Note: Descriptions are shown in the official language in which they were submitted.
CA 02394057 2002-07-18
r
1 METHODS AND APPARATUS FOR
2 BUILDING TAIL VERTICAL STRUCTURES
3
4 CROSS REFER~NC~E TO RELATED APPLICATIONS
The present application is a continuation-in-part of U.S. Patent application
6 serial number 10/131,838, filed April 25, 2002, and entitled "Methods and
Apparatus
7 for Forming Concrete Structures°, which claims priority under 35
U.S.C. ~ 120 to
8 U.S. Provisional Patent Application Serial No. 60/313,538, filed August 20,
2001 and
9 hereby incorporated herein by reference in its entirety. The present
application
further claims priority under 35 U.S.C. ~ 120 to U.S. Provisional Patent
Application
11 Serial No. 60/351,213, filed January 23, 2002 and hereby incorporated
herein by
12 reference in its entirety.
13
14 FIELD OF THE iNVENT10N
The invention claimed and disGosed herein pertains to apparatus and
16 methods for building relatively tall vertical structures, such as high-rise
buildings and
17 the like.
18
19 BACKGROUND OF THE INVENTION
This invention pertains to methods and apparatus for building relatively tall
21 vertically-oriented, or near-vertical, structures. "Near-vertical" means
that the
22 structure, or segments of whole structures, can be purposely constructed at
a slope
23 (or "out-of-plumb°, which is not to be confused with construction
plumbness
24 tolerances), tapered (so that an inside or outside surface is not plumb),
curved in
vertical section (for example, as in a cooling tower structure), or a
combination of
26 these geometryes. Examples of such vertical or near-vertical structures
include,
27 without limitation, towers, high-rise buildings for office, residential,
parking and
28 commercial space, and storage and industrial plants (such as manufacturing
or
29 process plants).
Modem high-rise building designs are generally based on a steel-braced
3 t frame with a glass curtain wall facade and a central shear-stiffening
element which is
32 typically a reinforced concrete shell core in which is commonly used to
house
33 elevators and utility ducts. To build to great heights while affording the
greatest
34 lateral stiffness and stability for a given structural weight, the primary
vertical load
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1 bearing members or columns of such high-rise buildings are an-ayed around
the
2 perimeter of the structure to thereby provide the largest sectional moment
for a given
3 area or weight of structural section.
4 The prior art method of modern high-rise construction is basically a floor-
by-
floor approach wherein an array of columns are continually spliced one on top
of the
b other in an upward progression and floor beams, girders, or trusses are
spanned
7 between these columns to define floors and to brace the columns from
buckling.
8 Concrete is used in the building as floor diaphragms and shear core
material, being
9 either pre-cast (in the case of some floor material) or cast with
conventional methods
(which is typically the approach for shear cores) as the high-rise progresses,
with
11 each floor providing a work platform to set pre-cast or form and pour the
concrete
12 immediately on or adjacent to that floor.
13 A recent nuance of high-rise structural design is to limit the number of
14 perimeter columns so that the view from inside the high-rise is less
obscured and so
that the architecture can be more dramatic. For better economics and stability
these
16 columns are typically steel cylinders filled with high strength low density
concrete, a
17 composite design intended to optimize the economics of the overall
structure so that
18 it may be practical to attain great heights. Another recent addition to
high-rise
19 buildings is to provide an active weight at or near the top of a building
to dampen the
oscillation amplitude of the structural response to wind-induced deflections.
21 There are several generally universal structural themes in prior art high-
rise
22 construction: (1 ) the stability of the perimeter steel braced frames is
dependent on
23 the floor structure or floor diaphragms attached to them; (2) braced frames
are
24 generally a weak-link system in that the primary gravity force load paths
are not
significantly redundant - that is, if the integrity of even one of these
perimeter
2G columns is lost anywhere along the height of the building, there is a
reasonable
27 possibility that such a failure will precipitate the collapse of the entire
building; (3)
28 construction dependence is linear and repetitive for weak link structures;
(4) if a
29 single floor drops below onto another floor, a "pan caking" effect can take
place,
resulting in the catastrophic failure of the entire building; (5) with the
advent of lighter
31 building materials and designs, the natural ability of a heavy structure to
dampen the
32 oscillations due to wind have been replaced by expensive active weight
dampening
33 systems at the top of the buildings; (6) the linear dependence in
construction
34 activities and the continuous repetition that characterizes prior art high-
rise
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1 construction methods make it relatively inefficient and makes for long
construction
2 durations; and (7) the floor based discretization of high-rises is
needlessly restrictive
3 to architecture, uses, and operation.
4 In my U.S. Patent Application Serial No. 10/131,838 I describe that prior
art
methods of constructing relatively short concrete structures, such as shear
walls,
6 typically employ conventional forming techniques. For relatively short
structures,
7 such as straight walls, conventional reinforced plywood forms are frequently
used.
8 For forming relatively short curved walls, prior art construction methods
include those
9 described in U.S. patent Nos. 4,915,345 (lehmann) and 5,125,617 (Miller et.
al.).
Prior art methods for constructing relatively tall closed-form concrete
structures
11 typically employ one of two approaches: (1 ) the jump-form method of
construction,
12 as generally described in U.S. patent No. 3,871,612 to Weaver, or (2) the
slip form
13 method of construction, such as generally described in U.S. patent No.
5,241,797.
l4 However, relatively tall open-form and combination-form structures are not
addressed by slip-forming or jump-forming, and are not economical with
16 conventional forming methods except as they are done in a "relatively
short" format.
l7 This means that these types of relatively tall, open-form structures are
not currently
18 produced in a systematic or machine-like fashion, as are relatively tall
closed-form
19 structures.
Prior art methods of constructing vertical concrete structures also employ the
21 method of segmental casting. Segmental casting or construction is generally
defined
22 as forming sections or segments of a larger reinforced concrete structure
(e.g. a
23 closed-form structure such as a silo, or an open-form structure such as a
tall
24 retaining wall) in vertical or near vertical segments which are cast with
discrete
horizontal or near-horizontal levels or cold joints (as in jump-forming) or in
a
26 continuous fashion (as in slip-forming). A complete structure is
constructed by
27 casting multiple, vertical or near-vertical segments either immediately
adjacent to
28 each other, or with gaps between them which are later filled with filler or
closure
29 segments which are cast in the same or similar manner. A structure cast in
vertical
segments can be identified as having vertical or near-vertical construction
joints
31 running the full height of the structure.
