Modular Vertical Stacking Load Bearing Wall and Shoring System

Abstract

A modular vertical stacking load bearing wall and shoring panel includes a set of opposing columns elongated parallel to a vertical axis, each having a coupler. Each coupler includes an interior plate located in a horizontal plane substantially parallel to the vertical axis and the plate separates the coupler into two sections. A bottom track and a top track are attached between the columns. A top horizontal beam member is attached between the columns with its top surface located below the bottom edge of the coupler. A set of horizontal braces is attached perpendicularly between the columns and are spaced apart. Furring strips are attached to the top track, the bottom track and the horizontal braces. Fire safing material may be deposited in the coupler to promote fire resistance.

Description

RELATED APPLICATIONS

This application is a non-provisional application claiming priority to co-pending U.S. provisional patent application Ser. No. 62/005,152, filed May 30, 2014, of Battisti, et al. entitled “Modular Vertical Stacking Load Bearing Wall and Shoring System,” which is incorporated herein by this reference.

TECHNICAL FIELD

The present invention is directed to the field of light weight steel mid-rise buildings, and, more particularly, to a modular vertical stacking load bearing wall and shoring system for use in multi-story buildings.

BACKGROUND

Current trends indicate that a large part of the population already lives in or desires to live in an urban environment close to transportation, shopping, entertainment, restaurants and other accoutrements of a modern city. Thus, the need for affordable high density multistory buildings is growing. Modular construction techniques offer relatively lower costs without sacrificing quality, safety and architectural esthetics.

Unfortunately, current modular designs are lacking in several respects. For example, current designs do not provide certified vertical fire resistance properties that reduce the danger of fires from spreading vertically through a multi-story building from floor to floor. The use of hollow structural steel in today's buildings can actually provide a chimney effect which allows the spread of a fire vertically throughout a building. When a fire spreads vertically it can do so quickly and unduly endanger the residents while causing extensive property damage. This is because older designs, such as that disclosed in U.S. Pat. No. 8,381,484 to Bonds, granted Feb. 26, 2013 and entitled “Insulated modular building frame,” rely on standard bolting for attaching one modular wall to another with no discernable accommodations for vertical fire resistance in vertical beam attachments.

A further drawback in current practice is that concrete slab flooring between floors must follow the wall construction. That is, the concrete slab must be in place prior to subsequent higher levels being erected. It would be desirable if the upper modular panels could be installed prior to the concrete floor slab being poured in order to avoid delays waiting for concrete curing, scheduling and other costly delays, for example. In this way the concrete work could follow floor construction, giving builders an attractive and cost effective option for performing this work.

In contrast to current modular designs, the present invention solves the need for inexpensive, reliable, stable and low cost construction of multi-story buildings with a coupling mechanism exhibiting superior fire-resistance-rated vertical construction materials and methods designed to restrict the vertical spread of fires. Further, the present invention allows flexibility in constructing floors from level to level not currently available in the art.

BRIEF SUMMARY OF THE DISCLOSURE

This summary is provided to introduce a selection of concepts in a simplified form that are further described below in the Detailed Description. This summary is not intended to identify key features of the claimed subject matter, nor is it intended to be used as an aid in determining the scope of the claimed subject matter.

The present invention provides a modular vertical stacking load bearing wall and shoring panel. The panel includes a set of opposing vertical support columns elongated parallel to a vertical axis, each of said opposing vertical support columns having a coupler, the coupler having the same horizontal cross-sectional shape as each of the vertical support columns but is sized to accept an inserted vertical support column. Each coupler also includes an interior plate, the interior plate being located in a horizontal plane substantially parallel to the vertical axis and having a surface that covers the inner area of the coupler to separate the coupler into two sections. The plate has a thickness shorter than the length of the coupler so as to create a top cavity in the coupler, and each coupler has a bottom perimeter edge. A bottom track is attached between the bottom portions of the set of opposing vertical support columns and a top track is attached between the bottom portions of the first set of opposing vertical support columns. A top horizontal beam column is attached perpendicularly between the set of opposing vertical support columns, the horizontal beam column having a top surface located in a horizontal plane defined by the bottom perimeter edge of the coupler. A plurality of horizontal braces is attached perpendicularly between the set of opposing vertical support columns, where each of the braces is spaced apart from the others according to a predetermined brace spacing value. A plurality of vertical furring strips is attached perpendicularly to the top track, the bottom track and the plurality of horizontal braces, where each of the vertical furring strips is spaced apart from the others according to a predetermined strip spacing value.

