cross beams B6 with each other and with interior riser C4 where their respective weld plates (PL6, PL26) align. Non-corner transfer beams B5 are positioned on side exterior risers C2. As can now be understood, the interior sides IS of non-corner transfer beams B5 are in the interior of the foundation area, whereas the exterior sides ES of non-corner transfer beams B5 are on the exterior of the foundation area.
Interior edge slab panels P3 may be positioned with their ends on cross beams B6, and one of their sides on ledge 15 of non-corner transfer beam B5. Interior edge slab panels P3 may be connected with non-corner transfer beams B5 with a metal plate Y where their respective weld plates (PL3, PL13) align. It should be understood that although welding is the preferred method of connection of metal plate Y and all other connections hereafter described, other methods are contemplated as well for metal plate Y and all other connections, such as for example bolting. Interior side slab panels P4 are also positioned with their ends on cross beams B6, but not over interior riser C4. Interior middle slab panels P6 are positioned with their ends on cross beams B6, and over interior riser C4. As best shown in FIG. 8, an L-shaped bent plate or angle J2 may be used to weld the ends of the two cross beams B6 together and/or with interior middle slab panels P6 where their respective weld plates (PL4, PL5) align. Butyl sealant 2, as is known in the art, may preferably be placed on ledge 15 of non-corner transfer beams B5 and on the top surfaces of cross beams B6 before slab panels (P3, P4, P6) are positioned thereon. It is contemplated that the thickness of butyl sealant 2 may preferably be ½ inch (1.3 cm). However, other thickness are contemplated as well. Moreover, other types of sealants are contemplated as well. It is also contemplated that there be no butyl sealant 2.
Turning to FIG. 7, the connection between exterior middle slab panel P5, end transfer beam B1, and end exterior riser C3 is shown. It is contemplated that in the preferred embodiment concrete would be poured in opening 72 of end exterior riser C3 before end transfer beam B1 would be positioned thereon. A metal plate Y may be positioned across and welded to the respective weld plates (PL1, PL7) of exterior middle slab panel P5 and end transfer beam BR. It is contemplated that a ½ inch thickness of butyl sealant 2, as is known in the art, may preferably be placed on ledge 9 of end transfer beams B1 before exterior middle slab panel P5 is positioned thereon. It is also contemplated that different thicknesses and/or types of sealant 2 be used, or that no sealant 2 be used. It is also contemplated that exterior middle slab panel P5 may be welded directly to end transfer beam B1 at their adjoining weld plates (PL1, PL7). It is also contemplated that exterior middle slab panel P5 may be bolted to end transfer beam B1. It is also contemplated that exterior middle slab panel P5 may rest on end transfer beam B1 with no connection between the two. It is also contemplated that exterior middle slab panel P5 may rest upon a neoprene pad or other similar material on end transfer beam B1, with no other connection between the two. Although the different connection methods for exterior middle slab panel P5 are described above, it is contemplated that the same connection methods may be used for any slab panel (P1, P2, P3, P4, P5, P6, P7, P8).
End transfer beam B1 may be connected with end exterior riser C3 with an L-shaped bent plate or angle J4 that is welded to the respective weld plates (PL8, PL24) on end exterior riser C3 and end transfer beam B1. It is also contemplated that end transfer beam B1 may be welded directly to end exterior riser C3 at their adjoining weld plates (PL8, PL24). It is also contemplated that end transfer beam B1 may be bolted to end exterior riser C3. It is also contemplated that end transfer beam B1 may rest on end exterior riser C3 with no connection between the two. It is also contemplated that end transfer beam B1 may rest upon a neoprene pad or other similar material on end exterior riser C3, with no other connection between the two. Although the different connection methods for end transfer beam B1 are described above, it is contemplated that the same connection methods may be used for any beam (B1, B2, B3, B4, B5, B6, B7, B8).
FIG. 8 is a detailed view of FIG. 6 showing the connection between interior middle slab panels P6, cross beams B6, and interior riser C4. As best shown in FIG. 9, cross beams B6 may be connected with each other and/or interior riser C4 with an L-shaped metal plate or angle J1 that is welded to the respective weld plates (PL6, PL26) on interior riser C4 and cross beams B6.
Turning to FIG. 10, the only difference between corner P1 and interior edge P3 slab panels is their respective length (LP1, LP3). The length of corner slab panel P1 is LP1. The length of interior edge slab panel P3 is LP3. Corner slab panel P1 may be positioned with one end on end transfer beam (B1, B2), one end on cross beam B6, and one side on corner transfer beam (B3, B4). Interior edge slab panel P3 may be positioned with each end on different cross beams B6, and one side on non-corner transfer beam B5. The preferred lengths (LP1, LP3), widths (WP, WP1), and thickness TH of corner P1 and interior edge P3 slab panels are shown below in TABLE 2. However, other dimensions are contemplated as well. Reinforcing steel R is shown schematically in phantom.
One weld plate PL1 is positioned at each end of corner P1 and interior edge P3 slab panels. As best shown in FIG. 11, weld plates PL1 are recessed into the top surface of corner P1 and interior edge P3 slab panels a minimal amount, such as for example ¾ inches (1.9 cm) for connection using metal plate Y (shown in FIG. 3). Other recess depths are contemplated as well. It is contemplated that weld plates PL1 may be four inches wide, eight inches long, and one-half inches (110.1 cm×20.3 cm×1.3 cm) thick. However, other dimensions are contemplated as well. Weld plate PL1 preferably has its longest side parallel with the width WP of the slab panel (P1, P3). It is contemplated that weld plates PL1 may each have two embedded studs ST1 that are one-half inches (1.3 cm) in diameter, and three and one-half inches (8.9 cm) in length. However, other numbers of studs ST1 and dimensions are contemplated.
As shown in FIG. 10, weld plate PL3 may be located in the center of the length (LP1, LP3) of slab panel (P1, P3) on the edge of one side. Weld plate PL3 may preferably be recessed into the top surface of corner P1 and side P3 slab panels 1½ inches (3.8 cm) for connection using metal plate Y (shown in FIG. 3). Other recess depths are contemplated as well. It is contemplated that weld plate PL3 may be four inches wide, eight inches long, and one-half inches thick. However, other dimensions are contemplated as well. It is contemplated that the longest side of weld plate PL3 may be parallel with length (LP1, LP3). It is contemplated that weld plate PL3 may have two embedded studs ST3 that are one-half inches in diameter, five and one-half inches (14 cm) in total length, which studs ST3 are bent at a 90° angle approximately in the middle of their length with their free end positioned toward the interior of the slab panel (P1, P3). However, other numbers of studs and dimensions are contemplated. As shown now be understood, weld plates (PL1, PL3) and respective attached studs (ST1, ST3) are embedded in corner P1 and interior edge P3 slab panels before they are cast in concrete. It should be understood that additional weld plate (PL1, PL3) locations are contemplated as well.