32 The distinction of "relatively tall" and "relatively short" structures is
best
33 defined by the construction methods typically employed to construct these
34 structures, and the inherent technical and economic reasons for using such
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1 methods. Tall structures tend to be closed-form structures for storing bulk
materials,
2 and so that they will be of sufficient rigidity and strength to contain the
stored
3 materials and, even during construction, they will be of sufficient rigidity
and strength
4 against horizontal loadings such as wind and seismic forces. Tall, closed-
form
structures also tend to be prismatic, and are often symmetrical about the
vertical
6 axis. Accordingly, there are economic efficiencies to be gained in taking a
less labor
7 intensive, more system-like or machine-like approach to forming the closed-
shape.
8 As a result, the prior art method typically employed is jump-forming or slip-
forming,
9 which lend themselves more readily to discrete or continuous casting of tall
structures. Short structures typically do not have the geometric efficiencies
of tall
I 1 structures and construction methods thereof typically employ conventional
forming
12 methods rather than more specialized methods such as jump-forming or slip-
forming.
13 In conventional forming methods the concrete forms are often close enough
to the
t4 ground or floor level to allow for an entirely different means of external
stability than
is afforded when the forms are a great distance from the ground, and therefore
allow
16 for a less costly platform, work deck, or floor access to the work. A shear
wall
17 chamber in a building, for example, though it may be relatively tall
compared to the
18 building itself, is normally constructed between floors, using each floor
as a work
19 platform, and therefore it is not considered "relatively tall". Such a wall
would,
however, be considered as "relatively tall" if it is free-standing for at
least several
21 floor heights or more during construction. In summary, relatively short
structures are
22 those which are typically produced using conventional forms because they
are only a
23 few stories tall and can therefore be economically accessed and manipulated
from
24 the ground or floor level, and relatively tall structures are those which
are more than
a few stories tall and require more of a machine-type approach to be most
26 economically accessed and manipulated to accomplish the casting of
reinforced
27 concrete.
28 In the prior art jump-form method of construction, a cylindrical shell
(closed-
29 form) structure is produced using a series of inside and outside steel
forms
continuously attached together within either of the two concentric rings, but
not
31 between the rings. The rings are stacked one upon another and poured with
32 concrete one level (levels typically vary 2' to 8' high) at a time until
such time as they
33 are 2 or more levels high. Then the bottom-most set of inside and outside
forms are
34 "jumped" or stacked on top of the top-most set of forms. This "jump"
process is
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l repeated until the structure height is achieved. Such an approach realizes a
2 structure comprised of vertically-stacked, monolithic closed-form rings
(typically 2' to
3 6' in height and 8" to 2' in thickness) with "cold" construction joints
between rings.
4 important elements of the prior art jump-form method of construction are as
follows:
(1) The forces of the fluid concrete are resolved in the hoop rigidity of the
circular
6 ring of forms, and therefore the diameter of the structure is limited to a
finite
7 diameter, the fluid concrete forces of which are not greater than the
tensile capacity
8 of the forms and form fasteners; (2) the forms are moved upward separately
of the
9 work deck by mechanically "jumping" them with jib cranes to the next level,
and the
work deck moves upward with the use of climber winches which thrust off of the
I 1 inside forms or off of supports which support from the ground and/or
intermittently
i2 along the height of the inside surface of the structure; (3) plumbness of
the structure
13 is maintained by references with a transit or plumbob and repositioning of
the form
14 heights about the vertical axis of the structure in subsequent "jumps"; (4)
the work
I S deck is only on the inside of the concrete cylinder being constructed; (5)
in order to
16 raise the inside forms, the work decking must be removed or tilted out of
the way
17 frequently, or gaps must be left between the deck and the wall face; (6)
the jump
18 form system must be thoroughly assembled and configured into a cylindrical
shape
19 from a large number of small, modular pieces; and (7) the forms are
released from
the ~ncrete surface by prying them off manually, typically one-at-a-time.
21 !n the slip-form method of construction, a closed-form shell structure is
22 effected by moving a single level of concentric, typically plywood forms
(commonly 4'
23 tall) continuously upward while installing rebar and pouring concrete until
the
24 structure height is achieved. Such an approach realizes a structure that is
essentially monolithic throughout to the extent that the constructor keeps the
26 operation continuous and there are no cold joints. Important particulars of
the slip-
27 form method of construction are the following: (1) unlike the jump-form
method, the
28 inside and outside forms are tied together with yokes (spaced approximately
every 2'
29 to 8', depending on the structure requirements for the form, around the
entire
perimeter of the structure section) and therefore the forces of the fluid
concrete are
31 resolved in the moment rigidity of the form-yoke combination; (2) the forms
hold
32 themselves and the accompanying work deck to the structure via a
combination of
33 pipes (which become buried in the concrete of the structure) and jacks that
tie into
34 the form-yoke system; (3) the forms and work decks) move upward together
via
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l thrust of the jacks on the pipes; (4) plumbness of the structure is
maintained by
2 references with a transit or plumbob and the form-deck system is re-oriented
about
3 the vertical axis of the structure by differential movement of the many
jacks that
4 support the forms and deck around the perimeter of the structures. There is
an
inherent flexibility of the pipes which, in conjunction with any imbalance of
the deck
6 load, often causes the deck and forms to "spin" or "sway". This must be
controlled
7 by some means of bracing the pipes against the structure andlor rebar in the
8 structure. There is currently no standard practice for controlling sway; (5)
the main
9 work deck is primarily on the inside of the shell or walls of the closed-
form structure
being constructed, with a swing scaffold hanging from the outside forms to
allow
11 finishing of the concrete surface; (6) the inside work deck spans across
the diameter
12 or span of the structure and is often comprised of the roof beams and roof
decking;
13 (7) the work deck is constructed such that there is little or no gaps
between the deck
14 and the forms; (8) the slip-form is typically not modular or re-usable and
must be
thoroughly constructed and configured into the closed-form shape from a large
l6 number of raw material pieces such as steel beams, lumber, and plywood; and
(9)
17 the forms are released from the concrete formed surface automatically and
18 continuously since slip-forming is a continuous process.
