Abstract:
A prefabricated building includes a pre-cast concrete chain wall foundation having upper and lower walls with a height and a thickness, the ratio of wall height to wall thickness being equal to or greater than 3 to 1 and the wall height is at least three (3) feet; and a prefabricated building positioned upon the precast concrete chain wall foundation, wherein the prefabricated building has walls that rest upon the upper surface of the pre-cast concrete chain wall foundation.

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
     Priority of U.S. Provisional Patent Application Ser. No. 60/758,384, filed Jan. 12, 2006, incorporated herein by reference, is hereby claimed. 
    
    
     STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT 
     Not applicable 
     REFERENCE TO A “MICROFICHE APPENDIX” 
     Not applicable 
     BACKGROUND OF THE INVENTION 
     1. Field of the Invention 
     The present invention relates to a method of erecting a building or like structure wherein a pre-cast concrete chain wall is first constructed and then transported to a selected building site. Even more particularly, the present invention relates to an improved method of elevating a building or other structure or equipment at a lower cost and/or reduced construction time. 
     2. General Background of the Invention 
     Cast-in-place concrete chain walls are typically used to elevate buildings in flood prone areas. One of the most common usages of the chain walls are for prefabricated modular buildings used by telecommunications or other communication companies. 
     Each individual company normally uses a standard size building. Thus the footprint of the chain wall is normally constant. The time and construction cost for building a cast-in-place chain wall at a particular site can be extremely expensive and time consuming. 
     After the concrete is poured, the concrete must be allowed time to cure. The wooden forms used for cast-in-place chain walls are then removed and typically disposed of. This entire process could range from 2-4 weeks (even longer if there are delays in obtaining materials or due to weather). There are known cases in which the wooden forms have failed and the final walls are bowed out of alignment. The concrete must be delivered to the site from a concrete plant which could be several miles from the site location. The compressive strength of the cast-in-place concrete chain wall is usually determined 28 days after the concrete is poured. 
     The present invention provides an improved method of installing an elevated building at a particular location and in a shorter time frame. The present cast-in-place method usually requires a contractor to order wooden forms, steel reinforcing bars, concrete trucks to pour, labor to form and pour the cast-in-place chain wall, and possible pump trucks and matting. 
     The present invention has many advantages over the current cast-in-place type systems. The pre-cast chain wall can be poured and stored in a storage facility months prior to the beginning of a job. The forms used for the pre-cast chain wall system can be metal, which can be used many times. The concrete can be poured in ideal weather conditions and is usually supplied by an on-site concrete manufacturer. The metal forms can be specifically tooled to accept attachments for landing, tie-down plates or other attachments which are typically required by the client. 
     These metal forms can be built with vertical grooves or any other type of decorative pattern to make the finished product more aesthetically pleasing than the present cast-in-place chain wall. 
     The exterior walls for the pre-cast chain wall can be smoother and contain little to no honeycomb finishes as compared to the cast-in-place chain wall. The steel reinforcement could be ordered in large quantities and shipped to the fabrication plant. The cast-in-place concrete chain walls can be poured in one day, and then set aside for curing. The fabrication plant can stockpile these pre-cast chain walls and deliver them as needed. 
     When a client orders a pre-cast concrete chain wall, he will know the compression strength of his new concrete wall before it is delivered to his site. The construction time for placing a pre-cast chain wall on site can be reduced from 2-4 weeks to a week or even a day. 
     As with a standard cast-in-place chain wall, a foundation is needed in some cases to support the wall and building. If for example, pilings are required to support the wall and building, the pilings could be driven to a certain elevation, and then the pre-cast chain wall can be placed on top of the piles, followed by the new prefabricated modular building. 
     A crane large enough to place the prefabricated modular building can first be used to set the lighter pre-cast concrete chain wall in place on top of the piles. The modular building can be attached to the chain wall using tie-down plates with bolts. The pre-cast chain walls can be made such that the tie-down bolts can double as attachments for lifting the wall. 
     A typical size (approximate dimensions) of a chain wall is 11 feet 6 inches×20 feet×4 feet high with wall thickness of 10 inches. These dimensions will vary based on the client&#39;s need and the building or structure loads. 
    