FIG. 11 shows corner P1 and interior edge P3 slab panels of FIG. 10. However, the side elevation views of exterior side P2 and interior side P4 slab panels of FIG. 12 are identical to FIG. 11 except with no weld plate PL3 and studs ST3. The preferred thickness TH for all slab panels (P1, P2, P3, P4, P5, P6, P7, P8) is shown in TABLE 2. However, other thicknesses TH are contemplated as well.
Turning to FIG. 12, the only difference between exterior side P2 and interior side P4 slab panels is their respective length (LP1, LP3). The length of exterior side slab panel P2 is LP1. The length of interior side slab panel P4 is LP3. The only difference between slab panels (P2, P4) and slab panels (P1, P3) is that slab panels (P1, P3) have an additional weld plate PL3. Exterior side slab panel P2 may be positioned with one end on end transfer beam (B1, B2), and one end on cross beam B6. Interior side slab panel P4 may be positioned with each end on different cross beams B6. The preferred lengths (LP1, LP3), widths (WP, WP1), and thickness TH of exterior side P2 and interior side P4 slab panels are shown below in TABLE 2. However, other dimensions are contemplated as well. Reinforcing steel R is not shown but is contemplated for all slab panels (P1, P2, P3, P4, P5, P6, P7, P8) and other components of the LESS.
One weld plate PL1 may be positioned at each end of exterior side P2 and interior side P4 slab panels. As best shown in FIG. 11, weld plates PL1 may be recessed into the top surface of exterior side P2 and interior side P4 slab panels a minimal amount, such as for example ¾ inch for connection using metal plate Y (shown in FIG. 3). As should now be understood, weld plates PL1 and attached studs ST1 are embedded in exterior side P2 and interior side P4 slab panels before they are cast in concrete. It should be understood that additional weld plate PL1 locations are contemplated as well.
Although not shown in FIGS. 10-12, extension corner slab panel P7 is identical to corner slab panel P1, except that extension corner slab panel P7 has length LP2 rather than length LP1. Extension side slab panel P8 is identical to exterior side slab panel P2, except that extension side slab panel P8 has length LP2 rather than length LP1. The preferred lengths LP2, widths WP, and thicknesses TH are shown below in TABLE 2. However, other dimensions are contemplated as well. As shown in FIG. 48, extension slab panels (P7, P8) may be used when an extension to the original foundation area is desired, such as for example a porch.
Turning to FIG. 12A, the only difference between exterior middle P5 and interior middle P6 slab panels is their respective length (LP1, LP3). The length of exterior middle slab panel P5 is LP1. The length of interior middle slab panel P6 is LP3. The only difference between slab panels (P5, P6) and slab panels (P2, P4) is that slab panels (P5, P6) have two additional weld plates PL4, which are located on the underside of the slab panels (P5, P6). Exterior middle slab panel P5 may be positioned with one end on end transfer beam (B1, B2), and one end on cross beam B6. Interior middle slab panel P6 may be positioned with each end on different cross beams B6. Both exterior middle P5 and interior middle P6 slab panels have their ends over end exterior C3 or interior C4 risers, unlike slab panels (P2, P4). The preferred lengths (LP1, LP3), widths (WP, WP1), and thickness TH of exterior middle P5 and interior middle P6 slab panels are shown below in TABLE 2. However, other dimensions are contemplated as well. Reinforcing steel R is not shown but is contemplated.
One weld plate PL1 may be positioned at each end of exterior middle P5 and interior middle P6 slab panels. As best shown in FIG. 12B, weld plates PL1 may be recessed into the top surface of exterior middle P5 and interior middle P6 slab panels a minimal amount, such as for example ¾ inch for connection using metal plate Y (shown in FIG. 3). As should now be understood, weld plates PL1 and attached studs ST1 are embedded in exterior middle P5 and interior middle P6 slab panels before they are cast in concrete.
As best shown in FIG. 12A, one weld plate PL4 may be positioned on both side edges of the underside of exterior middle P5 and interior middle P6 slab panels. It is contemplated that weld plate PL4 may be four inches wide, six inches long, and ⅜ inches (10.2 cm×15.2 cm×1 cm) thick. However, other dimensions are contemplated as well. It is contemplated that weld plate PL4 may have two embedded studs ST4 that are one-half inches in diameter, and three and one-half inches in length. However, other numbers of studs and dimensions are contemplated. It is contemplated that the short side of weld plate PL4 will be on the edge of the underside of exterior middle P5 and interior middle P6 slab panels. As best shown in FIG. 12B, the exterior surface of weld plate PL4 may be level or flush with the underside surface of exterior middle P5 or interior middle P6 slab panel so that exterior middle P5 or interior middle P6 slab panels may be connected together with angle J2 as shown in FIG. 8. As should now be understood, weld plates PL4 and attached studs ST4 are embedded in exterior middle P5 and interior middle P6 slab panels before they are cast in concrete. It should be understood that additional weld plate (PL1, PL4) locations are contemplated as well.
TABLE 2
Dimension English System Metric System
LP1 11′-11¾″ 3.65 m
LP2 11′-9⅝″ 3.60 m
LP3 11′-3⅝″ 3.45 m
LP4 0′-7⅞″ 20 cm
WP 3′-9″ 1.14 m
WP1 1′-10 1/2/″ 57.2 cm
TH 0′-6″ 15.2 cm
FIGS. 13-15 show cross beam B6 and its weld plates (PL5, PL6). Cross beam B6 may be positioned with its end on a side exterior riser C2, an interior riser C4, an extension exterior riser (C5A, C5B), or an extension interior riser C6. Longitudinal reinforcing steel bars or rods R and transverse reinforcing steel stirrups T, both shown in phantom, as are known in the art, may be positioned in cross beam B6 before it is cast in concrete. Although the preferred length LB6, width WB6, and height dimensions (HB5, HB6) are shown in TABLE 3, other dimensions are contemplated as well. As best shown in FIG. 13, two weld plates PL6 may be positioned at each end of cross beam B6 on each side. Two weld plates PL5 may be positioned at one end of cross beam B6 on each side in the top corner. As best shown in FIG. 14, the exterior surfaces of weld plates (PL5, PL6) may be flush or level with the exterior side surfaces of cross beam B6. It is contemplated that weld plates (PL5, PL6) may be four inches wide, six inches long, and ⅜ inches (10.2 cm×15.2 cm×1 cm) thick. However, other dimensions are contemplated as well. It is contemplated that the longer sides of weld plates (PL5, PL6) may be parallel with length LB6. It is contemplated that weld plates (PL5, PL6) may each have two studs (ST5, ST6) welded thereto that may be one-half inches (1.3 cm) in diameter, and four inches (10.2 cm) in length. However, other numbers of studs and dimensions are contemplated. Although weld plate (PL5, PL6) locations are shown, additional weld plate (PL5, PL6) locations are contemplated as well.
