Patent Description:
Various methods can be employed to fabricate and construct multi-story buildings. Traditionally, multi-story buildings have been constructed from the ground up, in which construction of the building begins on a ground level by attaching higher elevation structural elements on top of previously assembled lower structural elements to construct the building in upward direction, i.e., from bottom up. Such methods may be inefficient in terms of material handling and placement. Presently, structural framing elements may be assembled into a building frame one member at a time and above ground level. Tower cranes are used during construction to execute thousands of individual lifts for elements of the structure, building enclosure, finishes, mechanical and electrical equipment and many other components of a finished building. Furthermore, concrete or another hardenable material is pumped to the final elevation of each floor. These operations may require specialized equipment and setup logistics, and may be time-consuming and labor-intensive when constructing multi-story buildings.

One method of fabricating a building includes fabricating a vertical support core, and sequentially assembling a plurality of floor plates at an assembly level. Each of the floor plates is then lifted to a design level.

It is known document <CIT> disclosing a self-resetting frame structure that comprises steel columns, cross beams which are arranged between every two steel columns, prestressed tendons which are embedded in the cross beams between every two steel columns, and connection structures which are arranged between the cross beams and the steel columns to connect the cross beams with thesteel columns.

There is a need to provide a system and a device for securing a floor plate to a vertical support core at the design level.

A multi-story building that includes a vertical support core and a plurality of floor plates is described, wherein fabrication of the building includes, in one embodiment, assembling each of the floor plates at or near ground level, and lifting each of the floor plates to a design level on the vertical support core.

This includes a system for securing a floor plate to a structure that has a vertical support core having at least one vertically-oriented column including a first beam. The first beam has a first flange, a web portion, and a second flange. A first plurality of through bolt holes are formed in the first flange of the first beam, and the first flange of the first beam has an outer surface. A floor plate includes at least one horizontal girder with a second beam that has an upper flange, a lower flange, and a web portion. A first vertical stiffener is affixed to the upper flange, the lower flange, and the web portion on a first side of the second beam. A second vertical stiffener is affixed to the upper flange, the lower flange, and the web portion on a second side opposed to the first side of the second beam. A vertically-oriented lock-in bracket includes a third beam having a flange portion and a web portion, and a bracket horizontal stiffener. The web portion of the third beam is affixed to the first vertical stiffener of the second beam at a lower portion of the third beam, and a second plurality of through bolt holes are formed on the flange portion of the third beam at an upper portion thereof. A plurality of bolts are also included. When the floor plate is disposed at a design level on the vertical support core, the first plurality of through bolt holes in the first flange of the first beam are disposed opposite to and correspond to the second plurality of through bolt holes disposed on the upper portion of the flange portion of the third beam. When the floor plate is disposed at the design level on the vertical support core, the plurality of bolts are inserted through the first plurality of through bolt holes and the second plurality of through bolt holes and secured thereto.

An aspect of the disclosure includes the vertically-oriented lock-in bracket being affixed to the second beam of the floor plate and slidably arranged on the first beam of the vertical support core when the floor plate is disposed at an assembly level. The vertically-oriented lock-in bracket is slidably arranged on the first beam of the vertical support core when the floor plate is disposed at the assembly level.

Another aspect of the disclosure includes the bracket horizontal stiffener being arranged orthogonal to the flange portion and the web portion of the third beam at the lower portion of the third beam.

According to the invention, when the floor plate is disposed at the design level on the vertical support core, the web portion of the first beam, the web portion of the second beam, the first vertical stiffener, and the second vertical stiffener are coplanar.

Another aspect of the disclosure includes a plurality of first horizontal stiffeners being affixed to the web portion and the first and second flanges of the first beam.

Another aspect of the disclosure includes, when the floor plate is disposed at the design level on the vertical support core, the lower flange of the second beam, the bracket horizontal stiffener, and one of the first horizontal stiffeners are affixed to the first beam being coplanar.

Another aspect of the disclosure includes, when the floor plate is disposed at the design level on the vertical support core, others of the first horizontal stiffeners of the first beam are affixed to the first beam adjacent to the upper portion of the flange portion of the second beam.

Another aspect of the disclosure includes the floor plate being assembled at a first level on the vertical support core and lifted to the design level on the vertical support core.

Another aspect of the disclosure includes the floor plate being slidably disposed on the vertical support core prior to being lifted and secured to the vertical support core at the design level.

Another aspect of the disclosure includes the outer surface of the first flange of the first beam having a slip-critical surface, an outer surface of the flange portion of the third beam having a slip-critical surface, and the slip-critical surface of the outer surface of the flange portion of the first beam being arranged opposite to the slip-critical surface of the outer surface of the flange portion of the third beam to form a slip-critical interface when the floor plate is arranged at the design level on the vertical support core.