    
     
       BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS 
       For a further understanding of the nature, objects, and advantages of the present invention, reference should be had to the following detailed description, read in conjunction with the following drawings, wherein like reference numerals denote like elements and wherein: 
         FIG. 1  is a schematic diagram illustrating method steps for forming the pre-cast concrete chain wall of the present invention; 
         FIG. 2  is a schematic diagram illustrating a lifting of the pre-cast concrete chain wall of the present invention with lifting cables and placing it upon an optional piling foundation; 
         FIG. 3  is a schematic perspective view illustrating placement of the pre-cast concrete chain wall of the present invention upon an optional concrete footing foundation; 
         FIG. 4  is a schematic diagram of the preferred method of the present invention showing the pre-cast concrete chain wall placed upon a piling foundation and with tie down plates in position; 
         FIG. 5  is a perspective schematic view illustrating the use of tie down plates for holding the pre-cast concrete chain wall of the present invention to a foundation of concrete footings; 
         FIG. 6  is a perspective view illustrating placement of a building or like structure upon the pre-cast concrete chain wall of the present invention when support with an optional piling foundation; 
         FIG. 7  is a perspective view of a first embodiment of the apparatus of the present invention; 
         FIG. 8  is a partial perspective view of a second embodiment of the apparatus of the present invention; 
         FIG. 9  is a plan view of the second embodiment of the apparatus of the present invention; 
         FIG. 10  is a partial perspective side view of the second embodiment of the apparatus of the present invention; 
         FIG. 11  is a fragmentary elevation view of the second embodiment of the apparatus of the present invention; 
         FIG. 12  is a sectional view taken along lines  12 - 12  of  FIG. 8 ; 
         FIG. 13  is a sectional view taken along lines  13 - 13  of  FIG. 8 ; 
         FIG. 14  is a sectional view taken along lines  14 - 14  of  FIG. 8 ; 
         FIG. 15  is a fragmentary view illustrating part of the method of the present invention, preparing foundation; 
         FIG. 16  is a perspective view showing another step of the method of the present invention, lifting chain wall; 
         FIG. 17  is a perspective view showing another method step of the present invention, placing chain wall on prepared foundation; 
         FIG. 18  is a perspective view showing another method step of the present invention, lifting building; 
         FIG. 19  is a perspective view showing another method step of the present invention, placing building on chain wall; 
         FIG. 20  is a schematic diagram illustrating the optional pre-cast chain wall to piling tie-down detail. 
     