19 In the conventional forming method for relatively "short" closed-form and
open-form structures; a structure is produced by attaching the typically
rectangular
21 forms together into panels to form a partial or total wall or structure
height. These
22 panels are then backed by whalers to stiffen them between tie points, are
tied
23 through the wall by snap ties or tapered through-bolts, and are usually
braced or
24 "kicked" to the ground or to a nearby floor level or structure with strut
supports to
plumb and stabilize the forms. Curvilinear structures are produced with either
26 increments of straight forms or with special curvable forms. These
specialized forms
27 are a modified version of the straight form, with allowance for the form
stiffeners
28 andlor whaler systiem to be set manually to a certain radius. In either the
straight
29 wall or curved wall conventional form systems the work platform typically
has no
particular function other than as access to the work at the top of the forms.
31 Important particulars of the conventional forming method of construction
are as
32 follows: (1) Unlike the jump-form method or the slip form method, the
inside and
33 outside forms are tied together with special ties that remain in the
concrete, or with
34 tapered through-bolts which are extracted after casting the concrete, and
therefore
6 Case RU01-P06
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1 the forces of the fluid concrete are resolved in the tensile rigidity of the
tie or through-
2 bolt; (2) the forms and work platforms) are moved upward manually and
separately
3 after removal of the ties or through-bolts, and typically a level of forms
is left at the
4 top of a pour to rest the next set of forms upan; (3) plumbness of the
structure is
maintained by references with a level, transit or plumbob, and the form-
platform
6 system is re-oriented about the vertical axis of the structure by adjusting
the kicker
7 struts; (4) the work deck is attached to the forms and therefore spans along
the
8 perimeter (as compared to jump-forms and slip-forms which span across the
formed
9 opening); (5) the work platform being attached to the forms has a small gap
between
them and the form; (6) the conventional form system must be thoroughly
assembled
11 and configured from a large number of small, modular pieces to form a
structure; and
12 (7) the forms are typically released manually from the formed surface by
prying
13 action.
14 There are several shortcomings with the prior art. Specifically: (1 )
vertical
segmental construction is not addressed by jump-form or slip-form methods of
16 construction; (2) although segmental construction is addressed by
conventional
17 means, only relatively short structures can be economically effected by
conventional
18 means (i.e., conventional forming methods of construction are not
economically
19 adaptable for construction of relatively tall, closed-form or open-form
structures); (3)
although accurate geometric measurement is possible with all methods of
21 construction given modem surveying equipment, accurate geometric control is
not
22 inherently achievable for relatively tall and/or large footprint structures
constructed
23 with the current jump-form or slip-form methods of construction; (4) modern
jump-
24 forming and slip-forming techniques are very labor intensive; (5) none of
the three
concrete forming methods described above (jump-forming, slip-forming, and
26 conventional forming) are readily adaptable to both discrete and continuous
forming;
27 (6) the methods by which jump-fom~s, slip-forms, and conventional forms are
borne
28 by the evolving structure is cumbersome to productivity; (7) in all three
forming
29 methods there are significant limitations on geornetries due to the method
of
resolution of the hydrostatic force of the concrete between the inside and
outside
31 forms; and (8) jump-forming inherently does not allow for a work deck on
the outer
32 ring of forms.
33 None of the prior art methods of constructing concrete structures address
34 both discrete and continuous modes of operation in the vertical or near
vertical
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1 direction. Jump-forms are not designed, nor are they readily adaptable for,
slip
2 (continuous) forming. Slip-forms are not designed, nor are they readily
adaptable
3 for, discrete forming. Although discrete forming with slip-forms may be an
4 inadvertent result of stopping the slip form operation and letting the
concrete set-up,
it is not an intended function, nor is it a simple matter to get a slip-form
moving again
6 when the concrete sticks solidly to the forms. Conventional form systems are
either
7 designed to be used for horizontal slip-forming (e.g. a tunnel slip-form) or
are
8 designed for static (discrete) casting. They cannot be readily transitioned
for use in
9 a bi-model fashion.
Slip forms, though relatively failsafe in the sense that the support pipes are
11 continuously buried in the wall, are inherently cumbersome for placing
rebar and
12 concrete because the pipe and yoke system repeats itself so frequently
around the
13 perimeter. Because of this, structures with dense rebar andlor large
perimeters are
14 impractical with slip-fom~ing. The through-bolt or tie system which holds
conventional forms to the concrete structure also support the work platforms.
This
16 "tie-through" method of resolving the hydrostatic forces from the concrete
and
17 attaching the forms to the concrete is cumbersome to upward progression
because
18 of the labor-intensive process of removing and re-inserting bolts or ties.
19 In the prior art chord-form method of construction a vertical portion or
vertical
segment of a cylindrical structure is formed by tensioning the concentric set
of jump-
21 forms (of the type described in U.S. Patent No. 3,871,612, being
approximately 4' tall
22 by 6' long) to buttress trusses which are positioned vertically at either
end of the
23 vertical segment in modular lengths that are a multiple of the form height.
A chard
24 deck and an outside wrap-a-round deck span between these buttress trusses,
allowing access to both sides of the segment of jump forms. As with jump-
forming,
26 jib cranes are used to raise or "jump" the forms and climber winches are
used to
27 raise the chord deck that interfaces with the perimeter of the evolving
wall segment.
28 As a supplementary hoisting method to the climber winches, the inside and
outside
29 chord trusses and attached work~eck are hoisted by way of hydraulic
cylinders
along guides on the buttress trusses. Closure segments are effected by
31 reconfiguring parts of the buttress trusses and bolting them to the
adjacent
32 segments.
33 There are a number of shortcomings with the prior-art chord-form method:
(1)
34 As with the classical jump-form method which relies on the hoop tensile
capacity of
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l
1 the forms to resolve the hydrostatic forces from the concrete, there is a
practical
2 limitation on both the geometry and maximum diameter which can be achieved.
The
3 geometry is limited to curved walls, and the radius of the curved wall is
limited to that
4 finite value where the fluid concrete forces are not greater than the
tensile capacity
of the forms and form fasteners. A 60' radius curve is the practical limit for
using
b these types of forms; (2) As with jump-forming, the chord-form method
requires two
7 or more levels of forms, and it requires that these forms be "jumped", a
very labor
8 intensive process; (3) The chord-form method requires heavy buttress trusses
at
9 both ends for the full height of the segment being constructed. The capital
and
mobilization costs associated with these trusses are very high and set-up
times are
11 long, especially for very ta(1 segments; (4) Vertical alignment of the
segment can only
12 be achieved when each new buttress truss is installed, and only to the
degree to
13 which the truss can be tilted out of plumb to correct the alignment.
14 What is needed then is a method of, and apparatus for, constructing
relatively
tall structures, such as high-rise buildings, which achieves the benefits to
be derived
16 from similar prior art methods and devices, but which avoids the
shortcomings and
17 detriments individually associated therewith.