In another aspect, firing safing material is deposited in the top cavity.

In another aspect, the plurality of vertical furring strips comprise hat channel furring strips.

In another aspect, the plurality of horizontal braces comprise hollow structural steel tubing.

In another aspect, the top horizontal beam member comprises hollow structural steel tubing.

In another aspect, the plurality of vertical furring strips and the plurality of horizontal braces are spaced apart by an isolator element at each attachment region.

In another aspect, a radio frequency identification device attached to the panel.

In another aspect, the radio frequency identification device is programmed with information comprising including location data, site information, panel placement data, manufacturer data, loading sequence data, unloading sequence data and quality control data.

In another aspect, the invention provides a coupler for use in a modular vertical stacking load bearing wall and shoring panel. The coupler includes a tube elongated in a first direction, the tube having a width adapted to mate with at least one vertical steel column of a similar cross-sectional profile. An interior plate is located in a horizontal plane substantially parallel to the first direction and has a surface that covers the inner area of the tube to separate the tube into two sections, and wherein the plate has a thickness shorter than the length of the tube so as to create a top cavity in the tube.

In another aspect, firing safing material is deposited in the top cavity of the coupler.

BRIEF DESCRIPTION OF THE DRAWINGS

While the novel features of the invention are set forth with particularity in the appended claims, the invention, both as to organization and content, will be better understood and appreciated, along with other objects and features thereof, from the following detailed description taken in conjunction with the drawings, in which:

FIG. 1 schematically shows an assembly drawing of an example embodiment of a modular vertical stacking load bearing wall and shoring system for use in multi-story buildings.

FIG. 2 schematically shows a partial view of one example of joined modular panels with flooring installed.

FIG. 3 schematically shows a detailed partial view of the bottom of a vertical support column installed in a base.

FIG. 4 schematically shows a detailed cut-away view of an example of a pair of upper and lower vertical support columns installed in relation to a floor slab.

FIG. 5 schematically shows a more detailed sectional side view of the attachment of a furring strip to a horizontal brace.

FIG. 6 schematically shows a partial side view of a wall between the interior and exterior of a building constructed using the modular panels made in accordance with the instant disclosure.

FIG. 7 schematically shows an intermediate to horizontal section view of a horizontal brace and attached furring strips.

FIG. 8 schematically shows an example of a coupler including fire safing as employed in the presently disclosed embodiments.

FIG. 9 shows an example of a method using the disclosed prefabricated panel module system in block diagram form.

FIG. 10 shows Table 1 detailing load parameters for fire testing.

FIG. 11 shows how furnace temperature followed the standard time-temperature curve during fire testing.

FIG. 12 shows a comparison of the area under the time-temperature curve with the standard during fire testing.

FIGS. 13 and 14 respectively show temperature profiles for a fire test sample grouped as finish thermocouples and unexposed thermocouples.

FIG. 15 shows the horizontal deflection of a fire test sample.

FIG. 16 shows the vertical deflection of a fire test sample.

In the drawings, identical reference numbers identify similar elements or components. The sizes and relative positions of elements in the drawings are not necessarily drawn to scale. For example, the shapes of various elements and angles are not drawn to scale, and some of these elements are arbitrarily enlarged and positioned to improve drawing legibility. Further, the particular shapes of the elements as drawn, are not intended to convey any information regarding the actual shape of the particular elements, and have been solely selected for ease of recognition in the drawings.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

The following disclosure describes several embodiments for a modular vertical stacking load bearing wall and shoring system. Several features of methods and systems in accordance with example embodiments are set forth and described in the Figures. It will be appreciated that methods and systems in accordance with other example embodiments can include additional procedures or features different than those shown in the Figures. Example embodiments are described herein with respect to a modular vertical stacking load bearing wall and shoring system for use in multi-story buildings. However, it will be understood that these examples are for the purpose of illustrating the principles, and that the invention is not so limited. Additionally, methods and systems in accordance with several example embodiments may not include all of the features shown in the Figures.

Unless the context requires otherwise, throughout the specification and claims which follow, the word “comprise” and variations thereof, such as, “comprises” and “comprising” are to be construed in an open, inclusive sense that is as “including, but not limited to.”