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
       FIG. 1  illustrates the sequence of manufacturing a finished pre-cast concrete chain wall, designated generally by the numeral  6  in  FIG. 1 . In order to form the finished pre-cast concrete chain wall of  FIG. 1  that is designated generally by the numeral  6 , a user starts with a form  1  of metal, wood, or the like, that is fitted with a steel reinforcing cage  2  or like reinforcing. An optional louver  3  can be placed in form  1  for providing access under a featured building or for allowing water flow. Inserts  4  can be provided to accept bolts or tie downs, a landing, stairs, or the like. The arrow  5  in  FIG. 1  illustrates the pouring of any selected (e.g. commercially available) slurried concrete into the form  1 .  FIG. 1  also shows the finished pre-cast chain wall product number  6  after removal from the form  1 . 
     In  FIGS. 2 and 3 , the pre-cast concrete chain wall  6  has been rigged with lifting cables  7 , such rigging in combination with a lifting device (e.g. crane) is used to set the chain wall  6 . Cables  7  can be rigged to building  12  or other selected structure such as a generator or prefabricated cabinet (see  FIGS. 6 and 7 ). Once the cables  7  are used to set the pre-cast concrete chain wall  6 , a selected structure  12  such as a modular building is placed upon the chain wall  6  as shown in  FIG. 6 . 
     The completed combination of building  12 , pre-cast concrete chain wall  6 , and optional foundation  8  or  9  can be seen in  FIG. 7 . Tie down plates  10  can be used to secure the building  12  to the pre-cast concrete chain wall  6 . Similar tie down plates  10  can be used to secure the chain wall to the optional foundation  8  or  9 . 
       FIGS. 8-20  show a second embodiment of the apparatus of the present invention designated generally by the numeral  54  in  FIG. 19 . Second embodiment  54  includes a prefabricated building  48  and a pre-cast chain wall foundation  15 . Prefabricated building as used herein includes prefabricated cabinets and generators. Both are transported to a building site  16 , each using a transport vehicle  39 . In  FIGS. 8-14 , pre-cast chain wall foundation  15  has an upper end portion  23  and a lower end portion  22 . At about the time that the transport vehicle  39  transports pre-cast chain wall foundation  15  to building site  16 , a trench or excavation  18  is prepared at building site  16  so that the excavation or trench  18  can receive pre-cast chain wall foundation  15  in a leveled position. 
     In  FIG. 15 , an excavator  17  having a bucket or other digging implement  19  is shown digging an excavation  18  or trench. In  FIG. 20 , the excavation or trench  18  preferably provides a bottom  21  that is level or horizontal. The trench or excavation  18  can also provide one or more sidewalls  20 . 
     Pre-cast chain wall foundation  15  can include a number of columns  24 - 28 . These columns include corner columns  24  and intermediate columns  25 ,  26 ,  27 ,  28  as shown in  FIG. 8 . The upper end portion  23  of pre-cast chain wall foundation  15  provides a plurality of upper beams  30  and a plurality of lower beams  33 . Each of the columns  24 - 28  extends between an upper beam  30  and a lower beam  33  as shown. 
     The upper beam  30  can include longitudinal reinforcing bars  31  or rebars and spaced stirrups  32 . In  FIG. 13 , the lower beam or foundation beam  33  includes longitudinally extending reinforcing bars or rebars  34  and laterally spaced apart stirrups  35 . Likewise, each column  24 - 28  can be provided with vertical reinforcing bars or rebars  36  and vertically spaced apart stirrups  37 . 
     The upper beam  30  can include optional notches  29  as shown in  FIG. 8  to be used for support beams (e.g. wide flanged beams, I-beams, channel beams, etc.) for possible walkways, equipment such as generators and outside cabinets, or prefabricated building requiring additional support. 
     One or more plastic tubing sections  38  is provided at numerous locations on pre-cast chain wall foundation such as for example at the lower end portion of a column  24 - 28  as shown in  FIG. 11 . Each plastic tubing  38  can be a bore or passageway that extends through the pre-cast chain wall foundation  15  for enabling a steel cable or other connective strap to be inserted for optionally forming a tie between pre-cast chain wall foundation  15  and each of a number of piling  50  (see  FIG. 20 ). 
     When the pre-cast chain wall foundation  15  is transported to building site  16  using transport vehicle  39 , a lifting device  40  or like mechanism is employed to transfer pre-cast chain wall foundation  15  from transport vehicle  39  to the trench or excavation  18  at building site  16 .  FIG. 16  illustrates a lifting of pre-cast chain wall foundation  15  with a truck crane  40  or other lifting device having a boom  41  and lifting line or crane line  42 . Rigging  43  can be employed to form an interface between the crane or lifting line  42  and pre-cast chain wall foundation  15 . Such rigging  43  can include a plurality of slings  44  that are wrapped around the upper end portion  23  of pre-cast chain wall foundation  15  as shown in  FIG. 16 . 
     In  FIG. 17 , lifting device  40  has placed pre-cast chain wall foundation  15  in trench or excavation  18  wherein pre-cast chain wall foundation rests upon the bottom  21  of excavation or trench  18 . 
     A prefabricated building  48  or other building can be transported to building site  16  using a transport vehicle  39 . A lifting device such as truck crane  40  or other device can be used to transfer building  48  to pre-cast chain wall foundation  15 . In  FIG. 18 , the lifting line  42  interfaces with rigging  45  that can include slings  46  and optional spreader bars  47 . In  FIGS. 19-20 , pre-cast chain wall foundation  15  extends below the earth&#39;s surface  49  and rests upon the bottom  21  of excavation or trench  18 . 
     A plurality of piling such as treated timber piles  50  can optionally be used as part of a tie-down arrangement as shown in  FIG. 20 . As used herein, piling includes any known installed piling such as but not limited to footings, concrete or timber piling, screw piling, cast in place concrete pile, composite pile, or the like. In  FIG. 20 , a pile  50  such as a treated timber pile is driven a partial distance into the earth and below earth&#39;s surface  49 . The pile  50  is then cut if required to provide a level surface, and can be a treated pile, if necessary. 
     An opening or channel  51  is formed through the upper end portion of pile  50 . A galvanized wire rope  52  or other tie is inserted through channel or opening  51  leaving end portions  55  of galvanized wire rope or tie  52  exposed so that a tie can be formed between the end portions  55  and pre-cast chain wall foundation  15 . Pile  50  is then driven a further distance into the earth until its upper end is about even with the elevation of the bottom  21  of trench or excavation  18 . Shims can be placed on each pile  50  as needed. The trench or excavation  18  is then preferably widened for enabling a user to form a connection between end portions  55  and chain wall foundation  15 . The enlarged excavation  53  is simply an enlargement of the trench or excavation  18  at each pile location. The wire rope  52  is then threaded through plastic tubing  38  or channel formed through pre-cast chain wall foundation  15 . The wire rope  52  is then clamped or fastened together to form a tie between each piling  50  and pre-cast chain wall foundation  15 , each can be at a position below a column  24 - 28 . 
     The present invention provides an improved business method that enables a contractor or vendor to offer a pre-cast building to a customer for delivery in a very short period of time. Because the pre-cast chain wall foundation  15  is a pre-cast prefabricated structure, it can be transported to a job site in a very short period of time such as for example in less than a week or in less than a day. Similarly, building  48  can be a prefabricated building that can be transported using a transport vehicle  39 . The building  48  can be transported in a short period of time such as in less than a week or in less than a day to a selected job site or building site  16 . Using the business method of the present invention, the customer can be offered a building  48  and foundation  15  than can be erected in less than a week or even less than a day. Such a customer can also be offered a pre-cast chain wall foundation  15  that is already constructed and available for inspection before it is ever installed. 
     The following is a list of parts and materials suitable for use in the present invention. 
     