Another aspect of the disclosure includes the first beam of the vertical support core being a steel I-beam having a web portion that is arranged between the first flange and a second flange.

Another aspect of the disclosure includes the second beam being a steel I-beam having the web portion arranged between the first flange and the second flange.

Another aspect of the disclosure includes the third beam being a steel T-beam.

Another aspect, not forming part of the claimed invention, includes a device for securing, to a vertically-oriented first beam of a vertical support core, a horizontally-oriented second beam of a floor plate. The device includes a vertically-oriented lock-in bracket including a third beam having a flange portion and a web portion, and a bracket horizontal stiffener. A plurality of bolt holes are formed on the flange portion of the third beam at an upper portion thereof. The bracket horizontal stiffener is arranged orthogonal to the flange portion and the web portion of the third beam at a lower portion thereof. An outer surface of the flange portion of the third beam has a slip-critical surface. The vertically-oriented lock-in bracket is affixed to the horizontally-oriented second beam of the floor plate and is slidably arranged on the vertically-oriented first beam of the vertical support core when the floor plate is disposed at an assembly level. The vertically-oriented lock-in bracket is slidably arranged on the vertically-oriented first beam of the vertical support core when the floor plate is disposed at the assembly level. The vertically-oriented lock-in bracket is affixed to the vertically-oriented first beam of the vertical support core when the floor plate is disposed at a design level.

Another aspect, not forming part of the claimed invention, includes a system for securing a floor plate to a structure in the form of a vertical support core having at least one vertically-oriented column including a first beam, wherein the first beam has a first flange, a web portion, and a second flange, and the first flange of the first beam having an outer surface, and wherein the outer surface of the first flange of the first beam has a slip-critical surface. A floor plate includes at least one horizontal girder including a second beam, the second beam having an upper flange, a lower flange, and a web portion. A vertically-oriented lock-in bracket includes a third beam having a flange portion and a web portion, wherein the third beam is affixed to the second beam at a lower portion of the third beam, and wherein an outer surface of the flange portion of the third beam has a slip-critical surface. The slip-critical surface of the outer surface of the flange portion of the first beam is arranged opposite to the slip-critical surface of the outer surface of the flange portion of the third beam to form a slip-critical interface when the floor plate is arranged at the design level on the vertical support core.

The above summary is not intended to represent every possible embodiment or every aspect of the present disclosure. Rather, the foregoing summary is intended to exemplify some of the novel aspects and features disclosed herein. The above features and advantages, and other features and advantages of the present disclosure, will be readily apparent from the following detailed description of representative embodiments and modes for carrying out the present disclosure when taken in connection with the accompanying drawings and the claims.

It should be understood that the appended drawings are not necessarily to scale, and present a somewhat simplified representation of various preferred features of the present disclosure as disclosed herein, including, for example, specific dimensions, orientations, locations, and shapes. Details associated with such features will be determined in part by the particular intended application and use environment.

The components of the disclosed embodiments, as described and illustrated herein, may be arranged and designed in a variety of different configurations. Thus, the following detailed description is not intended to limit the scope of the invention, as claimed, but is merely representative of possible embodiments thereof. In addition, while numerous specific details are set forth in the following description in order to provide a thorough understanding of the embodiments disclosed herein, some embodiments can be practiced without some of these details. Moreover, for the purpose of clarity, certain technical material that is understood in the related art has not been described in detail in order to avoid unnecessarily obscuring the disclosure. Furthermore, the drawings are in simplified form and are not to precise scale. For purposes of convenience and clarity, directional terms such as top, bottom, left, right, up, over, above, below, beneath, rear, and front, may be used with respect to the drawings. These and similar directional terms are descriptive of the figures, and not to be construed to limit the scope of the disclosure. Furthermore, the disclosure, as illustrated and described herein, may be practiced in the absence of an element that is not specifically disclosed herein.

Referring to the Figures, wherein like numerals indicate like parts throughout the several views, <FIG> shows a vertical support core <NUM> for a building <NUM> that is arranged on a base <NUM>, wherein the building <NUM> is fabricated employing a top-down construction process. In general, the top-down construction process includes sequentially constructing a plurality of floor plates <NUM> at an assembly level <NUM>, lifting each of the floor plates <NUM> to a respective design elevation <NUM>, and securing each of the floor plates <NUM> to the vertical support core <NUM> of the building <NUM> in a descending order. Each of the floor plates <NUM> is secured to the vertical support core <NUM> of the building <NUM> employing a plurality of lock-in brackets <NUM>, one of which is described with reference to <FIG>, <FIG>, and <FIG>. The building <NUM> includes a single vertical support core <NUM> as shown with reference to <FIG>. Multiple vertical support cores may be employed in some embodiments. The concepts set forth herein are described with reference to an xyz-coordinate system, wherein x represents a lateral axis, y represents a longitudinal axis, and z represents a vertical axis. A horizontal plane is defined by the x and y axes.