Reference throughout this specification to “one example” or “an example embodiment,” “one embodiment,” “an embodiment” or combinations and/or variations of these terms means that a particular feature, structure or characteristic described in connection with the embodiment is included in at least one embodiment of the present disclosure. Thus, the appearances of the phrases “in one embodiment” or “in an embodiment” in various places throughout this specification are not necessarily all referring to the same embodiment. Furthermore, the particular features, structures, or characteristics may be combined in any suitable manner in one or more embodiments.

Reference throughout this specification to “vertical,” vertical axis,” “horizontal” or “horizontal axis” shall be with reference to the Cartesian coordinate system 7 as shown in FIG. 1 where the Z-axis represents a vertical orientation and the X-axis represents a horizontal orientation.

Reference throughout this specification to “tube,” tubes” and “tubing” refers to building components of different geometric shapes and profiles including, but not limited to, rectangular, square, circular, oval, and hexagonal. For example, HSS tubing typically has a rectangular profile when viewed from the top of its shortest dimension.

Reference throughout this specification to “HSS” refers to hollow structural steel as understood in the building construction industry.

Referring now to FIG. 1, an assembly drawing of an example embodiment of a modular vertical stacking load bearing wall and shoring system for use in multi-story buildings is schematically shown. A modular vertical stacking load bearing wall and shoring system 5 includes a panel 2 constructed from a plurality of modular components which may be assembled at an off-site manufacturing facility. The plurality of modular components include a plurality of vertical support columns 10, a horizontal top beam 12, a plurality of horizontal braces 14, a top track 13 and a bottom track 16. Each of the plurality of vertical support columns 10 are attached by insertion into a coupler 20 having the same cross-sectional shape, but sized to accept the insertion of the vertical support columns. A plurality of vertical furring strips 22, as for example, hat channel furring strips, are joined to the track 16, horizontal braces 14 and horizontal top beam 12. The modular components are assembled at the manufacturing facility using standard attachment mechanisms such as bolts, screws, welds and the like. Assembled modular panels 2 are then transported to a building construction site where they are assembled with additional modular panels and additional building structures. For example, shown in the broken line box 31 is a view illustrating installation of flooring between two modular panels (shown in more detail in FIG. 2). Broken line box 32 is a partial view the bottom of a vertical support column shown in more detail in FIG. 3.

In one embodiment the modular panel comprises an opposing pair of right and left vertical beams 10R, 10L, a top horizontal beam 12 covered by a metal deck 13. The vertical support columns and top horizontal beam may advantageously be fabricated from

Hollow Structural Steel (HSS) tubes welded to the top and bottom tracks. In one optional example, right and left vertical support columns of adjacent panels may be connected using erection bolts 30 placed at top, bottom and horizontal brace locations 30T, 30B and 30H respectively. The furring strips 22 may advantageously be welded at bottom, top and horizontal brace positions in the known fashion. Isolator tape 35 or the like is juxtaposed between the vertical furring strips 22 and the top horizontal beam 12 and the horizontal braces 14. The isolator tape 35 provides a spacing of about 0.25 inches (0.635 cm) between the beams and the furring strips.

Referring now to FIG. 2, a partial view of one example of joined modular panels with flooring installed is schematically shown in more detail. Broken line box 31 shows a left-hand vertical support column 10L from a first modular panel connected to a right-hand vertical support column 10R of a second modular panel as may be done at the building construction site. The right and left vertical support columns are optionally coupled together with erection bolts 30. Steel decking 40 is attached to the top horizontal beams of each modular panel and concrete floor slab 46 is poured level with the mid-points of couplers 20. The couplers 20 are placed to have a tight flush fit, leaving a gap between the vertical support columns 10R, 10L of about 0.5 in. (1.3 cm). The deck may comprise concrete and steel that may be W3 or dovetail styles according to architectural requirements for a particular application. The width between the vertical columns may vary, but in one embodiment it is desirable to keep the maximum width within about 8 ft. (2.4 m) between the outside face of couplers on the pair of opposing vertical columns defining the perimeter of a single modular panel.

Referring now to FIG. 3 a detailed partial view of the bottom of a vertical support column installed in a base is schematically shown. Broken line box 32 illustrates the bottom of a pair of vertical columns 10R, 10L from adjacent modular panels as may be installed into the concrete floor slab 46 of a lower module located below an upper module. Each vertical column 10R, 10L from above extends below the bottom base track 16 and inserts into a coupler 20 positioned below the top of the concrete floor slab 46.

