Modular building construction and lifting device and method for use therewith

Abstract

A method for erecting a modular building on the ground of a building site with the use of a lifting device having a support pedestal and having a mechanism therein for causing relative movement relative to the support pedestal comprising the steps of providing a floor supported by the ground and having an outer perimeter. A plurality of wall components are provided. The lower extremities of the wall components are hingedly secured to the perimeter of the floor. The lower extremities of the roof components are hingedly secured to the upper extremities of the wall components. The wall components and the roof components are positioned so that they lie in planes parallel to the floor. The support pedestal is vertically positioned on the floor. Pulling cables are secured to the upper extremities of the roof components and extend to the upper extremity of the support pedestal. A mechanism is coupled to the support pedestal and to the pulling cables for causing the cables to be pulled to cause raising of the roof components and in unison therewith the wall components until the wall components are vertical.

Description

[0001] This invention relates to a modular building construction and to a lifting device and method for use therewith.

[0002] In U.S. Pat. No. 4,669,231 issued on Jun. 2, 1987 there is disclosed a building construction and method utilizing modular components. However, it has been found that in such modular building constructions, it is still desirable to provide changes and improvements which help to reduce the cost of such construction and which also facilitate assembly, erection and disassembly. There is therefore a need for a new and improved modular building construction and a lifting device and method for use therewith which incorporates such improvements.

[0003] In general, it is an object of the present invention to provide a modular building construction and a lifting device and method for use therewith which makes possible substantially reduced costs.

[0004] Another object of the invention is to provide a building construction which utilizes a square-based floor plan without the use of load bearing columns.

[0005] Another object of the invention is to provide a building construction of the above character which only requires the use of two different finished components namely a wall component and a roof component.

[0006] Another object of the invention is to provide a building construction of the above character in which it is only necessary to multiply by four the two different completely finished components to enclose an internal volume based on a square floor plan.

[0007] Another object of the invention is to provide a building construction of the above character in which the components can be packaged in a small amount of space and shipped to the building site for erection.

[0008] Another object of the invention is to provide a building construction and method of the above character in which the components of the building construction can be assembled at the site and then the components erected in unison and then automatically locked in their final positions.

[0009] Another object of the invention is to provide a building construction of the above character which can be readily erected by unskilled labor.

[0010] Another object of the invention is to provide a control lifting device which can be readily used for erection and disassembly of the building construction of the present invention.

[0011] Another object of the invention is to provide a lifting device of the above character which can be readily transported from one location to another.

[0012] Another object of the invention is to provide a method for erection of the building construction utilizing the lifting device to make possible automated construction.

[0013] Another object of the invention is to provide a method of the above character in which the erection of the building construction can be accomplished during relatively strong winds.

[0014] Additional objects and features of the invention will appear from the following description in which the preferred embodiments are set forth in detail in conjunction with the accompanying drawings.

[0015] FIG. 1 is a schematic side elevational view of a modular building construction incorporating the present invention showing an assembly immediately prior to erection and the lifting device therein utilized for erection.

[0016] FIG. 2 is a schematic top plan view of the building construction shown in FIG. 1.

[0017] FIG. 3 is an enlarged partial side elevational schematic view of the lifting device shown in FIGS. 1 and 2.

[0018] FIG. 4 is an isometric view showing the modular building construction of FIG. 1 during the process of erection.

[0019] FIG. 5 is a side elevational schematic view of the lifting device shown in FIG. 3 and showing the manner in which the lifting device is being utilized to erect the building construction.

[0020] FIG. 6 is a schematic illustration showing the automatic locking device utilized for releasably interconnecting wall components.

[0021] FIG. 7 is a schematic illustration showing the automatic locking device utilized for releasably interconnecting the roof components.

[0022] FIG. 8 is a front elevational view showing the completed building construction.