18
19 SUMMARY OF THE INVENTION
One embodiment of the present invention provides for forming a building
21 support structure. The apparatus includes a plurality of inward-facing
concrete fomns
22 arranged adjacent to one another and in a closed-perimeter formation. The
23 apparatus also includes a plurality of truss modules, each truss module
being
24 associated with a respective inward-facing concrete form. The apparatus has
a
plurality of actuator devices, each of which is mounted on a respective truss
module.
26 The actuator devices are conftgured to translationatly move the associated
inward-
27 facing concrete form with respect to the respective truss module. An insert
concrete
28 form, arranged in .a closed-perimeter shape, is configured to be located
within the
29 closed-perimeter formation of the plurality of inward-facing concrete
forms. A yoke
system connects selected truss modules to the insert concrete form. A
plurality of
31 climbing devices are attached to the yoke system and are configured to
engage
32 associated climb rods to thereby move the apparatus along the climb rods.
33 Another embodiment of the present invention provides for a building having
a
34 foundation, a vertically oriented building support structure which is
supported on the
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r
1 foundation, and a building module supported by the building support
structure. The
2 building support stnrcture is defined by a horizontal cross section, which
can be a
3 closed shape, an open shape, or a combination of the two. When the
horizontal
4 cross section of the building support structure inGudes a closed shape, then
the
building support structure can have a perimeter wall forming the closed shape.
(n
6 this case the perimeter watt has an inner surface and an outer surtace, and
the inner
7 surface defines an open inner area within the building support structure.
The
8 building module can then be located juxtaposed to the perimeter wall outer
surface.
9 These and other aspects and embodiments of the present invention will now
l0 be described in detail with reference to the accompanying drawings,
wherein:
11
12 DESCRIPTION OF THE DRAWINGS
13 Fig. 1 is a side elevation view depicting an apparatus in accordance with
an
14 embodiment of the present invention.
Fig. 2 is a plan view depicting truss modules used in the apparatus depicted
in
16 Fig. 1.
17 Fig. 3 is a side elevation sectional view depicting truss modules used in
the
l8 ' apparatus depicted in Fig. 1.
19 Fig. 4 is a rear view depicting a form module and a strut module used in
the
apparatus depicted in Fig. 1.
21 Fig. 5 is a plan view of the form module and strut module depicted in Fig.
4.
22 Fig. 6 is a plan view depicllng frame components of a truss module depicted
23 in Fig. 2.
24 Fig. 7 is a rear view depicting end frames and an actuator frame used in a
truss module depicted in Fig. 2.
26 Fig. 8 is a side elevation view depicting an attitude control module that
can be
27 used in the apparatus depicted in Fig. 1.
28 Fig. 9 is a side elevation view of a climb module that can be used in the
29 apparatus depicted in Fig. 1.
Fig. 10 depicts a plan view of the truss modules of Fig. 2, but with work
31 decking placed on the tops of the trusses.
32 Fig. 10A depicts a plan view detail for a form-extending module.
I O Case RU01-P06
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1 Fig. 11 is a plan elevatwn view of truss modules of a concrete forming
2 apparatus of the present invention that can be used to fomn corners in
vertical
3 concrete structures.
4 Fig. 12 is a plan view of an assembly of apparatus of the present invention
assembled to form a vertical, rectangular concrete structure.
6 Fig. 13 depicts a side view of a high-rise building that can be constructed
7 using methods and apparatus of the present invention.
8 Fig. 14 is a plan sectional view of the building depicted in Fig. 13.
9 Fig. 15 is a partial side sectional view of the building depicted in Figs.
13
and 14.
11 Fig. 16 depicts a partial side view of the building support structure of
the
12 building depicted in Figs. 13 through 15.
13 Fig. 17 is a detail of a comer of the building support structure depicted
in
14 Fig. 14.
Fig. 18 depicts a partial side sectional view of the building support
structure
16 depicted in Fig. 14.
17 Fig. 19 is a detail from Fig. 15, depicting building modules connected to
the
18 building support structure.
19 Fig. 20 depicts a side elevation view of another high-rise building that
can be
constructed using methods and apparatus of the present invention.
21 Figs. 21 and 22 depict plan sectional views of the building of Fig. 24 at
two
22 different locations along the height of the building.
23 Fig. 23 depicts a plan sectional view of another shape of a relatively tall
24 building that can be constructed using methods and apparatus of the present
invention.
26 Fig. 24 depicts a side elevation view of another building support structure
that
27 can be constructed using methods and apparatus of the present invention.
28 Figs. 25 through 27 depict plan views of other building support structures
that
29 can be constructed using methods and apparatus of the present invention.
Fig. 28 depicts an isometric view of the high-rise building of Fig. 13 being
31 constructed in accordance with an embodiment of the present invention.
32 Fig. 29 depicts a side elevation sectional view of another high-rise
building
33 that can be constructed using methods and apparatus of the present
invention.
34 Fig. 29A shows a detail of the foundation of the building depicted in Fig.
29.
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r
1 Fig. 30 depicts a plan sectional view of the building depicted in Fig. 29.
2 Fig. 31 is a detail of the building depicted in Fig. 30, showing the
building
3 support structure.
4 Fig. 32 is a side sectional vierrv depicting a building module support
system
that can be used to connect a building module to a building support structure
in
6 accordance with the present invention.
7 Fig. 33 is a detail from Fig. 32 depicting the junction area between the
building
8 module and the building support structure.
9 Fig. 34 is a side sectional view of the detail depicted in Fig. 34.
Fig. 35 is a plan view depicting a concrete structure forming apparatus in
11 accordance with another embodiment of the present invention.
12 Fig. 36 is a side elevation view of the concrete structure forming
apparatus
13 depicted in Fig. 35.
14 Figs. 37A and 37B depict a side elevation detail of a concrete form sealing
and release device that can be used in the concrete structure forming
apparatus
t 6 depicted in Fig. 35.
17 Fig. 38 is a plan sectional view depicting another building support
structure
18 that can be constructed using methods and apparatus of the present
invention.
l9 Fig. 39 is a partial side view of the building support structure depicted
in
ZO Fig.38.
21 Fig. 40 is a plan view depicting a concrete structure forming apparatus in
22 accordance with another embodiment of the present invention and which can
be
23 used to form the concrete building support structure depicted in Figs. 38
and 39.
24 Fig. 41 is a side sectional view depicting the concrete structure forming
apparatus of Fig. 40 being used to construct the building support structure
depicted
26 in Figs. 38 and 39.