Referring now to FIG. 4, a detailed cut-away view of an example of a pair of upper and lower vertical support columns installed in relation to a floor slab is schematically shown. A pair of upper and lower vertical support columns 10U, 10B are installed in a coupler 20. The coupler 20 has a wall thickness of about 0.25 inches (0.635 cm). The top horizontal beam 12 is attached to a top track 16 by welding, such as, for example, puddle weld 52, along the length of the top track as needed. The floor slab 46 is poured and leveled flush to the top of the coupler 20. The top horizontal beam 12 is attached to the lower vertical column 10B by welding in a conventional manner, such as by a 3/16 in (0.48 cm) fillet weld.

In one example, a radio frequency identification device (RFID) 25 may be attached to one or more of the modular components. The location of the device may be any convenient place on the modular panel. Here, for the convenience of simplifying the description, it is shown attached to a vertical column. The RFID device may contain identifying data including location data, site information, panel placement, manufacturer and any other useful information to make transportation of the panels easier to manage. For example, using an RFID reader, a trucker could direct panels to be unloaded in a logical order and set up in a logical order for later retrieval. The use of RFID devices would also assure that the correct panels are delivered to the correct location thus reducing costs due to mistakes in delivering materials. Quality control information can also be included on the data set imprinted on the RFID.

Referring now to FIG. 5 a more detailed view of the attachment of a furring strip to a horizontal brace is schematically shown. As described above, the plurality of furring strips 22 may advantageously be welded at horizontal brace positions in a known fashion. Isolator tape 35 or the like is juxtaposed between the vertical furring strips 22 and the horizontal braces 14. The isolator tape 35 provides a spacing of about 0.25 inches (0.635 cm) between the beams and the furring strips. For interior use furring strips may be 1.25 in (3.175 cm) hat channel steel. Apertures 55, such as, for example circular or oval openings, may be included for added structural stability.

Referring no to FIG. 6 a partial side view of a wall between the interior and exterior of a building constructed using the modular panels made in accordance with the instant disclosure is schematically shown. A lower track 16 and an upper track 13 are attached to furring strips 22 by screws or other conventional attachment means. Exterior furring hat channel connects to the horizontal HSS beams for wind load support.

Referring now to FIG. 7, an intermediate to horizontal section view of a horizontal brace and attached furring strips is schematically shown. A horizontal brace 14 supports furring strips 22. The furring strips 22 are screwed to the horizontal brace by screws 15. An isolator 35 is interposed between each furring strip and the horizontal brace.

Referring now to FIG. 8, an example of a coupler including fire safing as employed in the presently disclosed embodiments is schematically shown. A coupler 20 includes a top section 80 and a bottom section 86. Welded between the top section 80 and the bottom section 86 is an interior plate 84 which forms a cavity 81 with the top section 80. The cavity 81 is at least partially filled with fire safing material 82. During construction vertical columns 10 are inserted into the top section 80 and the bottom section 86. In this way additional fire resistance can be built into any building constructed using the modular panels. The coupler 20 thus serves both to hold the vertical columns securely in place while, at the same time, providing protection from fire spreading vertically from floor to floor. Fire safing material typically comprises a thermal insulation blanket or fiber material and is commercially available.

As compared to known systems, the coupler 20 may be attached to a lower vertical column at an off-site facility. At the building site, the upper modular panels can be installed prior to the concrete floor slab being poured since the concrete floor slab will not extend beyond the top of the coupler. In this way the concrete work can follow floor construction, giving builders an option for scheduling this work for the first time.

Having described the invention above, it is now considered useful to the understanding of the invention to describe further aspects of the construction details of one example embodiment.