       
         
               
             
               
               
             
               
               
             
           
               
                   
               
               
                 PARTS LIST 
               
             
          
           
               
                 Part Number 
                 Description 
               
               
                   
               
             
          
           
               
                 1 
                 metal form for new pre-cast 
               
               
                   
                 concrete chain wall 
               
               
                 2 
                 steel reinforcing cage 
               
               
                 3 
                 optional louver to provide access 
               
               
                   
                 under future building, or allow 
               
               
                   
                 water flow 
               
               
                 4 
                 inserts to accept bolts for tie- 
               
               
                   
                 downs, landing, etc. 
               
               
                 5 
                 concrete to be poured into form 
               
               
                 6 
                 finished pre-cast chain wall 
               
               
                 7 
                 cables to set chain wall and 
               
               
                   
                 building 
               
               
                 8 
                 optional piling foundation 
               
               
                 9 
                 optional concrete footing 
               
               
                   
                 foundation 
               
               
                 10 
                 tie down plates 
               
               
                 11 
                 optional landing 
               
               
                 12 
                 building or other structure 
               
               
                 15 
                 pre-cast chain wall foundation 
               
               
                 16 
                 building site 
               
               
                 17 
                 excavator 
               
               
                 18 
                 trench or excavation 
               
               
                 19 
                 bucket 
               
               
                 20 
                 side wall of excavation (trench) 
               
               
                 21 
                 bottom of excavation (trench) 
               
               
                 22 
                 lower end portion 
               
               
                 23 
                 upper end portion 
               
               
                 24 
                 corner column 
               
               
                 25 
                 column 
               
               
                 26 
                 column 
               
               
                 27 
                 column 
               
               
                 28 
                 column 
               
               
                 29 
                 notches (5″-6″ deep) 
               
               
                 30 
                 upper beam 
               
               
                 31 
                 longitudinal reinforcing bar 
               
               
                 32 
                 stirrup 
               
               
                 33 
                 lower beam 
               
               
                 34 
                 longitudinal reinforcing bar 
               
               
                 35 
                 stirrup 
               
               
                 36 
                 vertical reinforcing bar 
               
               
                 37 
                 stirrup 
               
               
                 38 
                 plastic tubing or channel 
               
               
                 39 
                 transport vehicle 
               
               
                 40 
                 lifting device 
               
               
                 41 
                 boom 
               
               
                 42 
                 crane line 
               
               
                 43 
                 rigging 
               
               
                 44 
                 sling 
               
               
                 45 
                 rigging 
               
               
                 46 
                 sling 
               
               
                 47 
                 spreader bar 
               
               
                 48 
                 prefabricated building 
               
               
                 49 
                 earth&#39;s surface 
               
               
                 50 
                 treated timber pile 
               
               
                 51 
                 opening or channel 
               
               
                 52 
                 galvanized wire ropes 
               
               
                 53 
                 enlarged excavation 
               
               
                 54 
                 second embodiment of the present 
               
               
                   
                 invention 
               
               
                 55 
                 end portion 
               
               
                   
               
             
          
         
       
     
     All measurements disclosed herein are at standard temperature and pressure, at sea level on Earth, unless indicated otherwise. 
     The foregoing embodiments are presented by way of example only; the scope of the present invention is to be limited only by the following claims.