Method of erecting prefabricated building

United States Patent

[] 3,572,002

<td> 172]</td><td> Inventor</td><td> Walter B. Nichols</td>

<td> [21]</td><td> Appl. No.</td><td> 77 Lounsbury Road, Trumbull, Conn. 06611 847,010</td>

<td> [22]</td><td> Filed</td><td> Aug. 4,1969</td>

<td> [45]</td><td> Patented</td><td> Mar. 23,1971</td>

Continuation-in-part of application Ser. No. 631,799, Apr. 18,1967, now abandoned.

[56] References Cited

UNITED STATES PATENTS

2,912,076 11/1959 Costis........................... 52/86X

3,206,897 9/1965 Hilkeretal................... 52/I27X

3,236,020 2/1966 Toffolon....................... 52/745

3,271,921 9/1966 Divoky......................... 52/747

3,398,491 8/1968 Babcock....................... 52/741X

FOREIGN PATENTS

844,158 8/1960 GreatBritain................ 52/74'7

Primary Examiner—Price C. Faw, Jr Attorney—Beveridge &amp; De Grandi

[ 54 ] METHOD OF ERECTING PREFABRICATED BUILDING

Claims, 14 Drawing Figs.

[52] U.S.C1........................................................

[51] Int.Cl........................................................ E04bl/35,

[50] Field of Search......................... .................

745,747,742, 122, 72,66,127,86

ABSTRACT: A method of erecting a prefabricated portable building comprising the step of placing elongated base sills or the ground site in laterally spaced and parallel relationship, hinging a plurality of superstructure ribs to the sills at intervals spaced along the sills, attaching purlins between adjacent ribs using fasteners prefabricated thereon, and securing a plurality of foldable panel units to the ribs in overlying relationship with the purlins using releasable wedge assemblies prefabricated on the ribs.

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PATENTED MAR231971 3:572,002

SHEET 1 OF 3

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attorneys

PATENTED MAR231971

SHEET 2 OF 3

3,572,002

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PATENTED MAR231971 3,572 002

SHEET 3 OF 3

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BY

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3,572,002

METHOD OF ERECTING PREFABRICATED BUILDING

RELATED APPLICATIONS

This application is a continuation-in-part of my prior copending U.S. applications, Ser. No. 631,799 filed Apr. 18, 1967, entitled Prefabricated Building and Method of Erecting Same, and now abandoned, and Ser. No. 668,818 filed Sept. 19, 1967 entitled Improvements in Building Construction, now Pat. No. 3,494,083.

The present invention relates to a unique prefabricated building and method for erecting the same. Although particularly suitable in commercial construction such as hangers, warehouses, or manufacturing, plants, the present invention is also applicable in other types of construction.

One of the principal objects of the present invention is to provide a new and improved prefabricated building which may be quickly and easily erected for use and subsequently disassembled for storage or transportation to another site. Included herein is such a prefabricated building which may be erected or disassembled with a minimum of workmen using standard tools and without any special skills.

A still further object of the present invention is to provide a novel method of moving panels over a prefabricated portable building during erection or disassembly of the building.

Other objects of and advantages of the present invention will become apparent from the following more detailed description in conjunction with the attached drawings in which:

FIG. 1 is a perspective view of a building constructed in accordance with the present invention and shown with certain portions removed and others in phantom for purposes of illustration;

FIG. 2 is a perspective view of a panel unit employed in the building illustrated in FIG. 1;

FIG. 3 is a schematic view illustrating partly in phantom, sequential steps in erecting rib framework included in the building;

FIG. 4 is a fragmental perspective view of a rib included in the building and a tool which may be employed in erecting the rib;

FIG. 5 is a fragmental perspective view, with portions in phantom, illustrating attachment of a rib to a sill at the base of the building;

FIG. Sa is fragmental detail view illustrating assembly of fasteners for securing a rib to a sill;

FIG. 6 is a side elevational view of the building as completed;

FIG. 7 is an enlarged, fragmental view of a rib as viewed longitudinally of the building;

FIG. 8 is a cross-sectional view taken generally along lines 8-8 of FIG. 7;

FIG. 9 is a cross-sectional view taken generally along lines 9-9 of FIG . 1;

FIG. 10 is a fragmental, perspective view illustrating assembly of a purlin to a rib as included in the building;

FIG. 11 is a fragmental, transverse, cross-sectional view to two adjacent panels included in the panel unit of FIG. 2 illustrating the connection therebetween when in unfolded coplanar position;

FIG. 12 is a view similar to FIG. 11 except it is taken with respect to adjacent end panels of two successive panel units; and

FIG. 13 is a view similar to FIG. 8 but illustrating a modified and preferred rib construction.