Referring now to FIG. 9, an example of a method using the disclosed prefabricated panel module system is shown in block diagram form. A construction method using a modular vertical stacking load bearing wall and shoring system includes prefabricating a first prefabricated frame module and a second prefabricated frame module. As described above, each prefabricated frame module is constructed 901 by attaching a top horizontal beam member perpendicularly between a set of opposing vertical support columns elongated parallel to a vertical axis, attaching each of said opposing vertical support columns to a coupler, said coupler having the same horizontal cross-sectional shape as each of the vertical support columns, wherein each coupler includes an interior plate, the interior plate being located in a horizontal plane substantially parallel to the vertical axis and having a surface that covers the inner area of the coupler to separate the coupler into two sections, and wherein the plate has a thickness shorter than the length of the coupler so as to create a top cavity in the coupler, and wherein each coupler has a bottom perimeter edge, attaching a bottom track between the bottom portions of the set of opposing vertical support columns, attaching a top track between the bottom portions of the first set of opposing vertical support columns, where the horizontal beam member has a top surface located in a horizontal plane defined by the bottom perimeter edge of the coupler, attaching a plurality of horizontal braces perpendicularly between the set of opposing vertical support columns, spacing each of the braces apart from the others according to a predetermined brace spacing value. The set of opposing vertical support columns from the second prefabricated frame module are inserted 906 into the top couplers of the first prefabricated frame module's set of opposing vertical support columns. If desired, firing safing material is deposited 906 in each top cavity. Steel decking is attached to the top horizontal beam members of each modular panel 907 followed by installing a concrete floor slab having a top surface level with the tops of each coupler. An RFID device containing information as described hereinabove may also be installed during prefabrication of the panels 912.

Fire Test Results

A load-bearing wall assembly incorporating the novel coupling elements disclosed herein was fire tested on April 25, 2019 by an independent fire testing center. The test results showed superior fire resistance of the tested assembly under load. The fire test parameters and conditions are described below.

Summary of Test Method

Testing was performed using a vertical fire resistance test configuration employing the fire endurance conditions and standard time-temperature curve described in ASTM E119, Standard Test Methods for Fire Tests of Building Construction and Materials. The exposed surface of the assemblies was subjected to the standard E119 time-temperature curve, with temperature measurements taken inside the natural gas furnace using 9 thermocouples (TC_F) connected to a computerized data acquisition system. TC_F locations were symmetrically disposed and distributed to show the temperature near (within 6″) the exposed face of the test assembly.

Following are the criteria to which these tests were judged, according to ASTM E119:

• • Wall assembly will have sustained the applied load for the indicated time (1-hr, in this instance) without passage of flame or gases hot enough to ignite cotton waste;
  • Wall assembly will have not developed an opening that permits the projection of water from the hose stream beyond the unexposed surface (applicable for hose-stream portion of the test);
  • Transmission of heat through the wall will not have risen the temperature on its unexposed side more than 139° C. (average) above its initial temperature, or if a temperature higher than 30% (181° C.) of the specified limit occurs at any one point (single-point) on the unexposed side of the assembly.

Sample Description

Two separate 10′×10′ assemblies were constructed, one fire-endurance wall and one hose-stream retest wall. The steel frame assembly consisted of one layer of ⅝″ Type X gypsum connected to hat channel on each side a 3″ steel frame.

Structural Steel Frame

The 10′×10′ assembly had a 3″ structural tube steel frame with two vertical perimeter columns (3″×3″×10′ [16 GA (measured 0.065″)]), one horizontal header beam (6″×3″×9′6″ ¼″ thick]), and two horizontal bracing beams (2″×3″×9′6″ [16 GA (measured 0.060″)]) placed at third-points horizontally up the assembly. These five steel pieces were welded together to give the 10′×10′ structural frame.

A steel track (6″×2″×10′ [Scafco 600T200-43 mil]) was welded to the top header beam with 1.5″ overhang on each side. Two steel C-studs (6″×1⅝″×10′ [Scafco 6005162-43 mil]) were fastened to the columns with #6 ( 7/16″) framing screws, two at each horizontal beam and one at the top and bottom of the column. These studs are not intended for the final design, but were included to close off the fire test assemblies. A bottom track (6″×2″×10′ [Scafco 600T200-43 mil]) was then attached at the bottom with framing screws. To give additional support to the bottom track, a 6″ section of C-stud (support brace) was fastened (four #6 framing screws) to the inside of the column. The structural steel frame and top track had a mass of 220.0 lb. and 220.6 lb. for the fire endurance and hose-stream retest walls, respectively. The bottom cap and C-studs had a mass of 1.4 lb./ft. and 1.4 lb./ft., respectively.

Hat Channel

Seven hat channels (3″×1¼″×9′11½″ with 1½″ effective surface for fastening gypsum [150H125-33]) were fastened to each side to the inside of both the top and bottom track with a single framing screw at each end. Each hat channel was spaced 16″ on center with a hat channel in the center. A strip of 6″ isolator tape ( 01/4″ thick [Norton® Foam Tape]) was fixed onto the horizontal bracing beam between each hat channel. Two #6 (1¼″) drywall/gypsum screws were placed on both sides of the hat channel at each horizontal bracing beam intersection. Care was used to ensure the ¼″ gap between the hat channels and bracing beam was maintained.