FIGS. 16-18 show end transfer beam B1 and its weld plates (PL7, PL8, PL9). End transfer beam B1, like all transfer beams (B2, B3, B4, B5, B7, B8), has an L-shaped cross section (a smaller rectangle over a larger rectangle with a common exterior side ES). The exterior side ES of end transfer beam B1 has a height HB1 greater than the height HB2 of interior side IS, which creates a ledge 9 on the interior side IS. Slab panels (P1, P2, P5, P7, P8) may be positioned on ledge 9. The interior side IS of end transfer beam B1 is positioned on the interior of the foundation area. As with all transfer beams (B1, B2, B3, B4, B5, B7, B8), wall panels (not shown) may be positioned on top 3 of end transfer beam B1.
Although end transfer beam B1 is shown, it should be understood that end transfer beam B2 is a mirror image of end transfer beam B1. To create end transfer beam B2 from FIGS. 16-18, weld plate PL8 is located in the same relative position on the other side of end transfer beam B2, shown in FIG. 17 as location 8, and weld plate PL9 is located in the same relative position on the other side of end transfer beam B2, shown in FIG. 17 as location 7. Also, length LB2 is switched with length LB4. Longitudinal reinforcing steel bars or rods R and transverse reinforcing steel stirrups T, both shown in phantom, as are known in the art, may be positioned in the end transfer beam B1 before it is cast in concrete. Although the preferred length dimensions (LB1, LB2, LB3, LB4, LB7), width dimensions (WB1, WB2, WB3) and height dimensions (HB1, HB2, HB3) are shown in TABLE 3, other dimensions are contemplated as well. End transfer beam (B1, B2) may be positioned with one end on corner riser C1, end exterior riser C3, or extension exterior risers (C5A, C5B).
As best shown in FIG. 16, three weld plates PL7 may be positioned on top 3 of end transfer beam B1 at the edge nearest the interior side IS. As best shown in FIG. 17, weld plates PL7 may be recessed into the top surface of end transfer beam B1 a minimal amount, such as for example ¾ inch (1.9 cm) for connection with slab panels (P1, P2, P5, P7, P8) using metal plate Y (shown in FIG. 3). It is contemplated that weld plates PL7 may be four inches wide, eight inches long, and ⅜ inches thick. However, other dimensions are contemplated as well. It is contemplated that weld plates PL7 may each have two studs ST7 welded thereto that are one-half inches in diameter, and six inches in length. However, other numbers of studs ST7 and dimensions are contemplated. It is contemplated that weld plates (PL7, PL8, PL9) will have their longest side parallel to length LB1.
As best shown in FIG. 17, weld plate PL8 is positioned on the bottom left corner of the interior side IS of end transfer beam B1 as viewed facing the interior side IS. It is contemplated that the exterior surface of the weld plate PL8 may be flush or level with the interior side IS of end transfer beam B1. It is contemplated that weld plate PL8 may be four inches wide, six inches long, and ⅜ inches thick. However, other dimensions are contemplated as well. It is contemplated that weld plate PL8 may have two studs welded thereto that are one-half inches in diameter, and six inches in length. However, other numbers of studs and dimensions are contemplated. Also as best shown in FIG. 17, as viewed facing the interior side IS, weld plate PL9 may positioned on the bottom right of the interior side IS of end transfer beam B1 at distance LB7 from the right end. It is contemplated that the exterior surface of weld plate PL9 may be flush or level with the interior side IS of end transfer beam B1. It is contemplated that weld plate PL9 may be four inches wide, six inches long, and ⅜ inches thick. However, other dimensions are contemplated as well. It is contemplated that weld plate PL9 may have two studs welded thereto that are one-half inches in diameter, and six inches in length. However, other numbers of studs and dimensions are contemplated. Although weld plate (PL7, PL8, PL9) locations are shown, additional weld plate (PL7, PL8, PL9) locations are contemplated as well.
FIGS. 19-21 show corner transfer beam B3 and its weld plates (PL10, PL11, PL12). Exterior side ES of corner transfer beam B3 has a height HB1 greater than the height HB2 of the interior side IS, which creates a ledge 13 on the interior side IS. Corner slab panel P1 may be positioned on ledge 13. Interior side IS of corner transfer beam B3 is positioned on the interior of the foundation area.
Although corner transfer beam B3 is shown, it should be understood that corner transfer beam B4 is the mirror image of corner transfer beam B3. To create corner transfer beam B4 from FIGS. 19-21, weld plate PL11 is located in the same relative position on the other side of corner transfer beam B4, shown in FIG. 20 as location 11, and weld plate PL12 is located in the same relative position on the other side of corner transfer beam B4, shown in FIG. 20 as location 12. Also, length LB8 is switched with length LB9. Longitudinal reinforcing steel bars or rods R and transverse reinforcing steel stirrups T, both shown in phantom, as are known in the art, are positioned in corner transfer beam B3 before it is cast in concrete. Although the preferred length (LB6, LB8, LB9), width dimensions (WB1, WB2, WB3) and height dimensions (HB1, HB2, HB3) are shown in TABLE 3, other dimensions are contemplated as well. Corner transfer beam (B3, B4) may be positioned with one end on corner riser C1, side exterior riser C2, or extension exterior risers (C5A, C5B).
As best shown in FIG. 19, weld plate PL10 may be positioned on top 3 of corner transfer beam B3 at the edge nearest the interior side IS at length LB8 from the left side as viewed from the interior side IS. As best shown in FIG. 20, weld plate PL10 may be recessed into the top surface of corner transfer beam B3 a minimal amount, such as for example ¾ inch (1.9 cm) for connection with corner slab panel P1 using metal plate Y (shown in FIG. 3). It is contemplated that weld plate PL10 may be four inches wide, eight inches long, and ⅜ inches thick. However, other dimensions are contemplated as well. It is contemplated that weld plate PL10 may have two studs welded thereto that may be one-half inches in diameter, and six inches in length. However, other numbers of studs and dimensions are contemplated as well. It is contemplated that weld plates (PL10, PL11, PL12) may have their longest side parallel with length LB6.
As best shown in FIG. 20, weld plate PL12 may be positioned on the bottom right corner of interior side IS of corner transfer beam B3 as viewed facing interior side IS. It is contemplated that the exterior surface of the weld plate PL12 may be flush or level with the interior side IS of corner transfer beam B3. It is contemplated that weld plate PL12 may be four inches wide, eight inches long, and ⅜ inches thick. However, other dimensions are contemplated as well. It is contemplated that weld plate PL12 may have two studs welded thereto that may be one-half inches in diameter, and six inches in length. However, other numbers of studs and dimensions are contemplated.
Also as best shown in FIG. 20, as viewed facing interior side IS, weld plate PL11 may be positioned on the bottom left of interior side IS of corner transfer beam B3 at distance LB10 from the left end. It is contemplated that the exterior surface of the weld plate PL11 may be flush or level with the interior side IS of corner transfer beam B3. It is contemplated that weld plate PL11 may be four inches wide, eight inches long, and ⅜ inches thick. However, other dimensions are contemplated as well. It is contemplated that weld plate PL11 may have two studs welded thereto that are one-half inches in diameter, and six inches in length. However, other numbers of studs and dimensions are contemplated. Although weld plate (PL10, PL11, PL12) locations are shown, other weld plate locations are contemplated as well.