As used herein, the term " floor plate" includes but is not limited to all structural or frame members, e.g., joists and/or purlins; flooring, e.g., concrete floor; interior walls; exterior curtain walls; modular room subassemblies; lavatories; mechanical building elements, etc., that form a floor or level of the building <NUM>. The term "floor plate" may include a plate for a roof structure (not shown) of the building <NUM>, as well as a plate for a floor or level of the building <NUM>. Accordingly, the term "floor plate" is used herein to refer to both the roof structure for the roof of the building <NUM>, as well as a floor structure for one of the floors or levels of the building <NUM>. The reference numeral <NUM> may refer to and indicate any floor plate of the building <NUM>.

Referring again to <FIG>, the construction system includes the vertical support core <NUM>, which is an element of a vertical slip form system. The vertical support core <NUM> is formed from a plurality of vertical load-bearing columns <NUM>, cross-members, and outer shear walls that are formed from a hardenable material. In one embodiment, the vertical support core <NUM> has a rectangular cross-section with one of the vertical load-bearing columns <NUM> arranged at each of the corners thereof. Each of the vertical load-bearing columns <NUM> includes a first beam <NUM>, which is illustrated and described with reference to <FIG> and <FIG>. There may be <NUM>, <NUM>, <NUM>, <NUM>, or another quantity of vertical load-bearing columns <NUM> in the vertical support core <NUM>. Each of the first beams <NUM> may be a steel I-beam in one embodiment, or, alternatively, a steel box beam or another beam arrangement.

The vertical support core <NUM> also includes a plurality of horizontal roof beams <NUM> that are arranged on a top portion <NUM> thereof. The vertical support core <NUM> is designed to carry the vertical loads of the building <NUM>. As such, the shape of the vertical support core <NUM> may be designed as necessary to provide the required compressive strength, shear strength, and bending strength for the particular application, size, and location of the building <NUM>.

The hardenable material may include, but is not limited to, a concrete mixture or other similar composition. The hardenable material may include one or more additives to enhance one or more physical characteristics of the hardenable material, such as to reduce curing time, reduce slump, increase strength, etc. The specific type and contents of the hardenable material may be dependent upon the specific application of the building <NUM>, and may be dependent upon the specific geographic region in which the building <NUM> is being constructed. The specific type and contents of the hardenable material are understood by those skilled in the art, and are not described in detail herein.

A plurality of lift jacks <NUM> are attached to the roof beams <NUM> of the vertical support core <NUM>, and are employed to lift the floor plates <NUM> to their respective design elevations <NUM>. The lift jacks <NUM> may include, but are not limited to a plurality of strand jacks. Alternatively, the lift jacks <NUM> may include other devices capable of lifting each of the floor plates <NUM> of the building <NUM>. Strand jacks are able to grasp and move a cable to lift heavy objects. The specific features and operation of lift jacks <NUM> such as strand jacks are known to those skilled in the art. The lift jacks <NUM> couple to a bridle (not shown) that is disposed underneath each of the floor plates <NUM> via cables <NUM> and lockable joints <NUM>.

As shown, each of plurality of the floor plates <NUM> can be assembled on the bridle, which is placed at an assembly level <NUM> that is at or proximal to ground elevation. The plurality of the floor plates <NUM> are lifted to their respective design elevations <NUM> relative to the vertical support core <NUM> in a sequential descending order employing the lift jacks <NUM>. Element <NUM> indicates one of the floor plates <NUM> that has been lifted to its respective design elevation <NUM> for attachment to the vertical support core <NUM> employing an embodiment of a lock-in bracket <NUM>, which is described with reference to <FIG>, <FIG> and <FIG>.

Referring again to <FIG>, each of the floor plates <NUM> includes one or multiple girders <NUM> that are secured to the plurality of columns <NUM> of the vertical support core <NUM> of the building <NUM> employing the lock-in brackets <NUM>. Other elements of the floor plate <NUM> include a floor plate frame that includes framing members <NUM>, <NUM>, and spandrels <NUM>. Metal decking (not shown) is attached to the floor plate frame, and hardenable material is dispersed onto the metal decking. Mechanical building elements are assembled onto the floor plate frame beneath the metal decking when the floor plate <NUM> is disposed at the assembly level <NUM>.