Gypsum Layers

One layer of ⅝″ Type X gypsum (CertainTeed ⅝″ Type X Gypsum Board—⅝″ CT Type X 09:16 01 APR 14—UL R3660-S—F-4087) was applied on each side of the hat channels. Gypsum panels were shipped as 4′×10′ boards and cut to appropriate sections. Each panel was fastened with #6 (1¼″) drywall/gypsum screws at 8″ on center on the edge and 12″ on center in the field, with ¾″ spacing at the top and bottom of each panel and %″ spacing at the joints. The mass of the gypsum was 2.24 0.04 lb./ft². The joints and screw heads were coated with 2 layers of joint compound, including 2″ taped joints. Unfaced fiberglass insulation (CertaninTeed® R-11, UL R5832) with dimensions of 16″ wide and 3½″ thick were lined vertically filling the cavity of the wall.

Temperature

To obtain representative thermal information of the samples during the tests, the fire endurance assembly was instrumented with sample thermocouples (TC_s). There TC_s were placed in two groups:

• • Finish TC_s (1-5): Placed at relative center and quarter points of assembly between OSB face layer and studs.
  • Unexposed TCs (6-15): Placed at center and quarter points of assembly (TCs6-10) as well as other points (TCs11-15) throughout the assembly that may exhibit excessive heating. Some TC_s were shifted 2″ so that they did not directly line up behind a hat channel.

Loading and Deflection

Referring now to FIG. 10, Table 1 listing load parameters for fire testing is shown. A superimposed load (9800 lb./stud) was applied to the test assembly through a series of hydraulic rams positioned below the wall. Two load points (2×6 studs) were placed above the wall, 1′8″ from each side, to transfer the load directly to the horizontal header beam rather than directly to the side columns. The space between the load points was insulated. The panel was loaded to full design capacity of the top beam header and two side columns. The set point for the ram pressure (designed, Table 1) was maintained constant throughout testing with nominal variation. The actual ram pressure was measured during the tests, and the average in shown in Table 1. The load was recalculated and showed a minimal variation (1.6% and 0.9% for the fire endurance and hose-stream retest, respectively) from the design load. Two linear vertical displacement transducers (LVDT) were placed below each side of the fire resistance wall assembly, measuring vertical movement of the assembly. Horizontal deflection was also measured at the fire resistance assembly mid-height at each quarter point along the assembly.

Test Results

Testing of the fire resistance wall and hose-stream retest wall assemblies took place on April 25, 2014, respectively. Each assembly was fixed in place within the sample holder and insulated on the perimeter edges with ceramic wool insulation. The furnace temperature, sample temperatures, ram pressure, LVDT, and furnace pressure, were continuously monitored at 1 Hz until test termination. Also, horizontal deflection was measured every 5 minutes during the test. These data, as well as additional photographs, are presented below.

Fire Resistance Test

Furnace: Large-scale vertical exposure El 19 furnace—1-hr

fire exposure Laboratory Conditions: 18° C., 37% RH

The test was terminated after 1 hr., ensuring that sufficient energy had been applied to the assembly at 61 min (only 17 s lag). No flames passed through the assembly at that time, giving a wall rating of 61 min, rounding to the nearest integral minute. Thus, this fulfilled the requirement of flames or gases hot enough to ignite cotton waste for the 1-hr period. The furnace temperature followed the standard time-temperature curve as shown in FIG. 11. A comparison of the area under the time-temperature curve with the standard is also shown in FIG. 12. The area (0.5%) is well below the 10% recommended for a 1-hr test.

The temperature profiles for this sample are grouped as finish TC_s and unexposed TC_s as shown in FIGS. 13 and 14 respectively. TCsAVG superseded the average finish temperature threshold (139° C.+ambient 18° C.=157° C.) at 21 m 0 s giving a finish rating of 21 min., rounding to the nearest integral minute. The unexposed TC_s did not supersede either average or single-point (181° C.+ambient [18° C.]=199° C.) temperature threshold for the duration of the test. Therefore, this assembly passed the heat transmission requirement for the 1-hr. duration.

