US3435583A

US3435583A - Method of forming buildings

Info

Publication number: US3435583A
Application number: US541680A
Authority: US
Inventors: Victor Ben-Aziz
Original assignee: NATIONAL COORDINATORS Inc
Current assignee: NATIONAL COORDINATORS Inc
Priority date: 1966-04-11
Filing date: 1966-04-11
Publication date: 1969-04-01
Anticipated expiration: 1986-04-01

Description

April 1, 1969 v. BEN-AZIZ 3, 3

' METHOD OF FORMING BUILDINGS Filed April 11, 1966 She st of 2 FIGJ . INVENTOR. o 43 44 v/croe BE/v-Az/z v Arr-021x45) April 1,1969 v. BE -Az|z I 3,435,583

METHOD OF FORMING BUILDINGS Filed Aprii 11, 1966 v Sheet 3 of2 FIGZJ FIG.7

I NVENTOR.

11/0702 Bew-Az/z United States Patent US. Cl. 52-745 2 Claims ABSTRACT OF THE DISCLOSURE The specification of this application teaches a method of forming buildings in which a core structure is erected such that steel members incorporated in the structure are exposed at its exterior surface. Cranes or other lifting means are provided on that core structure for lifting heavy loads. Structures which will become floors of the building are assembled at the base of the core structure such that they encompass the core and are made of steel in regions adjacent the core. The floor structures are then lifted into place and afiixed temporarily to the core structure. Each floor is adjusted so that that portion of the floor which is adjacent the core structure is level. The floor is then secured, employing a metal to metal connection, to the core structure. Columns are erected at the margins of the floors and each floor is adjusted so that it is level in the regions of its outer periphery and is then fixed to the columns. An exterior wall structure is erected by attaching wall and window panels to the several floors. The several fioors are completed by applying layers of sheet steel and concrete to them.

The number of building units may be multiplied by creating separate core structures and floors for each building unit and by interconnecting the floors of the several units.

The present invention relates generally to methods of forming buildings, and more particularly to mass production procedures for constructing buildings in a quick and eflicient manner.

The art of constructing homes and other types of buildings, including industrial and oifice buildings, is extremely old, since shelter was one of the first items that man provided for himself. The methods employed in constructing buildings have not changed as markedly as have other technological industries. For instance, buildings have generally been built floor by floor commencing at the ground level. Such procedure begins with the foundation and each succeeding floor is successively placed thereon.

Additionally, the methods employed in fastening different structural members together have not changed appreciably over the years, thus necessitating considerable manual labor in the formation of a building structure.

It has been deemed desirable for a number of years to change the method of constructing buildings so as to erect it at a much faster rate and thereby cause it to be less expensive though as efiicient as present day buildings. Also, it has been deemed desirable to provide, in such method of construction, considerable flexibility such that the building contractor can construct virtually any size or shape building desired.

In view of the foregoing, it is an object of the present invention to teach a method of constructing buildings and the like whereby the same may be produced at a fast rate according to mass production methods.

Another object of the present invention is to teach a method of constructing buildings and the like as characterized above wherein a central core structure is initially provided and from which substantially all of the floors are raised into proper location.

Patented Apr. 1, 1969 ICC Another object of the present invention is to teach a method of forming buildings and the like as characterized above wherein the core structure is slip-formed of con crete and is provided with vertical steel columns to which the various steel floors are rigidly affixed in proper position.

A still further object of the present invention is to teach a method of forming buildings and the like as characterized above which includes arranging a plurality of such core structure in predetermined spaced relation and constructing the floors about each of them so that several building modules are thereby arranged in predetermined relation to be connected together to form a single composite building.

A further object of the present invention is to teach a method of forming buildings and the like as characterized above which is simple and inexpensive to practice and which provides a rugged and dependable building, with a high degree of resistance to lateral loads during and after construction. This and other objects and advantages of the invention are realized in part by erecting a core structure, providing means on the core structure for lifting heavy loads, assembling floors for said building on the ground and lifting said floors to the desired elevation and then firmly attaching the floors to said core at the desired individual elevation.