[0023] In general, the method is for erecting a modular building construction on the ground of a building site through use of a lifting device having a support pedestal and having a mechanism for causing movement relative to the support pedestal. The method includes providing a generally horizontal floor lying in a plane supported by ground at the building site and having an outer perimeter. A plurality of wall components having upper and lower extremities and a plurality of roof components having upper and lower extremities are provided. The lower extremities of the wall components are hingedly connected to the perimeter of the floor permitting the wall components to be disposed horizontally in planes generally parallel to the plane generally horizontal floor. The lower extremities of the roof components are hingedly connected to the upper extremities of the wall components and are disposed in horizontal positions overlying the wall components. The erecting device is vertically positioned with its lower extremity supported by the floor within the outer perimeter of the floor. The upper extremity of the support pedestal is anchored to the floor for withstanding sidewise forces. Flexible elongate elements are provided which have proximal and distal extremities with the distal extremities being secured to the upper extremities of the roof components and the proximal extremities being coupled to the upper extremity of the pedestal and to the mechanism. The mechanism is then operated to erect the wall and roof components by pulling on the flexible elongate elements to cause raising of the roof components and the wall components connected thereto to bring the wall components into a generally vertical position and the roof components into an inclined position with respect to the wall components to thereby enclose an internal volume overlying the floor. The wall components and the roof components are releasably secured together to provide the building construction. The lifting device is then removed from the enclosed internal volume.

[0024] More in particular, the building construction 11 as shown in FIG. 1 has been assembled and is ready for erection as hereinafter described. The building construction 11 is supported on ground 12 at a building site.

[0025] The building construction 11 consists of a floor 16 having an outer perimeter 17 which can be of any suitable configuration but preferably in accordance with the present invention is square in order to achieve the desired economies of the present invention. Thus, the outer perimeter 17 can be comprised of four sides 18 adjoining each other at 90 degree angles. The floor 16 can take various forms as of the type described in U.S. Pat. No. 4,669,231. For example the floor 16 can be in the form of a poured-in-place concrete slab or alternatively can be in the form of a floor elevated above the ground and supported by a foundation.

[0026] The building construction 11 is of a modular type and consists of a plurality of finished wall components 21 which can be rectangular as shown and which are provided with appropriate openings therein for doors, windows, and the like. As shown, each of the wall components 21 has an upper extremity 22, a lower extremity 23 and side extremities 24 and 26. By way of example assuming that the floor 16 is 7 meters by 7 meters square, the upper and lower extremities 22 and 23 would be 7 meters in width and the side extremities 24 and 26 can be 2.5 meters in height.

[0027] The building construction 11 also consists of a plurality of finished roof components 31 which are in the form of truncated triangles to provide a centrally disposed square opening 32 which will is formed when the building construction 11 is erected. Each of the roof components has an upper extremity 33 and a lower extremity 34. Assuming the same 7 meter square dimensions for the floor, the lower extremity of the roof component would have a width of 7 meters and the upper extremity 33 would have an appropriate width depending upon the size of the opening 32 as for example 1 meter. The roof components are also provided with inclined side extremities 36 and 37 which are inclined at an appropriate angle as for example an angle of at least 47 degrees.

[0028] These wall components 21 and roof components 31 can be manufactured off site and then loaded flat on trucks or in containers and shipped to the site for erection on the site.

[0029] Mating hinge constructions 41 of a conventional type are provided for securing the lower extremities 23 of the wall components 21 to the outer perimeter 17 of the floor 16 and similarly mating hinge constructions 42 are provided for connecting the upper extremities 22 of the wall components 21 to the lower extremities 34 of the roof components 31. If desired, one portion of a mating hinge construction 41 can be provided on the lower extremities 23 upon manufacture of the wall components with the other mating portion being shipped with the wall component for use in making a connection to the outer perimeter 17 of the floor 16 during fabrication of the floor 16 as for example in the pouring of a slab. Similarly, the portions of the mating hinge constructions 42 can be provided with one portion being provided on the upper extremity 22 of the wall component and the other portion being placed on the lower extremity 34 of the roof component 31. If desired, the hinge constructions 42 can be completed in the off-site manufacture and with the roof portion being folded over the corresponding wall component 21 and shipped in that manner to the building site.