<FIG> and <FIG> schematically illustrate details related to an embodiment of the lock-in bracket <NUM> for securing one of the floor plates <NUM> to the vertical support core <NUM> of the building <NUM>. Each of the first beams <NUM> of the columns <NUM> is a steel I-beam in one embodiment, with a first, outwardly facing flange <NUM> having an outer surface <NUM>, a second flange <NUM>, and a web portion <NUM>. A first plurality of through bolt holes <NUM> are formed in the first flange <NUM> of the first beam <NUM>, and are designed to accommodate torque-critical attachment fasteners <NUM>, e.g., bolts. Each of the horizontal girders <NUM> is formed with a second beam <NUM>, which is a steel I-beam in one embodiment, having an upper flange <NUM>, a lower flange <NUM>, and a web portion <NUM>. A first side <NUM> of the second beam <NUM> is disposed to face the vertical support core <NUM> and the lock-in bracket <NUM>, and a second side <NUM> that is opposed to the first side <NUM>.

A first vertical stiffener <NUM> is affixed to the upper flange <NUM>, the lower flange <NUM>, and the web portion <NUM> of the second beam <NUM> on the first side <NUM> of the second beam <NUM>. In one embodiment, the first vertical stiffener <NUM> is fabricated from <NUM> (<NUM> inch) thick steel plate, and is affixed by seam welding to the upper flange <NUM>, the lower flange <NUM>, and the web portion <NUM> of the second beam <NUM> on the first side <NUM>.

A second vertical stiffener <NUM> affixed to the upper flange <NUM> , the lower flange <NUM>, and the web portion <NUM> of the second beam <NUM> on the second side <NUM> of the second beam <NUM>. In one embodiment, the second vertical stiffener <NUM> is fabricated from <NUM> (<NUM> inch) thick steel plate, and is affixed by seam welding to the upper flange <NUM> , the lower flange <NUM>, and the web portion <NUM> of the second beam <NUM> on the second side <NUM>.

The vertically-oriented lock-in bracket <NUM> is affixed to the second beam <NUM> at a location that is adjacent to one of the first beams <NUM> of the columns <NUM>.

The vertically-oriented lock-in bracket <NUM> includes a third beam <NUM> having a flange portion <NUM> and a web portion <NUM>, and a bracket horizontal stiffener <NUM>. The web portion <NUM> of the third beam <NUM> is affixed to the first vertical stiffener <NUM> of the second beam <NUM> at a lower portion <NUM> of the third beam <NUM>, by seam welding, tack welding, or another joining process. A second plurality of through bolt holes <NUM> are formed on the flange portion <NUM> of the third beam <NUM> at an upper portion <NUM> thereof.

When the floor plate <NUM> is disposed at a design level <NUM> on the vertical support core <NUM> (as shown with reference to <FIG>) the first plurality of through bolt holes <NUM> in the first flange <NUM> of the first beam <NUM> are disposed opposite to and correspond to the second plurality of through bolt holes <NUM> that are disposed on the upper portion <NUM> of the flange portion <NUM> of the third beam <NUM>. In one embodiment, the first plurality of through bolt holes <NUM> in the first flange <NUM> of the first beam <NUM> are configured as oversized bolt holes that are elongated in the z-direction, i.e., in parallel with the vertical axis to enable vertical adjustment of the floor plate <NUM> when disposed at the design level <NUM> on the vertical support core <NUM>. When the floor plate <NUM> is disposed at the design level <NUM> on the vertical support core <NUM>, the plurality of torque-critical attachment fasteners <NUM> are inserted through the first plurality of through bolt holes <NUM> and the second plurality of through bolt holes <NUM> and secured thereto using nuts, lock washers, and/or other bolt fasteners.

The vertically-oriented lock-in bracket <NUM> is affixed to the second beam <NUM> of the floor plate <NUM> and is slidably arranged on the first beam <NUM> of the vertical support core <NUM> when the floor plate <NUM> is disposed at the assembly level <NUM>.

A bracket horizontal stiffener <NUM> is affixed to the lower portion <NUM> of the third beam with a planar orientation in the horizontal plane, i.e., the bracket horizontal stiffener <NUM> is orthogonal to the flange portion <NUM> and the web portion <NUM> of the third beam <NUM>.

