Building assembly system and method
A building frame (100) is designed as multiple assemblages (104), (200) and (300), which are built and then collapsed for shipment in one or more shipping containers (400), transported to a building site, and removed from the corresponding shipping containers (400). the assemblages (104), (200) and (300) are constructed as a building frame (100) at the permanent building site, or, alternatively, are assembled into subassemblies at a temporary building site, and are transferred to the permanent building site.
The present invention relates to assemblage construction, shipment and building construction, and, more particularly, to a method and system for design, prefabrication, shipping and construction of a building.
BACKGROUNDPrior to the invention, factory precut buildings have been shipped in kit form with loose pieces, lumber precuts and precut panels of sheathing and flooring. The loose and precut pieces arrive at a building site ready for assembly, without requiring measuring and cutting. However, the loose pieces must be unpacked and sorted. Then the loose pieces are assembled and constructed in a standard manner pertaining to on-site building construction. Prior to the invention, factory assembled roof trusses were available for shipment. However, the trusses are individual pieces that lack assemblage with framing members for walls and floors. Thus, the roof trusses need to be constructed onto load bearing walls, which consumes time and labor costs in significantly large amounts.
SUMMARY OF THE INVENTIONThe invention is a method and system of prefabricated assemblages that are shipped to a building site for construction of a building.
The invention relates to a building frame wherein the function of design simplifies it to evolve from a configuration that is collapsible for shipment, and into an deployed configuration to provide a frame for a building.
A method according to the invention includes the steps of; designing a building frame to fit in one or more shipping containers, and collapsing the building frame to fit in the shipping containers. According to an embodiment of the invention, the invention includes the step of transferring the collapsed building frame from containers to a building site where the building frame is constructed to make a building.
There is considerable cost advantage obtained by the invention, by prefabricating the building frame initially as one or more assemblages in a geographical location where material and labor costs are low, and shipping corresponding building frame assemblages by sea container to a region of the world where buildings and their construction costs are expensive.
The invention fulfills a considerable need for one or more buildings constructed over water or uneven terrain, and constructed at resort regions experiencing hurricane force winds in the tropics, or heavy snowfall in mountainous elevations, and/or high seismic activity.
The invention further includes a method of constructing a building frame that has been collapsed for shipment in corresponding shipping containers, by removing the building frame from the corresponding shipping containers, and transferring the collapsed building frame to an un-collapsed configuration, and onto a building site to provide a frame for a building.
Embodiments of the invention will be described by way of example with reference to the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
This description of the exemplary embodiments is intended to be read in connection with the accompanying drawings, which are to be considered part of the entire written description. In the description, relative terms such as “lower,” “upper,” “horizontal,” “vertical,”, “above,” “below,” “up,” “down,” “top” and “bottom” as well as derivative thereof (e.g., “horizontally,” “downwardly,” “upwardly,” etc.) should be construed to refer to the orientation as then described or as shown in the drawing under discussion. These relative terms are for convenience of description and do not require that the apparatus be constructed or operated in a particular orientation. Terms concerning attachments, coupling and the like, such as “connected” and “interconnected,” refer to a relationship wherein structures are secured or attached to one another either directly or indirectly through intervening structures, as well as both movable or rigid attachments or relationships, unless expressly described otherwise.
With reference to
In one embodiment of the invention, the truss (108) extends from a central axis (120) to a first post (116). In an alternative construction the truss (108) extends from the central location, and between the first post (116) and a second post (118). Thus, different combinations of floor loads and square footage are constructed by different length combinations of the first story floor girder (106) and the first story floor truss (108). Further, configurations of different first story floor elevations are constructed by having an elevated truss (108), and further, by having an elevated truss (108) of different lengths.
Each first story frame assemblage (104) is of post and beam construction having the floor girder (106) supporting a vertical first post (116) and a vertical second post (118). The girders (106) and (114), and the posts (116) and (118), are beams, including, and not limited to; box beams, I-beams, H-beams, and beams of varying cross sectional shapes. The beams are constructed of materials, including, and not limited to; steel, aluminum, wood, plastics, and composites having fibers, strands and agglomerates. Exposed surfaces of the girders (106) and (114), and the posts (116) and (118) are prefinished, for example, with a veneer of laminated bamboo. The vertical posts (116) and (118) are to be supported by the girder (106) when the frame assemblage (104) is constructed at a temporary or permanent building site. The posts (116) and (118) are either prefabricated with the frame assemblage (104), or are precut members for installation with the frame assemblage (104) at the building site. According to an embodiment of the invention, the posts (116) and (118) are pivotally attached to the corresponding girders (106) and (108) to collapse or fold, vertically, for packaging in a shipping container. According to another embodiment of the invention, the posts (116) and (118) are loose piece subassemblies for packaging in a shipping container. According to another embodiment of the invention the posts (116) and (118) are prefabricated by being joined and secured to the respective girders (106) and (108) by industry standard, steel construction gussets or by welding. For example, gussets and the box beams connect by, first, aligning bolt receiving openings through the gussets and the box beams, and then inserting threaded bolts through the aligned bolt receiving openings.