Displacement Data

Horizontal deflection measurements were taken every five minutes at three locations along the horizontal midline on the unexposed sample surface to monitor horizontal movement and/or buckling of the sample. It can be seen in FIG. 15 that the horizontal deflection (towards the furnace) reached up to reached a value of nearly 2″ at 60 min. The vertical displacement did not vary significantly for the duration of the test except for the jump at 7 min where there was a popping sound from the assembly. Overall, the panel deflected an average of 0.07″ at test termination (FIG. 16).

The invention has been described herein in considerable detail in order to comply with the Patent Statutes and to provide those skilled in the art with the information needed to apply the novel principles of the present invention, and to construct and use such exemplary and specialized components as are required. However, it is to be understood that the invention may be carried out by different equipment, and devices, and that various modifications, both as to the equipment details and operating procedures, may be accomplished without departing from the true spirit and scope of the present invention.

Claims

1. A modular vertical stacking load bearing wall and shoring panel comprising:

a set of opposing vertical support columns elongated parallel to a vertical axis, each of said opposing vertical support columns having a coupler, said coupler having the same horizontal cross-sectional shape as each of the vertical support columns, but is sized to accept an inserted vertical support column;

wherein each coupler includes an interior plate, the interior plate being located in a horizontal plane substantially parallel to the vertical axis and having a surface that covers the inner area of the coupler to separate the coupler into two sections, and wherein the plate has a thickness shorter than the length of the coupler so as to create a top cavity in the coupler, and wherein each coupler has a bottom perimeter edge;

a bottom track attached between the bottom portions of the set of opposing vertical support columns;

a top track attached between the bottom portions of the first set of opposing vertical support columns;

a top horizontal beam column attached perpendicularly between the set of opposing vertical support columns, the horizontal beam column having a top surface located in a horizontal plane defined by the bottom perimeter edge of the coupler;

a plurality of horizontal braces attached perpendicularly between the set of opposing vertical support columns, where each of the braces is spaced apart from the others according to a predetermined brace spacing value; and

a plurality of vertical furring strips attached perpendicularly to the top track, the bottom track, the top horizontal beam member and the plurality of horizontal braces, where each of the vertical furring strips is spaced apart from the others according to a predetermined strip spacing value.

2. The panel of claim 1 further comprising firing safing material deposited in the top cavity.

3. The panel of claim 1 wherein the plurality of vertical furring strips comprise hat channel furring strips.

4. The panel of claim 1 wherein the plurality of horizontal braces comprise hollow structural steel tubing.

5. The panel of claim 1 wherein the top horizontal beam member comprises hollow structural steel tubing.

6. The panel of claim 1 wherein the plurality of vertical furring strips and the plurality of horizontal braces are spaced apart by an isolator element at each attachment region.

7. The panel of claim 1 further comprising a radio frequency identification device attached to the panel.

8. The panel of claim 7 wherein the radio frequency identification device is programmed with information comprising including location data, site information, panel placement data, manufacturer data, loading sequence data, unloading sequence data and quality control data.

9. A modular vertical stacking load bearing wall and shoring system, comprising:

a first prefabricated frame module and a second prefabricated frame module, wherein each prefabricated frame module includes a set of opposing vertical support columns elongated parallel to a vertical axis, each of said opposing vertical support columns having a coupler element, said coupler having the same horizontal cross-sectional shape as each of the vertical support columns but is sized to accept an inserted vertical support column, wherein each coupler includes an interior plate, the interior plate being located in a horizontal plane substantially parallel to the vertical axis and having a surface that covers the inner area of the coupler to separate the coupler into two sections, and wherein the plate has a thickness shorter than the length of the coupler so as to create a top cavity in the coupler, and wherein each coupler has a bottom perimeter edge, a bottom track attached between the bottom portions of the set of opposing vertical support columns, a top track attached between the bottom portions of the first set of opposing vertical support columns, a top horizontal beam column attached perpendicularly between the set of opposing vertical support columns, the horizontal beam member having a top surface located in a horizontal plane defined by the bottom perimeter edge of the coupler, a plurality of horizontal braces attached perpendicularly between the set of opposing vertical support columns, where each of the braces is spaced apart from the others according to a predetermined brace spacing value, a plurality of vertical furring strips attached perpendicularly to the top track, the bottom track, the top horizontal beam member and the plurality of horizontal braces, where each of the vertical furring strips is spaced apart from the others according to a predetermined strip spacing value; and

wherein the second prefabricated frame module has its set of opposing vertical support columns inserted into the top couplers of the first prefabricated frame module's set of opposing vertical support columns.