27 Fig. 42 is a side sectional view of an insert concrete form that can be
used in
28 the concrete structure forming apparatus depicted in Figs. 40 and 41.
29 Fig. 43 is a side sectional view depicting a variation of the concrete
structure
forming apparatus depicted in Fig. 41.
31 Fig. 44 is a front view of the concrete structure forming apparatus
depicted in
32 Fig.43.
12 Case RUOI-P06
CA 02394057 2002-07-18
1 Fig. 45 is a side elevation sectional view depicting how the apparatus
2 depicted in Fig. 43 can be used to (OWef seNICe passageway modules into a
building
3 support structure as the building support structure is being constructed.
4 Fig. 46 is a plan sectional view depicting an arrangement for parking
vehicles
in the building depicted in Fig. 29.
5 Figs. 47A and 47B depict plan views of another structure forming apparatus
7 that can be used to form a building support structure of the present
invention.
8 Fig. 48 depicts a side elevation, sectional view of the structure forming
9 apparatus depicted in Fig. 47A.
Figs. 49 depicts a plan view of yet another structure forming apparatus that
11 can be used to form a building support structure of the present invention.
12 Fig. 50 depicts a side elevation, sectional view of the structure forming
13 apparatus depicted in Fig. 49.
14
DETAILED DESCi,~;,IPTION t~F THE INVENTION
i6 The present invention provides for methods and apparatus useful for
17 construction of relatively taU vertical and near-vertical concrete
structures. These
18 shuctures are especially suited for use as the primary structural support
for high-rise
I9 buildings, including residential, commercial and industrial buildings. The
apparatus
allows for such structures to be formed in either a slip-form type casting
mode, a
21 jump-form type casting mode, or a combination of these modes. The apparatus
can
22 be used to produce vertical and near-vertical concrete structures in a
segmental-type
23 casting mode, as well as in a monolithic casting mode. The apparatus of the
present
24 invention may from time-to-time be referred to herein as a "jump-slip
machine" since
it can be used to perform both of these prior art methods of forming concrete
26 structures. The term "jump-slip machine" is appropriate since the apparatus
can cast
27 vertical or near vertical reinforced concrete segments, or whole
structures, in either a
28 discrete (jump) or continuous (slip) mode. The methods and apparatus of the
29 present invention are particularly useful for forming any size of closed-
form, open-
form, or combination-form reinforced concrete vertical structures which can be
used
31 itself as a commercial or industrial building, or as the primary structural
component of
32 a residential, commercial or industrial building.
33 The apparatus of the present invention can include the apparatus described
in
34 my U.S. Patent application serial number 10/131,838, as weN as modified
variations
13 Case RU01-P06
CA 02394057 2002-07-18
1 thereof. One embodiment of the apparatus described in my U.S. Patent
application
2 serial number 10/131,838 provides for a concrete forming apparatus having
radially-
3 matched pairs of automatically or semi-automatically retractable (self
releasing) form
4 modules that can be actuated automatically and/or manually into rectilinear,
curvilinear, or geometric combination sub-segments with the use of
translational
6 actuators and/or adjustable length struts which bear upon and reference to
7 supporting truss modules. The apparatus can further include a work-deck
("deck")
8 portion which can move translationally with the forms, and preferably
conform to the
9 plan-view shape of the forms by way of an overlapping fan type work-deck
plates
and telescoping handrails. Very large, very complex vertical concrete
structures can
11 be formed when several of these types of apparatus are joined together in
series,
12 and when specialized versions of the apparatus (such as comer-forming
13 adaptations) are used.
14 As stated previously, the apparatus of the present invention can cast
monolithically, as well as in vertical segments. Further, the apparatus can
16 accomplish continuous casting (slip-forming) as well as discrete casting
(jump-
17 forming). Virtually any structure geometry can be formed using the
apparatus of the
18 present invention, including but not limited to structures that are
straight or curved,
19 prismatic or tapered, and stepped or non-stepped. In addition, the
apparatus of the
present invention uses significantly fewer components than prior art
apparatus,
21 requires less manpov~ier to operate, and provides improved geometric
control over
22 prior art methods of forming vertical concrete structures.
23 Turning now to Fig. 1, one embodiment of an apparatus 100 in accordance
24 with the present invention is depicted in a side elevation view. This
particular
embodiment was described in my U.S. Patent application serial number
101131,838.
26 The concrete forming structure 100 is depicted in the process of forming a
vertical
27 concrete structure or wall "W", which is supported on foundation "F". The
wail "W"
28 can be a segment of a structure which will comprise adjoining segments, or
it can be
29 considered as a cross section of a monolithic structure. A climb rod or
climb pipe 99
is embedded in the wall "W" and the foundation "F", and is used by the
31 apparatus 100 to pull itself upward in direction "Y", as will be described
more fully
32 below. The apparatus 100 includes first forming assembly (also known as a
33 "concrete forming module) 102 and second forming assembly {"concrete
forming
34 module") 104. First forming assembly 102 supports a first concrete form
114, and
14 Case RU01-P06
CA 02394057 2002-07-18
1 second forming assembly 104 supports a second concrete form 116. Concrete
2 forms 114 and 116 are in spaced-apart, generally parallel orientation to one
another,
3 thus defining void area 90 into which liquid concrete can be poured to
generate the
4 wall "VV". Preferably, forms 114 and 116 are fabricated in a semi-flexible
manner to
allow them to be urged into curvilinear shapes, as will be described more
fully below.
6 Forms 114 and 116 are preferably moveably supported by respective truss
7 modules 118 and 120. Truss modules 118 and 120 are in turn attached to the
8 respective yoke arms 103 and 105 of the yoke module 106. (Yoke arms 103
9 and 105 generally form a yoke, which is unnumbered in the figure.) Yoke
module 106 includes the climbing module 108 ("climbing device"), which can
engage
11 the climb rod 99, allowing the whole apparatus 100 to be pulled upward or
lowered in
12 direction "Y". A work deck (or "deck") comprises first deck portion 110 and
second
13 deck portion 112, which are attached to respective forms 114 and 116, and
14 supported by respective truss modules 118 and 120 in a moveable fashion to
allow
the deck portions 110 and 112 to be able to move translationally (i.e.,
towards or
16 away from the wall "W ) with respect to the truss modules 118 and 120.