DETAILED DESCRIPTION

Referring now to the drawings in detail, FIG. 1 illustrates one form of a building embodying the present invention and having a semicylindrical construction the major components of which include a pair of base sills 10 extending along the base on the opposite sides of the building; a plurality of arched ribs 12 spanning the sills and defining the superstructure framework; a plurality of secondary supporting members or purlins 14 extending between the ribs; and a plurality of panel units 18 attached to the ribs, to form the cover of the building.

Base sills 10 may be made from any suitable material such as wood having for example a 6 inches x2‘Ainches cross section and a length sufficient to extend between the opposite ends of the building as shown in FIG. I. For stability and load distribution, a plurality of base plates 20 are provided below sills 10 at the rib locations. In the shown embodiment as illustrated in FIG. 5 each base plate 20 has a U-shaped passage 22 in its upper face receiving the sills. Any suitable material such as wood dimensioned 24 inches X24 inches Χ3Άinches may be employed for the base plate. Although other modular dimensions may be employed, in one embodiment, the distance between ribs 12 or the centers of base plates 20, may be for example about 8 feet. Additionally in one standard size the sills 10 may be 64 feet long corresponding to the length of the building, with a lateral spacing of approximately 50 feet corresponding to the building width.

Ribs 12 may be also be constructed from wood, for example laminated Douglas Fir (2500 p.s.i.) having a cross section 3½ inches X6 inches. Each rib 12 may be formed of sections 12½ feet in length spliced together for example by the plates 24 so as to span the sills with a clear height at its crown of approximately 24 feet.

For purposes of erection and disassembly, ribs 12 arc pivotally connected to sills 10 for swinging movement between a generally horizontal position extending generally parallel to the plane of the sills such as illustrated the lowermost position shown in FIG. 3, and vertical erected position projecting upwardly from the sills as shown in FIG. 1. In the specific embodiment shown, this connection of the ribs to the sills is achieved by hinge anchor members each having a first leaf 30 fixed to the sill with an arm portion 32 projecting upwardly at right angles from the sill and engaged against the leg 13 of the associated ribs as shown in FIG. S.

Leaf arm 32 has formed at its upper extremity a portion of the hinge barrel which extends horizontally transversely of the sill at a point spaced above the sill as clearly shown in FIG. 5. The other leaf of the hinge designated 34 is attached to rib leg 13 and has formed therein the remaining portion of the hinge barrel. A conventional hinge pin 36 is received in the hinge barrel to complete the hinge assembly. It will thus be seen that in moving between the horizontal and vertical positions, the ribs will pivot about the hinge pins 26 which arc spaced upwardly from the sills to provide sufficient room for the ribs.

After erection into the vertical position, ribs 12 are secured to sills 10 by shoes shown as right angle members each having a first arm 40 bolted to the associated rib leg 13 in a position opposite hinge portions 32, 34 and a second arm 42 normally projecting from the rib leg, see FIG. 5. Shoe arm 42 is secured to the sill by threaded fasteners such as bolts or screws 46 inserted through apertures 44 in the shoe arm and into nuts 48 fixed in the sill. To facilitate placement and securement of fasteners 46, nuts 48 are of the T-type and embedded in the sill so that fasteners 46 may be secured in the nuts from above the shoes.

In erecting ribs 12, the endmost rib is first erected and secured through hinges 30, 32, 34 and shoes 40, 42 as described above after which the remaining ribs are erected and secured in successive order. After the first two ribs arc erected, assembly of purlins 14 between the ribs may be commenced, that is, during the erection of the remaining ribs.

In the shown embodiment, purlins 14 have a tubular construction formed from any suitable material, preferably aluminum water tubes 1 % inches O.D. and approximately 8 feet in length. The opposite ends of purlins 14 are fixed to adjacent ribs at two foot centers along the ribs by any suitable means which preferably include right angle male brackets SO fixed to the opposite ends of the purlins and cooperable female brackets 52 fixed to the opposite sides of the ribs at 2 feet centers. Brackets 40 each have depending arms 54 which are passed through the channel passage 56 in the cooperable female brackets 52 to align apertures 58 in the male brackets

3,572,002 with passages 60 extending transversely in the side faces of the ribs.