Each of
With reference to
The vertical post (204) is to be supported by the girder (202) when the frame assemblage (200) is constructed at a temporary or permanent building site. The post (204) is either prefabricated with the frame assemblage (200), or is a precut member for installation with the frame assemblage (200) at the building site. According to an embodiment of the invention, the prefabricated post (204) is pivotally attached to the corresponding girder (202) to pivot in the direction of the arrow (204a), and to collapse or fold, vertically, for packaging in a shipping container. According to another embodiment of the invention, the post (204) is a loose piece subassembly for packaging in a shipping container. According to another embodiment of the invention the post (204) is prefabricated by being joined and secured to the respective girder (202) by industry standard, steel construction gussets or by welding.
With reference to
Each pair of respective frame assemblages (200) and (300) has corresponding steel hinge connections (124) at their inner ends at the axis (120) for connecting the respective frame assemblages (200) and (300) in hinged pairs.
It is preferred to have the frame assemblages (104), (200) and (300) arranged in containers (400) in the order in which they would be removed relative to respective containers (400) by a crane. The containers (400) are transported by sea, and then by land, involving transfer of containers (400) from a ship to a truck that delivers the containers (400) as close as possible to the building site, where a crane removes the frame assemblages (104), (200) and (300) vertically, or alternatively, laterally, with respect to their containers (400) in the reverse order in which the frame assemblages (104), (200) and (300) were packaged in the containers (400). The frame assemblages (104), (200) and (300) are removed from containers (400) in the order in which they are assembled on site, i.e., on the building site, which can be a temporary building site or a permanent building site.
A crane refers to any industrial lifting apparatus capable of lifting a structure of about 8 tons overhead, which includes, and is not limited to, an industrial ginpole and a block and tackle lifting device.
An embodiment of a foundation (500) for the building (102) is shown in
When the building site is a temporary building site, the subassembly (610) is hoisted or lifted by the crane and transferred to a permanent building site, where it is lowered by the crane, and is attached by workers to one or another embodiment of the foundations (500). Thereby, the subassembly (610) is erected or constructed at the permanent building site. The subassembly (610) is joined and secured by industry standard gussets or by welding. Following construction of the first subassembly (600) the construction process disclosed by
Although the construction process is described with reference to a temporary building site (700), either a temporary building site (700) or a permanent building site is within the scope of the invention. The construction process that is described herein as being performed at a temporary building site, may be performed at a permanent building site.
Thus, each hinged pair of first story frame assemblages (104) has a perimeter floor girder (600). The perimeter floor girder (600) is attached by a hinge connection (124) to a first story girder (106) for pivoting side by side with the hinged pair of first story frame assemblages (104). When constructed at a permanent or temporary building site the perimeter floor girder (600) is pivoted out to bridge between the corresponding pair of first story frame assemblages (104).
Further, each subassembly (610) that is made from a hinged pair of first story frame assemblages (104) has a perimeter floor girder (600a). The perimeter floor girder (600a) is attached by a hinge connection (124) to a first story girder (106) for pivoting side by side with the hinged pair of first story frame assemblages (104) for fitting in a compact space for shipment in a container (400). When constructed at a building site the perimeter floor girder (600a) is pivoted out to bridge from one pair of first story frame assemblages (104) to another pair.
Following construction of the first story frame assemblages (104) with a floor (608) at the permanent building site, a pair of second story frame assemblages (200) is installed by the crane (702) onto the constructed pair of first story frame assemblages (104). The crane (702) lifts or hoists the second story frame assemblages (200) and sets them on the first story frame assemblages (104). Workers then attach the second story frame assemblages (200) to the first story frame assemblages (104) and to the mast (208) by industry standard gussets or by welding.