[0030] With the wall components 21 and the roof components 31 being manufactured in this manner and transported to the building site, lower extremities 23 of the wall components 21 hingedly connect the lower extremities 23 of the wall components 21 to the outer perimeter 17 of the floor 16. As shown in FIG. 4, the four wall components 21 are connected to the four sides 18 of the floor at ground level and are laid flat so they lie in the plane generally parallel to the plane of the floor 16. If the roof components 31 are not connected to the wall components 31, the lower extremities 34 of the roof components 31 are hingedly connected to the upper extremities 22 of the wall components 21 by the mating hinge construction 42. If not already in place, the roof components 31 are folded over so they lie on the wall components 21 and also lie generally lie in parallel planes parallel to the plane of the floor 16 at ground level.

[0031] In order to proceed with the erection of the wall components 21 and the roof components 31, a suitable lifting device 51 is provided which is moved over and onto the floor 16 and positioned on the floor 16 so that it is generally centrally disposed with respect to the outer perimeter 17 of the floor 16. By way of example the lifting device 51 can be of the type as shown in FIG. 3. As shown therein, the lifting device 51 includes a platform 52 which is adapted to rest upon the floor 16. A cylindrical sleeve 53 is secured to the platform 52. A vertical support pedestal 54 is removably placed in the cylindrical sleeve 53 secured to the platform 52. The pedestal 54 has a height which generally corresponds to the height of the apex of the roof to be provided in the building construction 11. The support pedestal 54 can be in the form of a large diameter pipe as for example 18 to 24 inches in diameter with a suitable height as for example 5 meters. The support pedestal 54 is preferably formed of a metal such as steel or aluminum with aluminum being preferable because of its light weight.

[0032] A telescoping hydraulic assembly 56 is mounted within the support pedestal 54 and is provided with a plurality of telescoping hydraulic cylinders 57, 58, 59 and 61 (see FIG. 5). The hydraulic cylinder 61 is pivotably coupled to an upstanding plate 62 secured to the pad 52 by a pin 63. The hydraulic cylinder 57 is pivotably connected to a plate 66 by a pin 67. The plate 66 is secured to a platform 68 extending transversely of the support pedestal 54 and is secured to vertical guides 69 slidably mounted within the support pedestal 54 for movement vertically of the interior wall 71 of the support pedestal 54. An upper mounting assembly 73 is removably positioned on top of the support pedestal 54. Flexible elongate elements in the form of anchoring cables 77 are secured to eyelets 78 provided on the mounting cap 76 and have their outer ends secured to the sides 18 of the outer perimeter 17 of the floor 16. Thus, there are provided four anchoring cables 77 spaced 90 degrees apart for anchoring the support pedestal 54 and maintaining it in a substantially vertical position during lifting operations. Turnbuckles 84 are provided on each of the anchoring cables 77 to facilitate retaining the anchoring cables 77 in taut conditions.

[0033] A pulley mechanism 86 is provided which includes a plurality of flexible elongate elements in the form of pulling cables 87 for making connections between the hydraulic telescoping assembly 56 and the roof and wall components 21 and 31 for erecting the same. One end of each of the pulling cables 87 is anchored to the movable platform 68 within the support pedestal 54 by extending it through a hole 88 in the platform 68 and being secured thereto by an anchor 89 secured to the pulling cable. The pulling cable 87 extends downwardly from the platform 68 and passes under a pulley 90 secured by a support bracket 91 to the pad or platform 52. The cable 87 then passes upwardly through another hole 92 provided in the platform 68 and upwardly through the support pedestal and passes through a hole 93 in the mounting cap 76 and over a pulley 94 carried by a bracket 96 mounted on the mounting cap 76. The pulling cable 87 then extends downwardly and outwardly through an eyelet 97 mounted on the upper extremity 33 of the roof component 31 and may be secured thereto. Alternatively, and also as shown in FIG. 1, to accommodate windy conditions during erection the pulling cable 87 can extend beyond the roof component 31 to the lower extremity thereof and then passed over the upper extremity 22 of the wall component 21 and passed under the wall component 21 and secured to the lower extremity 23 of the wall component 21 by suitable means such as an eyelet 101.