Extension corner transfer beam B7 is not shown, but it is identical to corner transfer beam B3 except that its length is LB11 rather than LB6. Also, weld plate PL10 on extension corner transfer beam B7 is located in the center of length LB11. Extension corner transfer beam B8 is the mirror image of extension corner transfer beam B7, just as corner transfer beam B4 is the mirror image of corner transfer beam B3. As described above for corner transfer beams (B3, B4), the relative positions of weld plates (PL11, PL12) are reversed for extension corner transfer beams (B7, B8). As shown in FIG. 48, extension transfer beams (B7, B8) are positioned when an extension to the original foundation area is desired, such as for example a porch.
FIGS. 22-24 show non-corner transfer beam B5 and its weld plates (PL13, PL15). Interior edge slab panel P3 may be positioned on ledge 15 created by the lower height HB2 on the interior side IS of the non-corner transfer beam B5, which interior side IS is positioned in the interior of the foundation area. Longitudinal reinforcing steel bars or rods R and transverse reinforcing steel stirrups T, both shown in phantom, as are known in the art, may be positioned in non-corner transfer beam B5 before it is cast in concrete. Although the preferred length LB5, width dimensions (WB1, WB2, WB3) and height dimensions (HB1, HB2, HB3) are shown in TABLE 3, other dimensions are contemplated as well. Non-corner transfer beam B5 may be positioned with an end on side exterior riser C2, extension exterior riser (C5A, C5B), or extension interior riser C6.
As best shown in FIG. 22, weld plate PL13 may be positioned on top 3 of non-corner transfer beam B5 at the edge nearest the interior side IS in the center of length LB5. As best shown in FIG. 23, weld plates PL13 may be recessed into the top surface of non-corner transfer beam B5 a minimal amount, such as for example ¾ inch (1.9 cm) for connection with interior edge slab panel P3 using metal plate Y (shown in FIG. 3). It is contemplated that weld plate PL13 may be four inches wide, eight inches long, and ⅜ inches thick. However, other dimensions are contemplated as well. It is contemplated that the longest side of weld plates (PL13, PL15) may be parallel with length LB5. It is contemplated that weld plate PL13 may have two studs welded thereto that are one-half inches in diameter, and six inches in length. However, other numbers of studs and dimensions are contemplated as well.
As best shown in FIG. 23, one weld plate PL15 may be positioned near each of the bottom left and right corners of the interior side IS of non-corner transfer beam B5 as viewed facing the interior side IS at distance LB10 from the ends. It is contemplated that the exterior surface of weld plates PL15 may be flush or level with the interior side IS of non-corner transfer beam B5. It is contemplated that weld plates PL15 may be four inches wide, eight inches long, and ⅜ inches thick. However, other dimensions are contemplated as well. It is contemplated that weld plates PL15 may have two studs attached thereto that are one-half inches in diameter, and six inches in length. However, other numbers of studs and dimensions are contemplated. Although weld plate (PL13, PL15) locations are shown, additional weld plate locations are contemplated as well.
TABLE 3
Dimension English System Metric System
LB1 11′-11¾″ 3.65 m
LB2 1′-10⅜″ 56.8 cm
LB3 3′-9¼″ 1.1 m
LB4 2′-6¾″ 78 cm
LB5 11′-11½″ 3.65 m
LB6 10′-11¼″ 3.33 m
LB7 1′-4½″ 41.9 cm
LB8 5′-3⅝″ 1.6 m
LB9 5′-7¾″ 1.72 m
LB10 0′-10¼″ 26 cm
LB11 11′-5¼″ 3.5 m
WB1 1′-0″ 30.5 cm
WB2 0′-4″ 10.2 cm
WB3 0′-8″ 20.3 cm
WB6 1′-0″ 30.5 cm
HB1 1′-6″ 45.7 cm
HB2 1′-1″ 33 cm
HB3 0′-5″ 12.7 cm
HB5 0′-7″ 17.8 cm
HB6 1′-6″ 45.7 cm
FIGS. 25-27 show corner riser C1. The base 26 has four outer sides (21, 23, 25, 27) forming a rectangle in plan view. Only two adjoining sides (21, 23) of the four outer sides (21, 23, 25, 27) at the base 26 are also at the top 28. The other two adjoining sides (25, 27) form a ledge 24 for receipt of end (B1, B2), corner (B3, B4) and extension corner (B7, B8) transfer beams. Corner risers C1 may be positioned in the corners of the foundation area as shown in FIGS. 3 and 4 so that sides (21, 23) are on the exterior of the foundation area. Corner risers C1 may also be positioned in the corners of extensions to the original foundation area as shown in FIG. 48.
As best shown in FIG. 27, weld plate PL20 may be positioned on the corner of ledge 24 at the intersection of sides (25, 27). Weld plate PL20 may preferably be eight inches wide, eight inches long, and ⅜ inches thick. Two ½ inch diameter metal studs that are preferably six inches long may be welded to weld plate PL20, and positioned in corner riser C1 before it is cast in concrete. Although weld plate PL20 location is shown, additional weld plate PL20 locations are contemplated as well. Although weld plate PL20 and stud dimensions are shown, other dimensions are contemplated. Longitudinal reinforcing steel bars or rods R and transverse reinforcing steel stirrups T, both shown in phantom, as are known in the art, are positioned in corner riser C1 before it is cast in concrete. Although the preferred height (HC1, HC2, HC3, HC4, HC5) and width dimensions (WC1, WC2, WC3, WC4, WC5, WC6, WC7) are shown in TABLE 4, other dimensions are contemplated as well. It is contemplated that base 26 of corner riser C1 may not be a square. It is contemplated that widths (WC1, WC4) may be increased to allow a plurality of pile A heads to fit within opening 20. It is contemplated that corner riser C1 may be made with different height HC1 while keeping height HC2 the same. It is also contemplated that corner riser C1 may be made with different height HC1 while keeping height HC3 the same.
An opening 20 extends from the base 26 to the top 28, forming four inner sides or surfaces 32. Although a rectangular opening 20 in plan view is shown, other shapes are contemplated as well, such as for example circular or oval. One or more indentions or recesses 22 may be in one or more inner sides 32 of corner riser C1. The measurement of angle Z may preferably be 45°. However, other measurements are contemplated as well. Although the shape, size, and location of recesses 22 are shown, other shapes, sizes, dimensions, and locations are contemplated as well. After corner riser C1 is positioned on pile A or other foundation member (FIGS. 40-43), concrete or grout may be poured into opening 20, filling opening 20 and recesses 22, if any, and locking corner riser C1 with pile A or other foundation member. As will be discussed below with FIG. 44, an alternate connection method is contemplated as well. Although end exterior riser C3 is shown in FIGS. 40-44, it is contemplated that the same connection methods may be used with any riser (C1, C2, C3, C4, C5A, C5B, C6).