According to an embodiment of the invention, the second story frame assemblages (104) and (200) and (300) are removed by the crane (702) from a corresponding shipping container (400), and are constructed at a temporary building site (700). Alternatively, one or more, or all of the first story frame assemblages (104) are constructed at the permanent building site (706) before constructing the second story frame assemblages (200) onto the first story frame assemblages. Alternatively, one or more, or all of the second story frame assemblages (200) are constructed at the permanent building site (706) before constructing the second story roof truss assemblages (300) onto the second story frame assemblages (200).
The second story assemblages (200) are removed from a container (400) and are unfolded, by being pivoted apart, for construction on a temporary or permanent building site. For example, at a permanent building site (706), each hinged pair of assemblages (200) are constructed on a previously constructed pair of first story frame assemblages (104). According to an embodiment of the invention, as disclosed by
Subsequently, the assemblages (300) are removed from a container (400) and are unfolded, by being pivoted apart, for construction on a temporary or permanent building site. For example, at a permanent building site)706), each hinged pair of assemblages (300) are constructed on a previously constructed pair of second story assemblages (200). Each rafter (304) and each purlin (302) are joined to the second story mast (208). The assemblages (300) are secured to the assemblages (200) and the mast (208) by industry standard gussets or by welding.
A method according to the invention includes the steps of; designing a building frame (100) to fit in one or more shipping containers (400), and collapsing the building frame (100) laterally (horizontally), or vertically, or both laterally and vertically, to fit in the shipping containers (400), and transferring the collapsed building frame (100) from containers (400) to a building site where the building frame (100) is constructed to make a building.
There is considerable cost advantage obtained by the invention, by prefabricating the building frame assemblages (104), (200) and (300) in a geographical location, including, but not limited to, Africa, China, Mexico and South America, where material and labor costs are low, and shipping the building frame assemblages (104), (200) and (300) by sea container to a region of the world where buildings and their construction costs are expensive.
The invention fulfills a considerable need for one or more buildings (102) constructed over water or uneven terrain, and constructed at resort regions experiencing hurricane force winds in the tropics, high seismic activity, or heavy snowfall in mountainous elevations.
The invention further includes a method of constructing a building frame (100) packaged for shipping container shipment, by removing the building frame (100) from the corresponding shipping container (400), and transferring the folded building frame (100) to an unfolded configuration, and onto a building site in an unfolded configuration.
As disclosed by
Further, the hollow box beam construction (800) is a rugged conduit for tensioning cables that become part of the building, and for guy ropes and cables that are temporarily used for hauling and lashing when assembling and constructing the structural elements. These point-to-point systems are installed inside the hollow structural elements of the frame (100), and thus, are protected during shipment and handling. It is important to have as many point-to-point systems installed, and as much decorative finish work installed and prefabricated, before shipment of the structural elements, to tailor the building frame assemblages (104), (200) and (300) for factory fabrication, instead of field fabrication, and to tailor the building frame assemblages (104), (200) and (300) for fabrication at a selected region where labor costs are low, when viewed on a world wide, country-by-country basis. Then the building frame assemblages (104), (200) and (300) can be shipped and constructed at a final building site (700) or (706), where fabrication of the assemblages is not as affordable and/or where the building site (706) is anything but dry, level land.
The building frame (100) is ready for assembly of walls and roofing. The walls and roofing do not require the point-to-point systems installed in them, prior to being sealed and/or covered with finishing materials. Thus, the walls and roofing are easily modular in form and construction to facilitate their installation on the frame (100).
The assemblages (104a) are collapsed or folded to a compact space. The order of collapse or order of folding is disclosed in the sequence of drawing figures,
A single crane pick removes the assemblages (104a) from a corresponding container (400) and lowers the assemblages (104a) to the permanent building site, as disclosed by
The invention provides a building frame wherein, the function of design simplifies it to evolve into an un-collapsed configuration, and onto a building site. The invention provides an assemblage, and to its construction, shipment and building construction, with particular emphasis on a method and system for its design, prefabrication, shipping and construction.
Although the invention has been described in terms of exemplary embodiments, it is not limited thereto. Rather, the appended claims should be construed broadly, to include other variants and embodiments of the invention, which may be made by those skilled in the art without departing from the scope and range of equivalents of the invention.
Claims
1. A method of designing a building, comprising the steps of:
- designing a building frame to fit in one or more corresponding shipping containers;
- constructing the building frame assemblage to fold laterally, or vertically, or both laterally and vertically to fit in the one or more corresponding shipping containers; and
- designing the building frame assemblage to remove vertically from the one or more corresponding shipping containers, and lower onto an construction site.