[0034] The pulley mechanism 86 includes one of such pulling cables 87 for each of the unitary hingedly interconnected roof component 31 and wall component 21 provided on each side of the four sides of the floor 16. The pulling cables 87 are centrally located on each side. It should be appreciated that if desired two pulling cables 87 can be provided and spaced apart appropriately so that the pulling forces exerted by the cables are substantially uniformly distributed over each unitary roof and wall component 31 and 21. Thus there can be provided eight of such pulling cables 87 rather than four which are coupled to the platform 68.

[0035] During windy conditions during erection of the wall and roof components 21 and 31 in addition to passing the cables 87 over the roof components 31 and the wall components 21, it may be desirable to provide removable snap rings 106 around at least one of the pulling cables 87 on each side and encircling the adjacent anchoring cable 77 to inhibit the wind from lifting up the roof component 31 during the time that the unitary roof components and the wall components 21 are being erected.

[0036] A conventional hydraulic power unit 111 is provided for controlling the actuation of the telescoping hydraulic assembly 56 and forms a part of the lifting device 51. This hydraulic power unit is movable as a part of the lifting device 51 and can include means for operating the hydraulic power unit so that the erection can be made with appropriate controls. Depending upon the application, the hydraulic power unit can be operated with electrical power from electricity provided at the site or by use of an on-site electrical power generator. If desired the power unit 111 can be operated by use of a remote control.

[0037] Operation and use of the lifting device 51 for the building construction shown in FIG. 1 assuming that the wall components 21 and roof components 31 have been unitarily mounted in the manner hereinbefore described at ground level and in which the lifting device 51 is in place and the anchoring cables 77 and the pulling cables are in place as hereinbefore described, erection can be accomplished.

[0038] As soon as everything is ready for erection, the hydraulic power unit 111 can be operated to supply hydraulic fluid to the telescoping hydraulic assembly 56 to cause extension of the telescoping hydraulic assembly 56 to progressively raise the platform 68 within the support pedestal 54 and thereby cause pulling inwardly of the pulling cables 87 toward the anchored support pedestal 54 to begin raising of the upper extremities 33 of the roof components 31 in unison. As the upward and inward movement of the roof components 31 continue, the roof components 31 pull with them in unison the wall components 21 hingedly connected thereto to cause the roof components and the wall components to be erected in unison as shown in FIG. 4. During this raising it can be seen that the outer surfaces of the roof components 31 and the wall components 21 are braced by the pulling cables 87 to brace against wind loads encountered by the roof components 31 and the wall components 21 during the raising procedure. In addition, the rings 106 serve to limit movement of the roof components during the erection because of the engagement of the rings 106 with the anchoring cables 77.

[0039] Releasable automatic locking devices 116 are provided for fastening together adjacent side extremities 24 and 26 of the wall components 21. This device 116 consists of an h-shaped metal piece 117 which is secured to the side extremity 24. The piece 117 includes a back portion 118 which extends in a direction generally parallel to the wall 21 and is provided with a large hole 119 therein. A side extending plate 121 extends perpendicularly from the back portion 118 and carries a pin 122 which is in general alignment with the hole 119. A u-shaped piece 126 is mounted on the side extremity 26 of the adjacent wall component 21 and has mounted thereon an eyelet 127 which is adapted to extend through the hole 119 and to come into engagement with the pin 122 to securely fasten the extremities 24 and 26 to each other. The pin 122 can be provided with an end surface which is inclined so that the eyelet 127 is cammed over the pin 122 before it drops into place.