17 As a general description of the operation of the apparatus 100 of Fig. 1,
the
18 truss modules 118 and 120 allow the respective forms 114 and 116 to be
placed into
19 proper position for the fom~ing of concrete to form the wall "W". Actuator
mechanisms 122 and 126 (associated with form 114) and actuator mechanisms 124
21 and 128 (associated with form 116) allow the individual forms 114, 116 to
be moved
22 in directions X and X', relative to the wall "W" and the truss modules 118
and 120. In
23 this way the forms can be retracted from the wall and the apparatus 100 can
then be
24 moved upward (In direction "Y"), as in a jump-forming operation. Likewise,
the
forms 114 and 116 can be maintained in the concrete forming position while the
26 apparatus 100 is moved upward, as in a slip-forming operation. The manner
in
27 which the apparatus 100 is operated (slip-form or jump-form) will depend on
a
28 number of variables, such as the type of structure being formed and the
desired
29 surface ftnish of the final structure. Further, forms 114 and 116 are
preferably made
from a semi-flexible material, such as heavy gauge sheet steel, to allow them
to be
31 deformed from a flat shape into a curved shape, as will be shown and
described
32 further below. The form 114 and 116 are preferably made from steel, the
thickness
33 of which will depend on the anticipated hydrostatic force of wet concrete
contained
34 between the walls, as well as the shape of the structure to be formed. For
structures
15 Case RU01-P06
CA 02394057 2002-07-18
1 with a relaitvely small radius of curvature in the plan view, thinner steel
will be used
2 for the forms 114, 116 to allow the farms to be urged into the proper shape.
The
3 forms 114, 116 can be further strengthened against hydrostatic forces by the
use of
4 vertically-oriented form stiffening members placed on the outside of the
forms (i.e.,
the side opposite the side which contacts the concrete in the void area 90).
6 The form assemblies 102 and 704 can further include the respective first and
7 second attitude control modules 130 and 132, which are more fully described
below.
8 in addition to providing attitude control (i.e., to "steer" the apparatus
100 in direction
9 X or X'), the attitude control modules 130, 132 also perform the function of
providing
a force-reacting member to generate reaction forces against the wail "W"
resulting
11 from the forces exerted on the forms 114, 116 by the actuator mechanisms
122, 124,
l2 126 and 128. Accordingly, the first and second attitude control modules 130
and 132
13 may also be properly known as respective "first and second reaction force
14 members".
Turning now to Fig. 2, the truss modules 118 and 120 of the apparatus 100 of
16 Fig. 1 are depicted in plan view. Truss module 118 is comprised of first
and second
17 end frames 138 and 140, and actuator frame 134, which is preferably
centered
18 between the end frames. End frame 138 and actuator frame 134 are spaced
apart,
19 and connected, by first space frame 146, while end frame 140 and actuator
frame 134 are spaced apart, and connected, by second space frame 148. Space
21 frames 146 and 148 will be described in more detail below. The two space
frames in
22 each truss module 118, 120 generally form an articulable space frame
assembly, so
23 that the apparatus 100 includes first and second articulable space frames.
Truss
24 module 118 supports work deck 110 (Fig. 1 ) by work deck support system
202,
described more fully below. A series of adjustable struts 155, 156, 206, 208
are
26 connected at a first end to form 114, and at a second end to actuators
(described
27 below) which are supported by actuator frame 134. As will be described more
fully
28 below, struts 155 156, 206, 208 allow form 114 to be moved translationally
in
29 directions X and X', and also allow the form 114 to be deformed from the
fiat shape
depicted in Fig. 2.
31 Truss module 120 of Fig. 2 is constructed similarly to truss module 118.
That
32 is, truss module 120 is comprised of first and second end frames 142 and
144, and
33 actuator frame 136, which is preferably centered between the end frames.
End
34 frame 142 and actuator frame 136 are spaced apart, and connected, by space
16 Case RU01-P06
CA 02394057 2002-07-18
1 frame 150, while end frame 144 and actuator frame 136 are spaced apart, and
2 connected, by space frame 152. Truss module 120 supports work deck 112 (Fig.
1 )
3 by work deck support system 204. A series of adjustable struts 158, 160,
210, 212
4 are connected at a first end to form 116, and at a second end to actuators
supported
by actuator frame 136. Struts 158, 160, 210, 212 allow form 116 to be moved
6 translationaliy in directions X and X', and also allow the form 116 to be
deformed
7 from the flat shape depicted in Fig. 2. The struts 155, 156, 206, 208, 158,
160, 210
8 and 212 can either be passive, in that they merely track movement of the
strut
9 actuators 196, 198 (described below), or they can be active, in which case
they can
be adjusted to a desired length by mechanical means (such as by internal screw
t 1 threads, or hydraulic pressure) and thereby be used to adjust the shape of
the
12 forms 114, 116.
13 The system of struts (155, 156, 206, 208, and 158, 160, 210, 212) in each
14 truss module (118, 120) can be known as respective first and second strut
modules.
Preferably each form 114 and 116 is provided with at least two adjustable
struts, and
16 preferably four adjustable struts. In the embodiment described below, each
form 114
17 and 116 is provided with eight adjustable struts arranged in a 4X2
arrangement (i.e.,
18 four struts oriented in a first horizontal plane, and four more struts
arranged in a
19 second horizontal plane which is parallel to the first horizontal plane).
Turning now to Fig. 3, a side elevation sectional view of the truss
21 modules 118 and 120 of Figs. 6 and 7 is depicted. In the view depicted in
Fig. 3 the
22 section line has been taken adjacent each of the actuator frames 134 and
136.
23 Further, the struts (155, 156, 206, 208, 158, 160, 210, and 212) depicted
in Fig. 2
24 have been removed in Fig. 3 for clarity. Each truss module 118 and 120 in
Fig. 3 is
provided with yoke brackets 180 to allow the yoke (106, Fig. 1) to be attached
to the
26 truss modules. Each truss module 118 and 120 is further provided with
attitude
27 module brackets 178 to allow the attitude modules 130, 132 of Fig. 1 to be
attached
28 to the truss modules.