The novel features which I consider characteristic of my invention are set forth with particularly in the appended claims. The invention itself, however, both as to its organization and mode of operation, together with additional objects and advantages thereof, will best be understood from the following description of specific embodiments when read in connection with the accompanying drawings, in which:

FIGURE 1 is a fragmentary top plan view of a building under construction according to the present invention, showing several alternative methods for raising the floor structures into place;

FIGURE 2 is a side elevational view showing the method steps of FIGURE 1;

FIGURE 3 is a fragmentary side elevational view of a building according to the present method of construction;

FIGURE 4 is a fragmentary horizontal sectional view, taken substantially along line 44 of FIGURE 2 of the drawings;

FIGURE 5 is a sectional view, taken substantially along line 55 of FIGURE 4;

FIGURE 6 is an enlarged fragmentary view of a portion of FIGURE 1;

FIGURE 7 is a sectional view taken substantially along line 77 of FIGURE 6;

FIGURE 8 is an enlarged fragmentary view of another portion of FIGURE 1; and

FIGURE 9 is a sectional view, taken substantially along line 99 of FIGURE 8.

Like reference characters indicate corresponding parts throughout the several views of the drawings.

Referring to FIGURES l and 2 of the drawings, there is shown therein many of the steps of the basic method of forming a building according to the present invention.

Initially, a core structure '20 is provided, formed of both concrete 22 and steel 24. Such method may employ virtually any manner for constructing the core structure 20, and such core structure may be formed of virtually any desired materials. For instance, it has been found that such core structure may be formed of concrete by slip-forming. Additionally, there may be provided one steel box column 26 at each of the four corners of the core structure.

As will be readily apparent to those persons skilled in the art, the core structure 20 may be formed in virtually any desired shape. For instance, it is contemplated that such core structure might constitute the housing for one or more elevator shafts of the finished building, and it may include suitable storage areas or lavatories and the like.

In any event, the core structure 20 is ultimately provided to the desired height, above the intended top most level of the proposed building.

Thereafter, suitable footings as shown at 28 are provided in the ground to support various vertical columns to be hereinafter erected. Such footings may be formed immediately following the construction of the core structure or they may be provided at any time prior to the erection of such columns thereon, as will be readily apparent to those persons skilled in the art.

As shown in FIGURE 2 of the drawings, the next step in the method of forming a building according to the present invention, may vary according to the desires of the particular contractor. For instance, as shown in the left-hand portion of FIGURE 2 of the drawings, a plurality of steel floor structures 30 may be formed about the core structure 20 in proper horizontal placement with respect thereto. It is contemplated that such floor structures 30 may be partially or wholly fabricated in a steel shop removed from the building site or they may be fabricated beneath and about the core structure 20 as shown.

In the alternative, it is contemplated that a platform 32 (right-hand portion of FIGURE 2) having vertical support members 34 may be provided whereon the floor structures 30 are formed. Such platform 32 is, of course, elevated from ground level and completely surrounds the core structure 20 to enable workmen to effect the proper fabrication of the floor structures or portions ther of as the case may be.

As shown in FIGURE 1 of the drawings, each floor structure 30 is formed with suitable exterior longitudinal and transverse

structural member

36, 38, 40, and 42 which are Welded together in a rectangular shape. Suitable interior longitudinal

structural members

44 and 46 are provided at one end of the floor structure, and corresponding structural members 48 and 50 at the other end. Suitable interior transverse structural members 52, 54, 56 and 58 are also provided as well as partial

transverse members

60, 62, 64, 66, 68, 70, 72 and 74. A connecting member 76 ties all of the partial

transverse members

60, 62, 64 and 66 together, while a corresponding member 78 ties together the members 68, 70, 72 and 74.

Suitable corner plates

80, 82, 84 and 86 are used to connect the various corner structural members together as shown most clearly in FIGURE 1 of the drawings.

It is contemplated that the floor structure 30 may be formed of any appropriate structural members such as I-beams, H-beams and the like. However, it has been found most appropriate to employ steel beams having I-sections to afford the necessary compression, bending, tensile and shear strengths.

All of such members are preferably welded together according to the best known present day practices to provide a unitary structure. It is, however, contemplated that the present invention is not limited to the use of steel members and that in the event other materials were to be used, the appropriate bonding or connecting means for such material would be used.