[0040] A similar releasable automatic locking device 131 is provided for the roof components 31 and as shown in FIG. 7 consists of a u-shaped plate 132 which is mounted on the side extremity 37 of a roof component 31. This u-shaped plate 132 has mounted thereon a v-shaped metal bracket 133. One leg 134 of the v-shaped bracket is provided with a large hole 136 therein. A plate 137 is mounted on the leg 134 adjacent the hole 136 and extends at right angles to the leg 134. A pin 138 is mounted on the plate 137 and is accessible through the hole 136. The device 131 also includes a u-shaped piece 141 mounted on the side extremity 36 of the roof component 31. An eyelet 142 is mounted on the piece 141 and is of a size so it is adapted to pass through the hole 136 and move into registration with the pin 138 and enter the eyelet 142 to firmly but releasably secure the extremities 36 and 37 of the roof components 31. The pin 138 can have an end surface which is inclined so that the eyelet can be cammed over the pin 38 to drop into place.

[0041] Thus, as the wall components 21 and the roof components 31 are being raised to almost their final positions with the wall components 21 being substantially vertical, the releasable automatic locking mechanism 116 provided on the wall components 21 and the releasable automatic locking devices 131 provided on the roof components 31 will come into engagement by the eyelets 127 and 142 snapping over the respective pins 122 and 138 by being cammed over the top inclined surfaces of the pins 122 and 138 and then snapping into place over the pins 122 and 138 and locking the wall components 21 and the roof components 31 together to provide a building construction in which there are provided four side walls formed by the four wall components 21 and a roof formed by the four roof components 31 are locked together to enclose an internal volume overlying the floor 16.

[0042] After the roof and wall components are locked into place, the lifting device 51 can be removed by unfastening the pulling cables 87 from the roof components 31 and from the wall components 21. The anchoring cables 77 can be detached from the floor 16. Thereafter, the entire lifting device 51 with the hydraulic power unit 111 and the cables 87 and 77 can be removed by passing through a door 151 (see FIG. 8) of the completed building construction 11. Thereafter, the enclosed space may be fitted to provide a single family home in the interior as in the manner described in U.S. Pat. No. 4,669,231. A skylight 152 is provided to close the opening 32. With appropriate planning, it is possible to erect the building construction 11 in as short a time as one day. The improvements provided within the building construction 11 can thereafter be completed in accordance with the desires of the user.

[0043] From the foregoing it can be seen that the building construction has been accomplished with a minimum number of components in which two different components forming a unitary assembly, i.e., the wall components 21 and the roof components 31, are preassembled on the four sides to be raised in unison for a total of eight components being utilized. These eight components can be packaged in a small space and transported from the manufacturing or off-site location to the building site. If necessary for transportation to a building site, each roof component can be divided into two pieces interconnected by hinges. The building construction can be readily assembled and disassembled by unskilled workers without the need for craft labor. After assembly on the ground, the building construction can be automatically erected by lifting the ground-assembled components in unison and having the components automatically lock in place upon arriving at final positions. Cranes and scaffolding are not needed for the erection of the building construction. By utilizing a standardized lifting device, it is possible to re-use the lifting device and to move it from one location to another. The building construction herein described which is based upon a square floor plan makes it possible to provide a building construction without load bearing columns which provides a great deal of flexibility in dividing the interior layout. With such a square layout, building constructions of various sizes can be readily obtained by locating building constructions adjacent to each other. They also can be assembled in clusters of different shapes to house institutional needs such as classrooms for schools, hospitals, rural clinics, offices, etc. They also can be utilized to provide temporary shelters as well as warehousing and offices in remote areas. By stockpiling these components it is possible to meet the needs of natural disasters to provide almost immediate emergency housing where such housing has been destroyed.