To lock male brackets 50 in female brackets 52 conventional releasable fasteners 62 known as a Simmons fastener may be employed. These fasteners 62 each include an anchor plate 64 fixed to the side face of the rib and having an aperture 66 overlying passage 60 in the rib, and a male member composed of inner and outer telescoping parts 68,70 biased apart by a spring 72 located in the outer part 72. Male member 68, 70 is placed through anchor plate aperture 66 into passage 60 in the rib and the inner male part 68 is depressed against spring 72 and rotated to snap lugs 74 on the inner male part 68 in corresponding notches 76 formed in the anchor plates as shown in FIG. 9. Inasmuch as Simmons fasteners are of conventional construction further description in this regard is not believed to be necessary. Moreover it will be understood that other releasable fasteners may be employed instead of that shown in the drawings.

After purlins 14 are secured between ribs 12, panel units 18 may then be assembled. In the specific embodiment illustrated and with reference to FIGS. 2, 11 and 12, each panel unit comprises six rectangular panels 80 made from any suitable material for example % inches plywood which has been spraycoated with an epoxy substance to make it water and weather resistant and also to increase its durability and strength. Panels 80 are flexibly interconnected along their sides by continuous elongated strips 82 of flexible material such as cross woven nylon with a vinyl coating marketed under the trademark HERCULITE. Adjacent panels 80 in each unit are interspaced a predetermined distance and the flexible strip 82 extends through the length of the panels while being bonded thereto by any suitable means such as an adhesive designated 84. Flexible strips 82 act as a hinge to permit the panels to be folded in overlying relationship as shown in FIG. 2 for purposes of storage and transportation. Additionally flexible strips 82 because of their material, also provide continuous weatherproof seals between the panels.

In order to connect adjacent panel units 18 together to maintain continuity particularly with regard to sealing, the end panels (see FIG. 12) are provided with a releasable fastener preferably a strip 86 of hook pile fabric or other material such as marketed under the trademark VELCRO. In each panel unit 18 one end panel is provided with a flexible strip 82α along its outer side so as to extend outwardly beyond that side for purposes of overlapping the end panel of the adjacent panel unit as shown in FIG. 12. Flexible strip 82α has a hook pile strip 86 attached along it underside so as to be engageable with a corresponding hook pile 86 continuously placed on the adjacent end panel. Hook pile strips 86 may be secured to the panels, by any suitable means, such as an adhesive. In engaging the hook pile strips 86, finger pressure is merely required. Once engaged, a continuous seal will be maintained between adjacent panel units. Upon disassembly of the building, hook pile strips 86 may be separated by slight manual effort.

In a preferred embodiment, to facilitate movement of the panels over the purlins prior to securement or after securement when it is desired to dismantle the building, a plurality of roller sleeves 14 are provided on each of the purlins intermediate the ends thereof. Preferably, the purlins are constructed with raised portions so as to maintain the sleeves in certain positions on the purlins so the sleeves will be aligned for each of the purlins in a row. For a more detailed description of the sleeve structure as well as the purlins, reference is made to my aforementioned prior copending applications, Ser. No. 631,799 filed Apr. 18, 1967 and Ser. No. 668,818 filed Sept. 19, 1967.

In moving the panels over the purlins during erection of the building, it is preferable that the panel units be folded to one of the building as shown in FIG. 1. The uppermost panel unit is then connected to a cable 2 by any suitable mechanism which would allow the upper panel unit to be moved over the purlins upon movement of the cable. Although in the shown embodiment, cable 2 is connected to the first panel by means of a hook and eye, one or more concentrical vise grips (not shown) may also be employed. In this latter event the handle of the vise grip would be connected to the cable 2 and the jaws of the grips would be clamped on the edge of the panel. As the first panel unit leaves the stack of panels and moves over the purlins it is stopped and the next panel unit may then be fastened to the first panel unit by interengaging the hook pile material on the units. Movement of the cable 2 may then be continued to move the first and second panel units together over the purlins as facilitated by the sleeves 14. When the second panel unit leaves the stack of panels the third panel unit may then be connected to the second panel unit by interengaging their respective hook pile material. This process is repeated until all of the panel units have been interconnected and moved over the purlins by using the same cable.

It should be noted that the hook pile material is of sufficient strength to maintain the panel units together in the proper assembled position as the panel units are being simultaneously moved over the purlins by means of the cable. Any suitable arrangement such as a winch 5 may be employed for moving the cable. In addition, the sleeves preferably are formed with grooves in their external peripheries for receiving the cable to guide and properly maintain the cables proper position during movement over the purlins.