FIGS. 28-30 show side exterior riser C2. The base 48 has four outer sides (41, 43, 44, 56) forming a rectangle in plan view. Only one outer side, shown as 56, of the four outer sides (41, 43, 44, 56) of the base 48 is also at the top 50. The three other outer sides (41, 43, 44) are the same height HC2, except for a groove 47 in the middle of the top of side 41, which is the side opposite the highest side 56. The two sides (43, 44) adjoining side 56 form ledges (52, 54) for receipt of corner (B3, B4) and non-corner B5 transfer beams. Groove 47 forms ledge 46 for receipt of cross beam B6. Side exterior riser C2 may be positioned around the perimeter of the foundation area as shown in FIGS. 3, 4, and 48 such that side 56 is the exterior side ES, and side 41 is on the interior of the foundation area.
As best shown in FIGS. 28 and 30, weld plates PL21 may be positioned on each of ledges (52, 54) on the edge nearest side 41. Weld plates PL21 may preferably be eight inches wide, eight inches long, and ⅜ inches thick. Two ½ inch diameter metal studs that are preferably six inches long may be welded to each weld plate PL21, and positioned in side exterior riser C2 before it is cast in concrete. Although weld plate PL21 locations are shown, additional weld plate PL21 locations are contemplated as well. Although weld plate PL21 and stud dimensions are shown, other dimensions are contemplated.
Longitudinal reinforcing steel bars or rods R and transverse reinforcing steel stirrups T, both shown in phantom, as are known in the art, may be positioned in side exterior riser C2 before it is cast in concrete. Although the preferred height (HC1, HC2, HC3, HC6, HC7) and width dimensions (WC1, WC4, WC5) are shown in TABLE 4, other dimensions are contemplated as well. It is contemplated that the base 48 of side exterior riser C2 may not be a square. It is contemplated that width dimensions (WC1, WC4) may be increased to allow a plurality of pile A heads to fit within opening 40. It is contemplated that side exterior riser C2 may be made with a different height HC1 while keeping height HC2 the same. It is contemplated that side exterior riser C2 may be made with a different height HC1 while keeping height HC8 the same.
An opening 40 extends from the base 48 to the top 50, forming four inner sides or surfaces 42. Although a rectangular opening 40 in plan view is shown, other shapes are contemplated as well, such as for example circular or oval. One or more indentions or recesses 22 may be in one or more inner sides 42 of side exterior riser C2. Although the shape, size, and location of recesses 22 are shown, other shapes, sizes, dimensions, and locations are contemplated as well. After side exterior riser C2 is positioned on pile A or other member (FIGS. 40-43), concrete or grout may be poured into opening 40, filling opening 40 and recess 22, if any, and locking side exterior riser C2 with pile A or other member. As will be discussed below with FIG. 44, an alternate connection method is contemplated as well.
FIGS. 31-33 show end exterior riser C3. The base 64 has four outer sides (62, 63, 65, 68) forming a rectangle in plan view. Only one outer side, shown as 62, of the four outer sides (62, 63, 65, 68) of the base 64 is also at the top 66. The three other sides (63, 65, 68) are the same height HC2, and form ledge 60 for receipt of end transfer beams (B1, B2). End exterior riser C3 is positioned around the perimeter of the foundation area as shown in FIGS. 3, 4, and 48 such that side 62 is the exterior side ES, and side 68 is on the interior of the foundation area.
Weld plate PL24 may be positioned on ledge 60 in the middle of side 68. Weld plate PL24 may preferably be eight inches wide, eight inches long, and ⅜ inches thick. Two ½ inch diameter metal studs that are preferably six inches long may be welded to weld plate PL24, and positioned in end exterior riser C3 before it is cast in concrete. Although weld plate PL24 location is shown, additional weld plate PL24 locations are contemplated as well. Although weld plate PL24 and stud dimensions are shown, other dimensions are contemplated. Longitudinal reinforcing steel bars or rods R and transverse reinforcing steel stirrups T, both shown in phantom, as are known in the art, are positioned in end exterior riser C3 before it is cast in concrete. Although the preferred height (HC1, HC2, HC3) and width dimensions (WC1, WC4, WC5) are shown in TABLE 4, other dimensions are contemplated as well. It is contemplated that base 64 of end exterior riser C3 may not be square. It is contemplated that widths (WC1, WC4) may be increased to allow a plurality of pile A heads to fit within opening 72. It is contemplated that end exterior riser C3 may be made with a different height HC1 while keeping height HC2 the same. It is also contemplated that end exterior riser C3 may be made with a different height HC1 while keeping height HC3 the same.
An opening 72 extends from the base 64 to the top 66, forming four inner sides or surfaces 74. Although a rectangular opening 72 in plan view is shown, other shapes are contemplated as well, such as for example circular or oval. One or more indentions or recesses 22 may be in one or more inner sides 74 of end exterior riser C3. Although the shape, size, and location of recesses 22 are shown, other shapes, sizes, dimensions, and locations are contemplated as well. After end exterior riser C3 is positioned on pile A or other foundation member (FIGS. 40-43), concrete or grout may be poured into opening 72, filling opening 72 and recesses 22, if any, and locking end exterior riser C3 with pile A or other foundation member. As will be discussed below with FIG. 44, an alternate connection method is contemplated as well.
FIGS. 34-36 show interior riser C4. The base 80 has four outer sides (84, 86, 88, 90) forming a rectangle in plan view. Two outer parallel sides, shown as 86 and 90, of the four outer sides (84, 86, 88, 90) of base 80 are also at top 82. The two other parallel sides (84, 88) are the same height HC6, and form ledges (96, 97) for receipt of cross beams B6. Interior riser C4 may be positioned in the interior of the foundation area as shown in FIGS. 3 and 4, such that parallel sides 86 and 90 are parallel with length LB6 of cross beams B6. As will be discussed below, although it is not shown, extension interior riser C6 is identical to interior riser C4 except that extension interior riser C6 has a different configuration of weld plates than interior riser C4.
As best shown in FIG. 36 for interior riser C4, one weld plate PL26 is positioned in the middle of each of sides 86 and 90 at top 82. Weld plate PL26 is preferably eight inches wide, eight inches long, and ⅜ inches thick. Two ½ inch diameter metal studs that are preferably six inches long may be welded to weld plate PL26, and positioned in interior riser C4 before it is cast in concrete. Although weld plate PL26 locations are shown, other weld plate PL26 locations are contemplated as well. Although weld plate PL26 and stud dimensions are shown, other dimensions are contemplated.
Longitudinal reinforcing steel bars or rods R and transverse reinforcing steel stirrups T, both shown in phantom, as are known in the art, are positioned in interior riser C4 before it is cast in concrete. Although the preferred height (HC2, HC6, HC7) and width dimensions (WC1, WC4, WC5) are shown in TABLE 4, other dimensions are contemplated as well. It is contemplated that base 80 of interior riser C4 may not be square. It is contemplated that widths (WC1, WC4) may be increased to allow a plurality of pile A heads to fit within opening 98. It is contemplated that interior riser C4 may be made with a different height HC2 while keeping height HC6 the same. It is also contemplated that interior riser C4 may be made with a different height HC2 while keeping height HC7 the same.