As also shown in FIGURE 1 of the drawings, the lefthand portion thereof shows a winch 88 having a rotatable pulley 90 associated therewith. A line or cable 92 cooperates with such pulley 90 and with an idler pulley 94 suspended beyond the side of core structure 20 by means of a steel frame 96. Such cable is bifurcated as at 98 to provide a pair of a cable portions 100 and 102 which are attached to opposite sides of a floor structure 30.

An alternative method is shown in the right-hand portion of FIGURE 1, and comprises a winch 104 having a rotatable pulley 106 and a pair of idler pulleys 108 4 and 110 suspended from the core structure by

members

112 and 114. Suitable cable 116 is provided for cooperation with both of the pulleys 108 and 110 as shown in the drawings.

It is contemplated that the winch 104 may be positioned on the core structure in a manner similar to the placement of winch 88 as above explained, or winch 104 may be positioned at ground level adjacent the core structure as shown most clearly in FIGURE 2. Thus, the action of winch 104 can be to lift the various floor structures as will hereinafter be described, irrespective of its position on the core structure or ground.

The winches 88 and 104, as well as the components associated therewith, are merely for purposes of illustration, it being realized that various forms and styles of pulling or hauling devices may be employed within the context of the present invention. In fact, it is contemplated within the present invention that external hoist means such as a separate derrick or the like may be employed.

The various prefabricated floor structures 30 are then hoisted into proper elevation as shown most clearly in FIGURE 2. The above described winches 88 and 104 or any combination thereof, may be used to accomplish this. The upper-most floor structure is hoisted first.

As shown most clearly in FIGURE 4 of the drawings, the columns 26 may be formed in a box-section and may be connected to the reinforcing steel 23 embedded in the concrete core structure. Such reinforcing steel may be welded to the columns 26, and the columns themselves may be formed by steel plate welded together in the desired configuration. As shown most clearly in FIGURE 5 of the drawings, the individual floor structures 30 may be initially and temporarily positioned adjacent the core structure by any appropriate means such as support bar 118 and adjusting wedges or shims 120. As shown, the support bar 118 fits within a suitable opening formed in column 26 to rest against the undersurface of a horizontal plate 26a. The wedges or shims 120 are then placed on bar 118 to support the adjacent corner of the floor structure 30. The height of the floor can then be adjusted by sliding the shims or wedges 120 toward or away from each other.

After all four corners of the floor structure have been suitably temporarily supported, as shown in FIGURE 5 of the drawings, permanent fastening means may be provided. A plate 122 welded to the side of column 26 may be bolted, riveted or welded to the floor structure 30 as shown in FIGURE 5. Also, an upper plate 124 and a lower plate 126 may be welded in position between the floor structure and the box column 26 as also shown therein. Whereas the upper plate 124 is smaller in width than the adjacent flange of the I-beam of the floor structure, the lower plate 126 should be larger than its adjacent flange to permit of welding from the top.

After the various interior corners of the floor structures 30 have been permanently anchored in place as shown, the temporary support means can be removed. In fact, as will be readily apparent, such temporary support means should be removed after

plates

122 and 124 are in place to provide access to the space required for plate 126. Such temporary support means is removed merely by separating the wedges or shims 120 so as to free the support bar 118.

Thereafter, succeeding lower floors of the building can be anchored to the core structure in like manner. Thus, there is provided a series of floor structures arranged along the core structure.

The perimeters on outer marginal edges of the various floor structures are then connected to suitable support columns. Such columns are shown at 128 and may take any desired form such as I-beams or H-beams as is well understood in the art. Such vertical columns are suitably anchored on and to the appropriate footings 28 as shown in FIGURE 2 of the drawings.

With the columns 128 in proper position, the individual floor structures 30 are leveled by means of the winches 88 and 104 or any other appropriate hoist means. With the perimeter of each floor at the proper elevation, the

Y floor structures are then welded firmly to the support columns 128. The particular manner employed in tying the floors to the support columns may vary, but several of such methods are shown in FIGURES 6-9, inclusive.

FIGURE 6 is an enlarged fragmentary Niew of the connection between one of the support columns 128 and the longitudinal exterior structural member 36 of one of the floor structures. The transverse structural member 60 may have its end portion formed such as to fit within the side of I-beam 36. While in such position, the two structural members are firmly welded together along all mating surfaces and edges. Then, the longitudinal structural member 36 is firmly welded to the vertical column 128 as shown in FIGURES 6 and 7. This then provides a strong firm connection between all of the members, as well as the vertical column 128. A supporting gusset or flange member 130 may be employed beneath the horizontal member 36 as shown most clearly in FIGURE 7.