29 Truss module 118 (Fig. .3) includes upper actuator frame 134, as well as
lower
actuator frame 174; truss module 120 includes upper actuator frame 136, as
well as
31 lower actuator frame 176. Lower actuator frames 174 and 176 are held in
spaced-
32 apart relationship from respective upper actuator frames 134 and 136 by
respective
33 rectangular main frames 248 and 249. Adjacent each actuator frame 134, 136,
174,
34 176 are space flame brackets 182, which allow the space frames (146, 148,
150,
17 Case RU01-P06
CA 02394057 2002-07-18
1 152, Fig. 2) to be attached to the actuator frames (e.g., space frame 148 of
Fig. 2 is
2 attached to actuator frames 134 and 174, and space frame 152 is attached to
3 actuator frames 136 and 176). Each actuator frame 134, 174, 136 and 176
supports
4 actuator devices or mechanisms ("actuators"), which will be described more
fully
below. The use of two actuator frames for each truss module provides improved
6 control over positioning of the forms 114 and 116, and allows additional
geometric
7 control and shaping of the final form of the concrete structure to be
produced.
8 Forms 114 and 116 are attached to respective actuator brackets 170 and 172,
9 which are in turn attached to first and second upper actuator shafts
(actuator
! 0 members) 184 and 186, and first and second lower actuator shafts 188 and
190, by
I 1 hinged connectors (e.g., pins, ball joints, or any such pivotal connector)
192, allowing
12 movement of the actuator brackets 170, 172 with respect to shafts 184, 186,
188
13 and 190 (Fig. 3). Actuator brackets 170, 172 serve to distribute the force
exerted by
14 the actuator shafts 184, 186, 188 and 190 over the face of the forms 114
and 116,
and also serve to stiffen the forms against the hydrostatic forces of wet
concrete
1 b contained between the forms. Decks plates 110 and 112 are attached to
respective
17 actuator brackets 170 and 172 by respective hinges 162 and 164, allowing
rotational
18 movement (clockwise or counterclockwise, as viewed in Fig. 3) of the deck
19 plates 110 and 112 with respect to forms 114 and 116. This allows the forms
114
and 116 to be "tilted" (as in 116a), while leaving the decks 110, 112 level
with the
21 ground. Decks 110 and 112 are also provided with respective handrails 166
22 and 168. Deck 110 is supported on truss module 118 by deck support system
202,
23 and deck 112 is supported on truss module 120 by deck support system 204.
The
24 deck support systems 202, 204 will be described more fully below.
Preferably, lower
pivotal connection 192 is a connection (such as a slotted connection) which
allows
26 slight vertical movement of the form (114 or 116) with respect to the upper
pivotal
27 connection (also 192), to allow the form (114, 116) to "tilt" (as in 116a)
without
28 causing a binding.of an actuator member (184, 186, 188, 190) in the
associated
29 actuator frame (134, 136, 174, 176, respectively). This feature will
account for the
effective "shortening" in the effective height of a form face as it is tilted
relative to the
31 other form face.
32 Actuator shafts 184, 186, 188 and 190 are preferably smooth at the area
33 where they enter bushed bores (not numbered) in the actuator frames 134,
136, 174
34 and 176 proximate the forms 114 and 116. Thereafter, the shafts 184, 186,
188
1 g Case RU01-P06
CA 02394057 2002-07-18
1 and 190 are preferably threaded so that they can be engaged by screw-thread
2 actuators 196, 198 and 200. Although hydraulic actuators can be used for
3 actuators 196, 198 and 200, screw thread actuators are preferable since they
4 provide positive engagement of the shafts 184, 186, 188 and 190, even in the
event
of loss of power. The screw-thread actuators 196, 198, 200 can be actuated by
6 electric motor, hydraulic force, or manually. Each actuator frame 134, 136,
174
7 and 176 comprises first and second strut actuators (actuator devices) 196
and 198
8 which are preferably moveably mounted in actuator frames 134, 136, 174 and
176,
9 and the actuators 196, 198 are preferably configured to move along guides
194
within each actuator frame. Actuators 196 and 198 are preferably screw thread
1 i actuators (such as screw jacks), and engage the threads of shafts 184,
186, 188
12 and 190. Each strut actuator 196, 198 is preferably connected to two
struts. This
13 can be seen by viewing Fig. 3 in conjunction with Fig. 4. Fig. 4 is a rear
elevation
14 sectional view of truss module 120 of Fig. 3 with the section being taken
immediately
behind strut actuators 196, and shows the struts associated with module 120.
16 Specifically, struts 160 and 158 are connected to upper strut actuator 196
in upper
17 actuator frame 136, struks 212 and 210 are connected to upper strut
actuator 198
18 (not seen in Fig. 4) in upper actuator frame 136, struts 214 and 216 are
connected to
19 lower strut actuator 196 in lower actuator frame 176, and struts 218 and
220 are
connected to lower strut actuator 198 (not seen in Fig. 4) in lower actuator
21 frame 176. The system of struts (158, 160, 210, 212, 214, 216, 218 and 220
of
22 Fig. 4) can alternately be termed a "strut module" or a form-shaping
module, the
23 latter comprising form-shaping members (e.g., any or all of the indicated
struts). The
24 actuator frames are not specifically shown, and are not numbered, in Fig.
4. Viewing
Fig. 2 and Fig. 3 together, struts 155 and 156 are connected to upper strut
2b actuator 196 in upper actuator frame 134, and struts 206 and 208 are
connected to
27 upper strut actuator 198 in upper actuator frame 134. Lower strut actuators
196
28 and 198 in lower ,actuator frame 174 are similarly connected to struts that
are
29 equivalent to struts 214, 216, 218 and 220 of Fig. 4. Each of the eight
strut
actuators 196 and 198 can be individually actuated, or they can be actuated in
31 concert, or in any combination. When strut actuator 196 or 198 is actuated,
and the
32 respective shaft 184, 186, 188 or 190 is held in a fixed position in the
actuator frame
33 (134, 136, 174, 176), then the actuator 196 or 198 is caused to move along
34 guides 194 within the actuator frame in a transiational position relative
to the shaft,
19 Case RU09-P06
CA 02394057 2002-07-18
1 as indicated by directional arrow "A" in strut frame 176 (Fig. 3). As will
be more fully
2 described below, use of the strut actuators can cause the shape of the forms
114
3 and 116 to be altered, thus allowing the apparatus 100 to be used for
forming curved
4 concrete segments.