An opening 98 extends from the base 80 to top 82, forming four inner sides or surfaces 92. Although a rectangular opening 98 is shown in plan view, other shapes are contemplated as well, such as for example circular or oval. One or more indentions or recesses 22 may be in one or more inner sides 92 of interior riser C4. Although the shape, size, and location of recesses 22 are shown, other shapes, sizes, dimensions, and locations are contemplated as well. After interior riser C4 is positioned on pile A or other member (FIGS. 40-43), concrete or grout may be poured into opening 98, filling opening 98 and recesses 22, if any, and locking interior riser C4 with pile A or other foundation member.
Extension interior riser C6 differs with interior riser C4 only in the placement of its weld plates PL26. Extension interior riser C6 has four weld plates PL26 positioned in the four corners at the top 82. As shown in FIG. 48, like interior riser C4, extension interior riser C6 is positioned so that its sides (86, 90) are parallel with length LB6 of cross beams B6 as seen in plan view. Cross beams B6 may be positioned on ledges (96, 97). Unlike for interior riser C4, non-corner transfer beams B5 may be positioned on ledges 82 of extension interior riser C6. Extension interior riser C6 may be positioned on what would have been the perimeter of the foundation area had there been no slab extension.
FIGS. 37-39 show extension exterior riser C5A. The base 132 has four outer sides (144, 146, 148, 150) forming a rectangle in plan view. In the preferred embodiment, one corner of extension exterior riser C5A, where outer sides (148, 150) intersect, is at top 130. In an alternative embodiment, it is contemplated that the top of exterior extension riser C5A may be flush or level with ledges (136, 138) so that the corner where outer sides (148, 150) intersect does not extend upward from the height HC2 of ledges (136, 138). In such alternative embodiment, four outer sides (144, 146, 148, 150) would all be the same height HC2, except for groove 142 in the middle of the top of side 146, which groove 142 forms a ledge 134 for receipt of cross beam B6. As can now be understood, the preferred embodiment of extension exterior riser C5A has a spike 139 extending upward from ledges (136, 138). Ledges (136, 138, 140) may receive transfer beams (B1, B2, B3, B4, B5). As shown in FIG. 48, extension exterior riser C5A may be positioned at the intersection of the perimeter of the foundation area without an extension slab, and one side of the extension slab. Spike 139 may be positioned on the exterior of the foundation area.
Extension exterior riser C5B is identical to extension exterior riser C5A, except spike 139 is located at the corner created by sides (144, 150) for extension exterior riser C5B. The weld plate PL30 located at the corner created by those sides (144, 150) for extension exterior riser C5A is relocated to the corner created by sides (148, 150) for extension exterior riser C5B. As with extension exterior riser C5A, extension exterior riser C5B does not have spike 139 in an alternative embodiment. As shown in FIG. 48, extension exterior riser C5B may be positioned at the intersection of the perimeter of the foundation area without an extension slab, and one side of the extension slab. Spike 139 may be positioned on the exterior of the foundation area.
As shown in FIG. 39 for extension exterior riser C5A, one weld plate PL30 is positioned on each of the three corners where spike 139 is not located. Weld plate PL30 is preferably eight inches wide, eight inches long, and ⅜ inches thick. Two ½ inch diameter metal studs that are preferably six inches long may be welded to weld plate PL30, and positioned in extension exterior riser C5A before it is cast in concrete. Although weld plate PL30 locations are shown, other weld plate PL30 locations are contemplated as well. Although weld plate PL30 and stud dimensions are shown, other dimensions are contemplated.
Longitudinal reinforcing steel bars or rods R and transverse reinforcing steel stirrups T are contemplated but are not shown for clarity, and may be positioned in extension exterior riser C5A before it is cast in concrete. Although the preferred height (HC1, HC2, HC7) and width dimensions (WC1, WC2, WC4) are shown in TABLE 4, other dimensions are contemplated as well. It is contemplated that base 132 of extension exterior riser C5A may not be square. It is contemplated that widths (WC1, WC4) may be increased to allow a plurality of pile A heads to fit within opening 154. It is contemplated that extension exterior riser C5A may be made with a different height HC1 while keeping height HC2 the same. It is also contemplated that extension exterior riser C5A may be made with a different height HC1 while keeping height HC7 the same.
An opening 154 extends from the base 132 to top 130, forming four inner sides or surfaces 152. Although a rectangular opening 154 is shown in plan view, other shapes are contemplated as well, such as for example circular or oval. One or more indentions or recesses 22 may be in one or more inner sides 152 of extension exterior riser C5A. Although the shape, size, and location of recesses 22 are shown, other shapes, sizes, dimensions, and locations are contemplated as well. After extension exterior riser C5A is positioned on pile A or other member (FIGS. 40-43), concrete or grout may be poured into opening 154, filling opening 154 and recesses 22, if any, and locking extension exterior riser C5A with pile A or other foundation member.
TABLE 4
Dimension English System Metric System
HC1 5′-10½″ 1.8 m
HC2 4′-4″ 1.3 m
HC3 1′-6½″ 47 cm
HC4 0′-9″ 22.9 cm
HC5 0′-2″ 5.1 cm
HC6 3′-11″ 1.2 m
HC7 0′-5″ 12.7 cm
WC1 2′-5″ 73.7 cm
WC2 0′-8″ 20.3 cm
WC3 1′-9″ 53.3 cm
WC4 1′-1″ 33 cm
WC5 0′-1½″ 3.8 cm
FIGS. 40-43 show the preferred connection between risers (C1, C2, C3, C4, C5A, C5B, C6) and different types of deep and shallow foundation members. Although end exterior riser C3 is shown in FIGS. 40-43, it should be understood that any riser (C1, C2, C3, C4, C5A, C5B, C6) may be so connected. FIG. 40 shows end exterior riser C3 positioned on a single pile A end or head, which is itself an upwardly extending connector. Concrete has been poured in the opening 72 and recess 22. FIG. 41 shows end exterior riser C3 positioned on a drilled bell bottom pier M with reinforcing steel R placed in pier M before it was poured extending into opening 72 of end exterior riser C3. Reinforcing steel R is an upwardly extending connector. Concrete has been poured in opening 72 and recess 22.
FIG. 42 shows end exterior riser C3 positioned on a pile cap or pad N made of reinforced concrete with reinforcing steel R placed in pad N before it was poured extending into opening 72 of end exterior riser C3. Reinforcing steel R is an upwardly extending connector. Pile cap N has been poured on the ends or heads of a plurality of piles A. Concrete has been poured in the opening 72 and recess 22. An architectural brick facade finish 120 is shown cast onto the exterior surface of end exterior riser C3. It is contemplated that the finish 120 may be painted to match the finished surface on the exterior of the house or other structure positioned on the foundation. Other finishes are contemplated as well, such as for example wood or stone. Although an architectural finish 120 is only shown in FIG. 42, it is contemplated that an architectural finish could be placed on any of the components of the LESS as shown in FIGS. 14-39. FIG. 43 shows end exterior riser C3 positioned on exterior grade beam E with reinforcing steel R placed in grade beam E before it was poured extending into opening 72 of end exterior riser C3. Concrete has been poured in the opening 72 and recess 22.