Claims

1. A method for erecting a modular building on the ground of a building site with the use of a lifting device having a support pedestal and having a mechanism therein for causing relative movement relative to the support pedestal comprising the steps of providing a generally horizontal floor lying in a plane supported by the ground at the building site and having an outer perimeter, providing a plurality of wall components having upper and lower extremities and having first and second side extremities and a plurality of roof components having upper and lower extremities and having first and second side extremities, hingedly securing the lower extremities of the wall components to the perimeter of the floor with the wall components being disposed in planes generally parallel to the plane of the generally horizontal floor, hingedly securing the lower extremities of the roof components to the upper extremities of the wall components and positioning the roof components so that they overlie in parallel planes the wall components, positioning a lifting device so that it is supported by the floor and is disposed within the perimeter of the floor, erecting a support pedestal over the floor so that it is disposed substantially vertically, anchoring the upper extremity of the support pedestal with respect to the floor, providing pulling cables secured to the extremities of the roof components and extending to the upper extremity of the support pedestal, providing a mechanism coupled to the support pedestal and to the pulling cables and causing the cables to be pulled to cause raising of the roof components and in unison therewith the wall components until the wall components are substantially vertical and fastening together the wall components when they are in a vertical position and fastening together the roof components to enclose an internal volume overlying the floor, detaching the anchoring cables and the pulling cables and removing the lifting device from the enclosed volume.

2. A method as in claim 1 wherein the fastening together of the wall components and the roof components is accomplished automatically at the end of the raising of the wall components and the roof components into their final positions.

3. A method as in claim 1 further including the step of securing the roof components to the anchoring cables to limit movement of the roof components during windy conditions encountered during erection of the roof and wall components.

4. A method as in claim 1 further including the step of securing pulling cables so that they extend from the upper extremities of the roof components over the outer surfaces of the roof components and the wall components secured to the floor to aid in controlling the movement of the wall components and roof components during erection of the wall components and the roof components during windy conditions.

5. A method as in claim 1 further including the step of providing two pulling cables for each area unitary wall component and roof component assembly.

6. A method for erecting a modular building on the ground of a building site and comprised of a plurality of wall components and roof components by the use of a lifting device having a support pedestal and having a mechanism therein for causing relative movement relative to the support pedestal comprising, assembling the wall and roof components at ground level for the sides of the modular building, raising the roof and wall components from the ground level by the use of the lifting device until the wall and roof components are in their final positions and permanently securing the wall and roof components in their final positions to enclose a space between the erected wall and roof components.

7. A method as in claim 6 wherein the step of permanently securing the wall and roof components in their final positions is accomplished by automatically locking the wall and roof components in their final positions as the roof and wall components are being moved into their final positions.

8. A modular building construction for erection on the ground of a building site comprising a floor lying in a plane supported by the ground and having an outer perimeter, a plurality of wall components having upper and lower extremities, a construction hinge connecting the lower extremity of the wall component to the floor at the outer perimeter of the floor, the wall components lying in a plane parallel to the plane of the floor, a plurality of roof components having upper and lower extremities and overlying the wall components and lying in planes parallel to the wall components, a hinge construction securing the lower extremities of the roof components to the upper extremities of the wall components to provide unitary wall and roof components which are hinged together.

9. A modular building construction as in claim 8 wherein said wall and roof components are erected with the wall components being substantially vertical and the roof components being inclined at an angle with respect to the wall components and enclosing an internal volume overlying the floor.

10. A modular building construction as in claim 9 including latching mechanisms for fastening the wall components to each other and for fastening the roof components to each other.

11. A modular building construction as in claim 10 wherein said latching mechanisms are formed so that they are releasable to permit disassembly of the modular building construction after it has been erected.

12. A modular building construction as in claim 10 wherein said latching mechanisms are formed so that they are automatically engaged during erection of the wall components and roof components.

13. A lifting device for use in erecting a building construction in which the building construction is comprised of a plurality of wall components and roof components which are hingedly interconnected and a floor with the wall components being hingedly connected to the floor and the roof components being hingedly connected to the wall components comprising a support pedestal adapted to be mounted on the floor and positioned vertically of the floor, means carried by the pedestal for maintaining the support pedestal in a vertical position on the floor, pulling cables carried by the upper extremity of the support pedestal and being adapted to be secured to the extremities of the roof components and a mechanism coupled to the support pedestal for supplying pulling forces to the pulling cables.

14. A device as in claim 13 wherein said mechanism includes a plurality of pulleys engaging the cables and a mechanical assembly disposed within the support pedestal for engaging and pulling on the cables.

15. A device as in claim 14 wherein said mechanical assembly is comprised of a telescoping hydraulic assembly.