When the floor plate <NUM> is disposed at the design level <NUM> on the vertical support core <NUM>, the web portion <NUM> of the first beam <NUM>, the web portion <NUM> of the second beam <NUM>, the first vertical stiffener <NUM>, and the second vertical stiffener <NUM> are coplanar, and thus form a continuous vertically-oriented sheet of steel.

A plurality of first horizontal stiffeners <NUM> are affixed to the web portion <NUM> and the first and second flanges <NUM>, <NUM> of the first beam <NUM> by seam welding or by another method. When the floor plate <NUM> is disposed at the design level <NUM> on the vertical support core <NUM>, the lower flange <NUM> of the second beam <NUM>, the bracket horizontal stiffener <NUM>, and one of the first horizontal stiffeners <NUM> that are affixed to the first beam <NUM> are coplanar and thus form a continuous horizontally-oriented sheet of steel. When the floor plate <NUM> is disposed at the design level <NUM> on the vertical support core <NUM>, others of the first horizontal stiffeners <NUM> of the first beam <NUM> are affixed to the first beam <NUM> adjacent to the upper portion <NUM> of the flange portion <NUM> of the third beam <NUM>.

The outer surface <NUM> of the first flange <NUM> of the first beam <NUM> has a slip-critical surface, and an outer surface <NUM> of the flange portion <NUM> of the third beam <NUM> has a slip-critical surface. When the floor plate <NUM> is disposed at the design level <NUM> on the vertical support core <NUM>, the slip-critical surface of the outer surface <NUM> of the first flange <NUM> of the first beam <NUM> is arranged opposite to the slip-critical surface of the outer surface <NUM> of the flange portion <NUM> of the third beam <NUM> to form a slip-critical interface. A slip-critical interface is a joint that relies upon friction between the two elements to effect the joining, and have a low likelihood of slip during the life of the structure, without reliance upon a fastener such as a bolt.

<FIG> schematically illustrates an isometric view of a portion of the system and device for securing one of the floor plates <NUM> to one of the columns <NUM> of the vertical support core <NUM> employing the vertically-oriented lock-in bracket <NUM>. One of the first beams <NUM> of the column <NUM> is attached via the lock-in bracket <NUM> to one of the second beams <NUM>, which is one of the girders <NUM> of the floor plate <NUM>. Also shown is one of the framing members <NUM>, which passes through an opening in the second beam <NUM>. As appreciated, this arrangement is repeated on each of the corners of the vertical support core <NUM>, thus facilitating securement of the floor plate <NUM> to the vertical support core <NUM>.

Claim 1:
A system for securing a floor plate (<NUM>) to a structure, comprising:
a vertical support core (<NUM>) having at least one vertically-oriented column (<NUM>) including a first beam (<NUM>);
wherein the first beam has a first flange (<NUM>), a web portion (<NUM>), and a second flange (<NUM>),
a first plurality of through bolt holes (<NUM>) being formed in the first flange of the first beam, and
the first flange of the first beam having an outer surface (<NUM>);
a floor plate (<NUM>) including at least one horizontal girder (<NUM>) including a second beam (<NUM>), the second beam having an upper flange (<NUM>), a lower flange (<NUM>), and a web portion (<NUM>);
a first vertical stiffener (<NUM>) affixed to the upper flange, the lower flange, and the web portion on a first side (<NUM>) of the second beam;
a second vertical stiffener (<NUM>) affixed to the upper flange, the lower flange, and the web portion on a second side (<NUM>) opposed to the first side of the second beam;
a vertically-oriented lock-in bracket i (<NUM>) including a third beam (<NUM>) having a flange portion (<NUM>) and a web portion (<NUM>), and a bracket horizontal stiffener (<NUM>);
wherein the web portion of the third beam is affixed to the first vertical stiffener of the second beam at a lower portion (<NUM>) of the third beam, and
wherein a second plurality of through bolt holes (<NUM>) are formed on the flange portion of the third beam at an upper portion (<NUM>) thereof; and
a plurality of bolts (<NUM>);
wherein, when the floor plate is disposed at a design level (<NUM>) on the vertical support core, the first plurality of through bolt holes in the first flange of the first beam are disposed opposite to and correspond to the second plurality of through bolt holes disposed on the upper portion of the flange portion of the third beam; and
wherein, when the floor plate is disposed at the design level on the vertical support core, the plurality of bolts are inserted through the first plurality of through bolt holes and the second plurality of through bolt holes and secured thereto,
the system characterized in that when the floor plate is disposed at the design level on the vertical support core, the web portion (<NUM>) of the first beam, the web portion (<NUM>) of the third beam, the first vertical stiffener (<NUM>) and the second vertical stiffener (<NUM>) are coplanar.