In the embodiment shown in FIG. 8, panels 80 arc placed on molding strips 17 fixed to the opposite side faces of the ribs below the upper faces 15 of the ribs. The spacing of molding strips 17 below the rib face 15 is equal to the thickness of the panels 80 so that the top surfaces of the latter are flush or continuous with the top face 15 of the rib. Additionally the ends of panels 80 are placed in abutting engagement against the side faces of the rib to form a closed joint.

To secure and lock panel units 18 in place on the ribs and purlins, a plurality of releasable clamping assemblies 90 are provided on the upper faces 15 of the ribs at suitable intervals as may be required throughout the ribs. In the preferred embodiment, clamping assemblies 90 are of the wedge type each including a stud provided by a threaded bolt 92 fixed in the rib and projecting perpendicularly from upper face 15 thereof a suitable distance for purposes of accommodating a wedge as will be described. The head 94 of bolt 92 forms a stop for the pressure applying elements to be described, while the bottom end of the bolt is locked by a nut and washer assembly 96 engaged against the bottom face of the rib. A spacer tube 98 is placed about bolt 92 and extends between rib face 15 and a washer 100 abutting bolt head 94 so that a predetermined distance between bolt head 94 and rib face 15 may easily be produced during fabrication.

Slidably and rotatably received about spacer tube 98 is a pressure block 102; the latter having a central aperture 103 through which spacer tube 98 passes. Pressure block 102 has a flat bottom face 104 adapted to transversely engage a pair of elongated, continuous pressure bars 106 which extend over the opposite sides of rib face 15 into engagement with the ends of panels 80 throughout the full length of the rib. Pressure bars 106 partially overly rib face 15, and to insure proper positioning of pressure bars 106, elongated spacer strips 108 are fixed along the longitudinal centerline of rib face 15 to be engaged by the inner side edges of pressure bars 106 as shown in FIG. 9. Spacer strips 108 are intermittently placed along rib face 15 between bolts 92.

For sealing purposes, a pair of elongated continuous strips 109 of neoprene or other rubberlike resilient sealing material, are interposed respectively between the bottom faces of pressure bars 106 and the ends of panels 80 with portions of the sealing strips 109 also contacting rib face 15 as shown in FIG. 8. During shop fabrication of pressure bars 106, sealing strips 109 may be bonded thereto by a suitable adhesive. Additionally during assembly at the construction site, sealing strips 109 may, if desired, also be bonded to the upper surfaces of the ends of panels 80 and/or upper face 15 of the rib.

Completing the clamping assembly is a wedge 110 having an elongated slot 112 receiving spacer tube 98 above pressure

3,572,002 block 102 so that the wedge is mounted for slidable and rotatable movement relative to the spacer tube as well as the pressure block. In securing panels 80, wedge 110 is oriented transversely of the pressure block and longitudinally over the upper rib face IS as shown in FIG. 7 and then the wedge is hammered to apply pressure on pressure block 102 which in turn forces pressure bars 106 downwardly firm engagement against panels 80. To releasably retain wedge 110 in its advanced, pressure applying, position, its underside is formed with corrugations or ratchet teeth 113 which are engageable with the edges of the underlying pressure block. As shown in FIG. 7, the edges in the pressure block 102 are teeth formed in the top of the latter with a shape and dimensions complementary to teeth 113 of wedge 110.

Preferably the wedges and pressure blocks are made from aluminum, and in one exemplary construction, pressure bars 106 may have a cross section of 1¾ inches by S'/ainches and the locating strips, 1 ‘^inches by finches. It is preferred that locating strips 108 and the clamping assemblies 90 be incorporated on the ribs during fabrication in the shop so that during assembly of the building in the field, it is only necessary to apply the pressure bars 106, orient the wedges and pressure blocks and then merely hammer the wedges into the final locking position. No adjustment Of the bolts 92 in the field is required since, spacer tubes 98 insure uniform wedging action of the wedges and consequently uniform clamping pressures applied to the panels 80. Spacer tubes 98 moreover act as a bearing between the bolt 92 and the wedge and pressure block.

FIG. 13 illustrates a preferred modification of the rib construction shown in FIG. 8 wherein molding strips 17 are omitted and panels 80 placed directly on upper face 15 of the rib. In this modification locating strips 108 also serve to properly position panels 80 on rib face 15. The other parts of the joint in the modification of FIG. 13 are the same as that in FIG. 8. It will be apparent that the joint shown in either FIG. 8 or FIG. 13 as employed together with flexible strips 82 between the panels, render the building entirely weatherproof.