Turning to FIG. 44, it is contemplated that as an alternative to recesses 22, or in addition to recesses 22, channels 36 may be cast in end exterior riser C3. Alternatively, channels 36 may be placed after end exterior riser C3 is cast in concrete, such as by drilling. Channel 40, shown in phantom, may be placed in pile A1, such as by drilling. Reinforcing bar 38 may be inserted through the aligned channels (36, 40). It is contemplated that there may be two additional channels (not shown) placed in end exterior riser C3 that are perpendicular to channels (36, 40). Channel 41, perpendicular to channels 36, may be placed in pile A1, such as by drilling. Reinforcing bar 39 may be inserted through the aligned channels. It is contemplated that in the preferred embodiment, concrete may be poured in opening 72 after reinforcing bars (38, 39) are positioned. However, it is also contemplated that no concrete may be poured in opening 72. Although end exterior riser C3 is shown in FIG. 44, it should be understood that any riser (C1, C2, C3, C4, C5A, C5B, C6) may be so connected.
FIGS. 45-47 show the use of one or more shims (100, 102, 104, 106, 108, 110) in alternative embodiments to level the foundation slab system. It should be understood that in the preferred embodiment, no shims (100, 102, 104, 106, 108, 110) are used. It is contemplated that the shims (100, 102, 104, 106, 108, 110) may be metal plates, such as steel. However, other materials are contemplated as well.
In FIG. 45, end exterior riser C3, end transfer beam B2, and exterior middle slab panel P5 are assembled together. Concrete has been poured in opening 72. Shims (100, 102) are shown insertable under end transfer beam B2. In the preferred embodiment, shims (100, 102) would not be initially used, and end transfer beam B2 would be attached to end exterior riser C3 with angle J5 welded to their respective weld plates (PL8, PL24). However, it should be understood that if uneven vertical movement occurred after the system was erected, the welds around angle J5 may be broken, and one or more shims (100, 102) may be inserted. It should also be understood that shims (100, 102) may be necessary with the initial erection for leveling purposes, such as for example if uneven settlement occurs during construction, or the dimensions of the components are not within expected tolerances. Although end exterior riser C3 and end transfer beam B2 are shown, it should be understood that one or more shims (100, 102) may be placed as shown in FIG. 45 under any cross B6 and/or transfer beams (B1, B2, B3, B4, B5, B7, B8) or above any riser (C1, C2, C3, C4, C5A, C5B, C6).
Turning to FIG. 46, corner riser C1, end transfer beam B2, and corner slab panel P1 are assembled together. Concrete has been poured in opening 20. Shims (104, 106) are shown insertable under end transfer beam B2. In the preferred embodiment, shims (104, 106) would not be initially used, and end transfer beam B2 would be attached to corner riser C1 with angle J7 welded to their respective weld plates (PL9, PL20). However, it is also contemplated that end transfer beam B2 may be attached to corner riser C1 with angle J6 welded to their respective weld plates (PL9, PL20), which angle J6 would be positioned adjacent to end transfer beam B2. It should be understood that if uneven vertical movement occurred after the system was erected, the welds around angle (J6, J7) may be broken, and one or more shims (104, 106) inserted. It should also be understood that shims (104, 106) may be necessary with the initial erection for leveling purposes. Although corner riser C1 and end transfer beam B2 are shown, it should be understood that one or more shims (104, 106) may be placed as shown in FIG. 46 under any cross B6 and/or transfer beams (B1, B2, B3, B4, B5, B7, B8) or above any riser (C1, C2, C3, C4, C5A, C5B, C6).
In FIG. 47, interior riser C4, cross beam B6, exterior middle slab panel P5, and interior middle slab panel P6 are assembled together. Concrete has been poured in opening 98. Shims (108, 110) are shown insertable under exterior middle P5 and interior middle P6 slab panels. In the preferred embodiment, shims (108, 110) would not be initially used, and exterior middle P5 and interior middle P6 slab panels may be attached to cross beam B6 with angles J9 welded to their respective weld plates (PL4, PL5). However, it should be understood that if uneven vertical movement occurred after the system was erected, the welds around angles J9 may be broken, and one or more shims (108, 110) inserted. It should also be understood that shims (108, 110) may be necessary with the initial erection for leveling purposes. Although exterior middle P5 and interior middle P6 slab panels and cross beam B6 are shown, it should be understood that one or more shims (108, 110) may be placed as shown in FIG. 47 under any of slab panels (P1, P2, P3, P4, P5, P6, P7, P8) or above any of beams (B1, B2, B3, B4, B5, B6, B7, B8).
FIG. 48 shows an extension from the original foundation slab area of FIG. 3. Three extension risers (C5A, C5B, C6) have replaced three side exterior risers C2, so that an extension of the foundation area of FIG. 3 may be made in a different shape and size, such as for example a porch. Corner transfer beam B3 and non-corner transfer beam B5 are positioned on extension exterior riser C5A, as are cross beam B6 and end transfer beam B1. Corner transfer beam B4 and non-corner transfer beam B5 are positioned on extension exterior riser C5B, as are cross beam B6 and end transfer beam B2. Extension interior riser C6 is shown isolated for clarity. However, cross beams B6 may be positioned on ledges (96, 97), and non-corner transfer beams B5 may be positioned on top 82.
In the extended slab area, there are two end transfer beams B1. The left ends of both end transfer beams B1 as viewed from their interior sides IS are positioned on end exterior risers C3. The right ends of end transfer beams B1 as viewed from their interior sides IS are positioned on either corner riser C1 or extension exterior riser C5A. In the extended slab area, there are two end transfer beams B2. The right ends of both end transfer beams B2 as viewed from their interior sides IS are positioned on end exterior risers C3. The left ends of end transfer beams B2 as viewed from their interior sides IS are positioned on either corner riser C1 or extension exterior riser C5B. The left end of extension corner transfer beam B7 as viewed from it interior side IS is positioned on side exterior riser C2, and the right end is positioned on corner riser C1. The right end of extension corner transfer beam B8 as viewed from it interior side IS is positioned on side exterior riser C2, and the left end is positioned on corner riser C1. Exterior corner slab panels P7 may be positioned in the corners of the extension area, each with one end on cross beam B6 and the other end on end transfer beam B1 or B2, and one side on extension end transfer beam B7 or B8. Extension side slab panels P8 may be positioned each with one end on cross beam B6 and the other end on end transfer beam B1 or B2. Although it is not shown for clarity, the extended slab area may be completed with extension side slab panels P8.