2. The method of claim 1, and further comprising the steps of:
- designing the building frame as having separate assemblages in a corresponding shipping container;
- removing the assemblages from the corresponding shipping container, and
- constructing the separate assemblages at a building site.
3. The method of claim 2, and further comprising the step of:
- arranging the separate assemblages in the corresponding shipping container according to the order in which the separate assemblages are removed from the corresponding shipping container.
4. The method of claim 3, and further comprising the steps of:
- removing the separate assemblages in said order from the corresponding shipping container;
- constructing the separate assemblages at a temporary building site; and
- transferring the separate assemblages to a permanent building site.
5. The method of claim 4, and further comprising the steps of:
- constructing a first story assemblage at the temporary building site; and
- transferring the first story assemblage to the permanent building site;
- constructing a second story assemblage at the temporary building site; and
- transferring the second story assemblage to the permanent building site.
6. A method of constructing a building frame assemblage packaged for shipment in a shipping container, comprising the steps of:
- vertically removing the building frame assemblage that has been folded either vertically or laterally or both vertically and laterally to fit in the shipping container; and
- lowering the building frame assemblage on a building site in an unfolded configuration.
7. The method of claim 6, and further comprising the steps of:
- building a floor on the building frame assemblage; and
- constructing the building frame assemblage and the floor at a permanent building site.
8. The method of claim 6, and further comprising the step of: securing the assemblage to the permanent building site.
9. The method of claim 6, and further comprising the steps of:
- building a floor on the building frame assemblage at a temporary building site;
- transferring the building frame assemblage and the floor to a permanent building site; and
- securing the building frame assemblage to the permanent building site.
10. A method for constructing a building frame assemblage, comprising the steps of:
- prefabricating the building frame assemblage in a geographical location where material and labor costs are low;
- shipping the building frame assemblage by container to a region of the world where buildings and their construction costs are expensive; and
- transferring the building frame assemblage to a building site.
11. The method of claim 10 wherein, the step of transferring the building frame assemblage further comprises the step of:
- removing the building frame assemblage from a shipping container by a crane.
12. The method of claim 10 wherein, the step of transferring the building frame assemblage further comprises the steps of:
- removing the building frame assemblage from a corresponding container by a crane; and
- setting the building frame assemblage on a temporary building site;
- and further comprising the steps of:
- assembling a floor on the building frame assemblage; and
- transferring the building frame assemblage and the floor from the temporary building site to a permanent building site.
13. The method of claim 10 wherein, the step of transferring the building frame assemblage further comprises the steps of:
- removing the building frame assemblage from a corresponding container by a crane; and
- lowering the building frame assemblage on a platform;
- and further comprising the steps of:
- assembling a floor on the building frame assemblage; and
- transferring the building frame assemblage and the floor from the platform to a permanent building site.
14. The method of claim 10 wherein, the step of transferring the building frame assemblage further comprises the steps of:
- removing the building frame assemblage from a corresponding container by a crane; and
- lowering the building frame assemblage on a permanent building site;
- and further comprising the step of:
- assembling a floor on the building frame assemblage.
15. A building frame comprising:
- at least first story frame assemblages; and
- the assemblages being collapsible to fit in a corresponding shipping container; and
- the assemblages being arranged according to the order in which they are removed from the corresponding shipping container and used in the construction of a building.
16. The building frame as recited in claim 15, and further comprising:
- the assemblages being collapsible laterally.
17. The building frame as recited in claim 15, and further comprising:
- the first story assemblages being cantilever supported at the permanent building site.
18. The building frame as recited in claim 15, and further comprising:
- second story frame assemblages for building on the first story assemblages; and
- the second story frame assemblages being collapsible to fit in a corresponding shipping container.
19. The building frame as recited in claim 15, and further comprising:
- second story frame assemblages for building on the first story assemblages; and
- roof truss assemblages for building on the second story assemblages;
- the second story frame assemblages being collapsible to fit in a corresponding shipping container, and the roof truss assemblages being collapsible to fit in a corresponding shipping container.
20. The building frame as recited in claim 19, and further comprising:
- the assemblages being collapsible laterally.
Type: Application
Filed: Oct 29, 2003
Publication Date: Jul 20, 2006
Inventor: Brian Foucher (Harrisville, NH)
Application Number: 10/696,004
International Classification: E04B 1/00 (20060101);