10. The system of claim 9 further including firing safing material deposited in each top cavity.

11. The system of claim 9 wherein the plurality of vertical furring strips comprise hat channel furring strips.

12. The system of claim 9 wherein the plurality of horizontal braces comprise hollow structural steel tubing.

13. The system of claim 9 wherein the top horizontal beam member comprises hollow structural steel tubing.

14. The system of claim 9 wherein the plurality of vertical furring strips and the plurality of horizontal braces are spaced apart by an isolator element at each attachment region.

15. The system of claim 9 further comprising a radio frequency identification device attached to the panel.

16. The system of claim 15 wherein the radio frequency identification device is programmed with information comprising including location data, site information, panel placement data, manufacturer data, loading sequence data, unloading sequence data and quality control data.

17. The system of claim 9 further comprising:

a left-hand vertical support column from the first prefabricated frame module connected to a right-hand vertical support column of a third prefabricated frame module;

steel decking attached to the top horizontal beam members of each modular panel; and

a concrete floor slab having a top surface level with the tops of each couplers.

18. A construction method using a modular vertical stacking load bearing wall and shoring system, comprising:

prefabricating a first prefabricated frame module and a second prefabricated frame module, wherein each prefabricated frame module is constructed by attaching a top horizontal beam member perpendicularly between a set of opposing vertical support columns elongated parallel to a vertical axis, attaching each of said opposing vertical support columns to a coupler, said coupler having the same horizontal cross-sectional shape as each of the vertical support columns but is sized to accept an inserted vertical support column, wherein each coupler includes an interior plate, the interior plate being located in a horizontal plane substantially parallel to the vertical axis and having a surface that covers the inner area of the coupler to separate the coupler into two sections, and wherein the plate has a thickness shorter than the length of the coupler so as to create a top cavity in the coupler, and wherein each coupler has a bottom perimeter edge, attaching a bottom track between the bottom portions of the set of opposing vertical support columns, attaching a top track between the bottom portions of the first set of opposing vertical support columns, where the horizontal beam member has a top surface located in a horizontal plane defined by the bottom perimeter edge of the coupler, attaching a plurality of horizontal braces perpendicularly between the set of opposing vertical support columns, spacing each of the braces apart from the others according to a predetermined brace spacing value, attaching a plurality of vertical furring strips perpendicularly to the top track, the bottom track, the top horizontal beam member and the plurality of horizontal braces, where each of the vertical furring strips is spaced apart from the others according to a predetermined strip spacing value; and

inserting the set of opposing vertical support columns from the second prefabricated frame module has into the top couplers of the first prefabricated frame module's set of opposing vertical support columns.

19. The method of claim 18 further including depositing firing safing material in each top cavity.

20. The method of claim 18 wherein the plurality of vertical furring strips comprise hat channel furring strips.

21. The method of claim 18 wherein the plurality of horizontal braces comprise hollow structural steel tubing.

22. The method of claim 18 wherein the top horizontal beam member comprises hollow structural steel tubing.

23. The method of claim 18 further comprising spacing the plurality of vertical furring strips and the plurality of horizontal braces by installing an isolator element at each attachment region.

24. The method of claim 18 further comprising attaching a radio frequency identification device to the panel.

25. The method of claim 24 further comprising programming the radio frequency identification device with information including location data, site information, panel placement data, manufacturer data, loading sequence data, unloading sequence data and quality control data.

26. The method of claim 18 further comprising:

connecting a left-hand vertical support column from the first prefabricated frame module to a right-hand vertical support column of a third prefabricated frame module;

attaching steel decking to the top horizontal beam members of each modular panel; and

installing a concrete floor slab having a top surface level with the tops of each coupler.

27. A coupler for use in a modular vertical stacking load bearing wall and shoring panel, the coupler comprising:

a tube elongated in a first direction, the tube having a width adapted to mate with at least one vertical steel column of a similar cross-sectional profile;

an interior plate, the interior plate being located in a horizontal plane substantially parallel to the first direction and having a surface that covers the inner area of the tube to separate the tube into two sections, and wherein the plate has a thickness shorter than the length of the tube so as to create a top cavity in the tube.

28. The coupler of claim 27 further comprising firing safing material deposited in the top cavity.