After panel units 18 have been attached throughout the rib and purlin framework, opposite end walls (not shown) with doors or windows may be attached to the structure by any conventional method assuming that the use of the building requires such. It will also be understood that panel units 18 may have incorporated therein, windows 19 as shown in FIG. 1.

To summarize assembly of the building in accordance with the present invention, sills 10 are layed on the ground site in proper spaced relationship and with the underlying base plates 20 at the proper intervals corresponding to the spacing of ribs 12. The end rib is then hinged to the sills by inserting the hinge pins 36 in their barrels. From the horizontal position lying on the ground surface, the end rib is then raised to the upright position by pivoting at its hinges. Fasteners 46 are then placed through rib shoes 42 and engaged in the underlying nuts 48 to secure the rib in the vertical position. Depending on the size and span of the rib, it may be desirable to provide a temporary external support for the end rib when first erected. However, when the purlins are attached, the external support will not be required in view of the support and rigidity offered by the purlins.

In raising the ribs into the erected position, elongated poles 120 may be used as illustrated in FIG. 1. Although not necessary, ribs 12 may be provided with one or more recesses 122 each formed by bracket members 124 (see FIG. 4) for receiving a ball 126 attached on the end of a pin 129. Pole 120 may then be provided at its end with a socket illustrated as a llshaped bracket 130, having an aperture 132 for receiving pin 128. In this manner, poles 120 may be releasably attached to ribs 12 for purposes of erection and thereafter easily removed. However, instead of the bracket and pin assembly shown in FIG. 4, the pole may be provided with nails or spikes (not shown) projecting from their ends which may be engaged in the ribs for purposes of erecting the ribs. Additionally any other suitable means may be employed for raising the ribs into the vertical position.

After the end rib is erected, the next adjacent rib is swung into vertical position and secured, and at this stage placement 5 of purlins 14 between the two erected ribs may be commended, that is, while erection of the remaining ribs continues. Assembly of the purlins is easily effected merely by insertion of their brackets 54 through female brackets 52 on the sides of the ribs. This aligns bracket apertures 58 with aper1 θ tures 66 and rib passages 60 after which Simmons fasteners 62 are merely inserted through the latter, and rotated into locking position. In assembling purlins 14, the lowermost purlin is first installed and then the next higher purlin and so on so that a ladder structure is formed to facilitate assembly without requiring scaffolding. It will also be recognized that the installation of the purlins provides added support to the ribs so that during construction, virtually no external support is required.

After a sufficient number of purlins have been installed, as2Q sembly of panel units 18 may be commenced. In applying the panels, they are unfolded from the storage position generally shown in FIG. 2 and then placed on the purlins with the opposite ends of the panels engaged against the rib faces 15 as in the preferred modification shown in FIG. 13. This step is 25 facilitated by spacer strips 108 which properly locate the panels. Pressure bars 106 with their underlying seal strips 109 are then applied over the ends of the panels and then pressure blocks 102 are oriented transversely of the ribs to engage the upper surface of pressure bars 106. Oriented transverse to 30 pressure blocks 102 as shown in FIG. 7, wedges 110 are then hammered to downwardly wedge the pressure blocks which in turn¹ force pressure bars 106 firmly against the panels to secure them in place. The next adjacent panel unit 18 may then be installed in the same manner, and to connect the end panels of adjacent panel units the hook piles 86 are interengaged by finger pressure applied along strips 82α (see FIG. 12).

To disassemble the building for storage or transportation to another site, the above steps arc essentially reversed. The disassembled parts may be stored in a highly compact manner without crating and transported by truck, train, ship or plane. The same parts may again be assembled to construct the building without requiring new parts or replacements or any procedural departure from the method of assembly described above. Not only is the building easily and rapidly constructed with minimum personnel requiring only standard tools, but also it possesses sufficient strength in combination with a relatively light weight. In one embodiment such as that described above, the building will support a 40 pound per square foot roof load and exhibit vibration-free characteristics when subjected to a 100 mile per hour wind. Additionally in this embodiment the knock down volume of the building is approximately 1043 cubic feet with a total weight of 14,000 pounds 66 which provide a 3,000 square foot building.

Although the building shown and described herein has a semicylindrical configuration, it will be appreciated that the present invention may be applied to construct buildings having a rectangular frame or A-frame construction as well as 00 others.

Moreover, other modifications readily apparent from the foregoing description and associated drawings, although not specifically mentioned herein, will nevertheless be included within the spirit and scope of the invention as indicated in the 65 appended claims.