Method of Use
In the preferred method or process, one or more of the components would be pre-cast in reinforced concrete before being transported to the construction site. After the site is surveyed, and shallow or deep foundation members, if any, are properly placed, risers (C1, C2, C3, C4, C5A, C5B, C6) may be positioned as illustrated in FIGS. 3, 4, and/or 48. Corner risers C1 may be positioned at the exterior corners of the foundation area. Side exterior risers C2 may be positioned on the exterior perimeter of the foundation area, and receive cross beams B6. End exterior risers C3 may be positioned on the exterior perimeter of the foundation area, and do not receive cross beams B6. Interior risers C4 may be positioned in the interior of the foundation area, and receive cross beams B6. As shown in FIG. 48, if an extension along the side of the foundation area were desired, such as for example a porch, then two or more adjacent side exterior risers C2 may be replaced with extension risers (C5A, C5B, C6).
Risers (C1, C2, C3, C4, C5A, C5B, C6) may be positioned on and fixed with previously placed shallow or deep foundation members, such as piles, piers, or other members, as shown in FIGS. 40-44. Concrete may be poured in openings (20, 40, 72, 98, 154) and recesses 22 of risers (C1, C2, C3, C4, C5A, C5B, C6) to connect them with the foundation members. The foundation members preferably have connectors, such as for example reinforcing steel R or pile heads, extending into the openings (20, 40, 72, 98, 154) before the concrete is poured. It should be understood that since risers (C1, C2, C3, C4, C5A, C5B, C6) and other components of the LESS are relatively compact and lightweight, a small construction vehicle or device, such as a BOBCAT® brand loader distributed by Ingersoll-Rand Company Limited of Bermuda, or a small truck mounted crane, may be used to position the risers (C1, C2, C3, C4, C5A, C5B, C6) or other components of the LESS. The relatively smaller equipment can advantageously maneuver between trees or other obstructions at the job site.
Cross beams B6 may be positioned as shown in FIGS. 3, 4, and 48. At least one end of each cross beam B6 may positioned on an interior riser C4. The other end of each cross beam B6 may be positioned on side exterior C2 or interior riser C4. If a foundation area extension is used, as shown in FIG. 48, then cross beam B6 may be positioned with either one or both ends on extension risers (C5A, C5B, C6). Cross beam B6 may be fixed to risers (C2, C4, C5A, C5B, C6) using welding, bolting, or other connection methods as are known in the art or described above.
Transfer beams (B1, B2, B3, B4, B5) may be positioned as illustrated in FIGS. 3 and 4. End transfer beams (B1, B2) may be placed between corner C1 and end exterior C3 risers. The appropriate end transfer beam (B1, B2) is selected based upon the location of the weld plates (PL8, PL9) on the side of end transfer beam (B1, B2). The weld plate PL8 or PL9 on the end of end transfer beam (B1, B2) may be positioned at end exterior riser C3, with the interior side IS of end transfer beam (B1, B2) on the interior of the foundation area. Corner transfer beams (B3, B4) may be placed between corner C1 and side exterior C2 risers. The appropriate corner transfer beam (B3, B4) is selected based upon the location of the weld plate (PL11, PL12) on the side of transfer beam (B3, B4). The weld plate PL11 or PL12 on the end of the transfer beam (B3, B4) is positioned at the side exterior riser C2, with the interior side IS of end transfer beam (B1, B2) on the interior of the foundation area. Non-corner transfer beams B5 may be placed between side exterior risers C2, with interior side IS of corner transfer beam B5 on the interior of the foundation area. Transfer beams (B1, B2, B3, B4, B5) may be fixed to risers (C1, C2, C3, C4) using welding or other connection methods as are known in the art or described above.
If a slab extension is desired as shown in FIG. 48, then extension risers (C5A, C5B, C6) may be positioned where side exterior risers C2 would otherwise be located. The left end of end transfer beam B1 as viewed from its interior side IS is positioned on end exterior riser C3, and its right end is positioned on either corner riser C1 or extension exterior riser C5A. The right end of end transfer beam B2 as viewed from its interior side IS is positioned on end exterior riser C3, and its left end is positioned on either corner riser C1 or extension exterior riser C5B. The left end of extension end transfer beam B7 as viewed from its interior side IS is positioned on side exterior riser C2, and the right end is positioned on corner riser C1. The right end of extension end transfer beam B8 as viewed from it interior side IS is positioned on side exterior riser C2, and the left end is positioned on corner riser C1.
With no slab extension, slab panels (P1, P2, P3, P4, P5, P6) may be positioned on cross B6 and/or transfer beams (B1, B2, B3, B4, B5) as shown in FIGS. 3 and 4. Corner slab panels P1 are positioned in the corners of the foundation area. Exterior side slab panels P2 are positioned along the exterior perimeter of the foundation area in the exterior bays EB with one end resting on end transfer beam (B1, B2), and the other end resting on cross beam B6. Exterior side slab panels P2, unlike exterior middle slab panels P5, are not placed over end exterior C3 or interior risers C4. Exterior middle slab panels P5 are positioned along the exterior perimeter of the foundation area in the exterior bays EB with one end resting on end transfer beam (B1, B2), and the other end resting on cross beam B6. Exterior middle slab panels P5, unlike exterior side slab panels P2, are placed over end exterior C3 or interior risers C4.
Interior edge slab panels P3 are positioned along the exterior perimeter of the foundation area in the interior bays IB with their two ends resting on cross beams B6, and one side resting on non-corner transfer beam B5. Interior side slab panels P4 are positioned in the interior of the foundation area with their two ends resting on cross beams B6. Interior side slab panels P4, unlike interior middle slab panels P6, are not placed over interior risers C4. Interior middle slab panels P6 are positioned in the interior of the foundation area with their two ends resting on cross beams B6. Interior middle slab panels P6, unlike interior side slab panels P4, are placed over interior risers C4. Slab panels (P1, P2, P3, P4, P5, P6) may be fixed to the cross B6 and/or transfer beams (B1, B2, B3, B4, B5) using welding or other connection method as is known in the art.
If a slab extension is desired as shown in FIG. 48, then exterior corner slab panels P7 may be positioned in the exterior corners of the extension area, each with one end on cross beam B6 and the other end on end transfer beam B1 or B2, and one side on extension end transfer beam B7 or B8. Extension side slab panels P8 may be positioned each with one end on cross beam B6 and the other end on end transfer beam B1 or B2 to complete the extended slab area.
Channels or openings for mechanical, electrical, and plumbing (MEP) lines may be placed in slab panels (P1, P2, P3, P4, P5, P6, P7, P8) or other components before slab panels (P1, P2, P3, P4, P5, P6, P7, P8) or other components are cast in concrete. Alternatively, the channels or openings for the MEP lines may be placed, such as by drilling or cutting, at the construction site. If slab panels (P1, P2, P3, P4, P5, P6, P7, P8) or beams (B1, B2, B3, B4, B5, B6, B7, B8), either initially or after erection, or at any time in the future, become unleveled, then shims (100, 102, 104, 106, 108, 110) as shown in FIGS. 45-47 may be placed either under the slab panels (P1, P2, P3, P4, P5, P6, P7, P8) or beams (B1, B2, B3, B4, B5, B6, B7, B8) to level them.
The foregoing disclosure and description of the invention are illustrative and explanatory thereof, and various changes in the details of the illustrated apparatus and system, and the construction and the method of operation may be made without departing from the spirit of the invention.