The connection between a side vertical column 128 and a transverse side member such as

members

38 and 42, is shown most clearly in FIGURES 8 and 9' of the drawings. Here, it may be desirable to extend the longitudinal member beyond the transverse member with the transverse member terminating in the side contour of the longitudinal member. That is, the transverse member 42 is formed in predetermined lengths or sections, each of which has its opposite end portions contoured to fit the side of the I-beam of the various longitudinal support members. Such sections are then welded at the positions shown most clearly in FIGURES 8 and 9.

With the perimeter of the particular floor structure 30 raised to the proper elevation, the end of the longitudinal support member 44 is welded to the adjacent Vertical column 128. As shown in FIGURE 9 of the drawings, side plate 130 is provided on one side of the web of the longitudinal support member 44, such plate being welded to both the vertical column and the longitudinal support member.

Thereafter, steel deck 132 is welded to the upper flanges of the various floor structures 30' and lightweight concrete to the desired depth is poured thereon as shown at 134. In this way, strong firm floors are provided for the building.

It is also contemplated within this invention that the floors of the building might be completed, including partition walls and other components, before they are lifted into place. In fact, any desired degree of completion can be made to the floors before being raised, limited only by the size and strength of the winches or other hoist means.

It may be found desirable as shown most clearly in FIGURE 3 of the drawings to tie together the upper ends of the various vertical support columns 128. In FIGURE 3 one such horizontal tie member is shown at 136.

As also shown in FIGURE 3 of the drawings, suitable curtain wall structure can thereafter be attached to the edges of the floors to provide the exterior facade for the building. Such curtain wall structure includes suitable mullions and sills, as well as wall and window panels to provide a lightweight but weather resistant exterior for 6 the building. The building shown in FIGURE 3 of the drawings further includes a penthouse on the upper most floor of the building. Also, additional side structures as shown at and 142 may be provided after the main part of the building has been erected.

It is contemplated that the aforedescribed method of constructing a single building structure may be employed to build a structure comprising many such individual units. That is, it is contemplated that several building modules may be provided each having its own core structure and its own floor structure thereabout. The adjacent floor structures are then connected together as by welding, riveting, bolting or the like to provide a long complex of buildings arranged in a contiguous manner.

It is thus seen that the present invention teaches a method of forming a building structure which is capable of providing a firm sturdy structure in a quick and efficient manner.

Although I have shown and described certain specific embodiments of my invention, I am fully aware that many modifications thereof are possible. My invention, therefore, is not to be restricted except insofar as is necessitated by the prior art and by the spirit of the appended claims.

Iclaim:

1. The method of forming a building comprising the steps of, erecting a hollow core structure having steel vertical columns accessible at the exterior thereof, providing means on said core structure for lifting heavy loads, assembling floors for said building on the ground about said core structure having steel portions accessible at the interior margins of said floors adjacent said core structure, lifting said floors by said means to the desired elevation, temporarily fixing said floors to said core structure, leveling said floor in regions adjacent said core structure by use of wedges, thereafter permanently fixing said floors to said columns by welding said steel interior margins of said floors to said steel vertical columns of said core structure, providing vertical columns about the perimeter of said building, leveling said floors about said perimeter and attaching same to said perimeter columns, and securing exterior wall structure for said building to said floors about the perimeter of said building.

2. The method of forming a building according to claim 1, including the further step of pouring concrete on each of said floors to provide the desired strength and rigidity thereof.

References Cited UNITED STATES PATENTS 3,199,259 8/1965 Long 52745 2,675,895 4/1954 Loewenstein 52236 2,871,544 2/1959 Youtz 52745 2,964,143 12/ 1960 Fayeton 52745 3,038,568 6/1962 Morgan 52236 3,058,264 10/1962 Varlonga 52236 3,156,071 11/1964 Van Bijlevelt 52745 3,251,167 2/1966 Curran 52688 3,254,466 6/1966 Von Heidenstam 52745 3,260,028 7/1966 Fraser 52745 3,295,288 1/1967 Bakke et al. 52741 3,302,363 2/1967 Frey 52745 FRANCIS K. ZUGEL, Primary Examiner.