In addition to the strut actuators 196 and 198, each actuator frame 134, 136,
6 174 and 176 is preferably provided with a main actuator (actuator device)
200
7 (Fig. 3), so that the apparatus 100 includes at least first and second main
actuator
8 devices. Main actuators 200 are also preferably screw jack type actuators
and
9 engage screw threads on shafts 184, 186, 188 and 190. When an actuator 200
is
actuated, the associated shaft (184, 186, 188 or 190) moves translationally
relative
11 to the associated actuator frame (134, 136, 174 or 176), as indicated by
arrow "B" in
12 actuator frame 176. When this occurs, the strut actuators ( 196 and 198)
move
13 together with the shaft within actuator frame, causing the form (114 and/or
116) to
14 move in direction °B". in this way a form 114 or 116 can be pulled
away from the
formed concrete structure (e.g., wall "W" of Fig. 1), or moved towards the
area where
16 the wall "W" is to be fomned (defined by void 90 of Fig. 1 ). For example,
if
17 actuators 200 (Fig. 3) in actuator frames 134 and 174 are actuated in
concert,
18 form 114 can be moved leftward (as viewed in Fig. 3) to the position
indicated
19 by 114a. Further, a form (114 andlor 116) can be tilted with respect to
vertical
orientation by actuating only the main actuator 200 in either the upper or
lower
21 actuator frame (or by operating the upper and lower actuators 200 at
differential
22 rates). For example, if only upper main actuator 200 in actuator frame 136
is
23 actuated (while lower main actuator 200 in frame 176 is not actuated), then
the
24 upper portion of form 116 can be tilted in a clockwise direction (as viewed
in Fig. 3)
to the position indicated by 116a. From the foregoing description, it can be
seen that
26 actuators 200 might properly be termed "form translating actuators" since
they can
27 be used primarily to move forms 114 and 116 in translational direction
towards, and
28 away from, the face of the structure °W" (Fig. 1 ) being formed (or
to be formed).
29 Likewise, actuators 196, 198 might properly be termed "form shaping
actuators"
since they are used primarily to reshape forms 114 and 116 from a flat
(linear) shape
31 to a non-linear or curvilinear shape (e.g., as depicted in Fig. 17).
Moreover, the
32 system of form shaping actuators 196, 198 (Fig. 3) and struts (158, 160,
210, 212,
33 214, 216, 218, 220, Figs. 2 and 4) can be termed "first and second form
shaping
34 devices", since their primary function is to alter the shape of the forms
114, 116.
20 Case RU01-P06
CA 02394057 2002-07-18
1 Generally, the "form shaping device° comprises a form shaping
actuator (196, 198)
2 mounted on the respective truss module (118, 120), and a form shaping member
3 (e.g., struts 210, 212, 214, 216, 218, 220) having a first end connected to
the
4 respective form (114 or 116), and a second end connected to the form shaping
actuator (196, 198). The form shaping actuator (196, 198) is configured to
move the
6 second end of the form shaping member (strut) relative to the respective
truss
7 module (118, 120), thereby urging the form (114, 116) into a curvilinear
shape. As
8 mentioned above, actuators 196, 198 and 200 (as well as actuators 260 and
264,
9 described below with respect to the attitude control module 130 of Fig. 8)
are
i 0 preferably screw jack type actuators, and can be actuated manuafiy,
electrically or
I 1 hydraulically. Actuators 196, 198, 200, 260 and 264 can also be hydraulic
actuators
12 (e.g., hydraulically driven piston actuators or hydraulically driven gear
reduction
13 drives), electric actuators (e.g., gear reduction drives driven by electric
motor), and
14 any other type of actuator which allows a member to be repositioned with
respect to
a supporting frame.
16 Further, main actuators 200 can be individually placed in a "locked"
position
17 so that the jack-screw within the actuator 200 is not free to translate
within the
18 actuator 200, thus fixing the shaft (184, 186, 188 andlor 190) relative to
the
19 associated actuator frame (134, 136, 174 and/or 176). When a main actuator
is
placed in a "locked" position, actuation of a strut actuator 196, 198 will
cause the
21 actuator 196, 198 to move within the actuator frame (134, 136, 174, 176)
along the
22 guides 194, in the manner described above. This will result in altering the
shape of
23 the form 116 from the flat shape depicted in Fig. 2 to a curved shape, as
will be
24 describe further below.
Turning to Fig. 5, the strut system associated with truss module 120 of Fig. 2
26 and 8 is depicted in a plan view. Upper strut actuators 196 and 198 can be
seen. It
27 is useful to briefly view Fig. 4, which depicts a sectional view of the
strut system
28 depicted in Fig. 5; wherein the section is taken between the strut
actuators 196
29 and 198. Fig. 4 depicts the set of upper struts 212, 160, 158 and 210 which
are
depicted in the plan view of Fig. 5, as well as the lower set of struts 218,
214, 216
31 and 220 which cannot be seen in Fig. 5. As can be seen by viewing Figs. 4
and 5,
32 there are 4 sets of struts: two upper inner struts 160, 158, two upper
outer struts 212,
33 210, two lower inner struts 214, 216, and two lower outer struts 218, 220.
Each strut
34 is preferably configured to be a variable length member. Preferably, each
strut
21 Case RU01-P0~6
CA 02394057 2002-07-18
1 comprises an inner and an outer cylinder which are slideable with respect to
one
2 another. However, other configurations can be employed to allow the struts
to be of
3 variable length, such as a sliding rail configuration.
4 Turning back to Fig. 5, first ends of upper outer shuts 212 and 210 are
pivotally connected to strut actuator 198 by pins or ball joints 197, and
second ends
6 of upper outer struts 212 and 210 are pivotally connected to respective form
frame
7 members 226 and 228 by pins or ball joints 213. Likewise, first ends of
upper inner
8 struts 160 and 158 are pivotally connected to strut actuator 196 by pins or
ball
9 joints 195, and second ends of upper inner struts 160 and 158 are pivotally
connected to respective form frame members 222 and 224 by pins or ball joints
215.
I I A similar connection configuration is provided for lower struts 218, 214,
216 and 220,
12 as indicated in Fig. 4. Likewise, a set of eight complementary struts for
truss
13 module 118 (Fig. 2) are pivotally connected to strut actuators 196 and 198
of truss
14 module 118, and form 114 associated therewith. Viewing Fig. 5, the function
of the
strut actuators 196 and 198 in changing the shape of the form 116 can be
16 appreciated. As shaft 186 is held in a fixed position relative to truss
module 120
17 (Fig. 3), by virtue of the screw jack within main actuators 200 being
"locked" (as
i 8 described above), form 116 can be deformed from the flat position
indicated to a
19 concave or a convex position (relative to the outside surface "OS" of form
116). For
example, if strut actuators 196 and 198 are translated along shaft 186 in
direction "P"
21 while strut actuator 200 is held fixed relative to shaft 186, then the form
116 will be
22 forced into a convex shape, whereas if strut actuators 196 and 198 are
translated
23 along shaft 186 in direction P' while strut actuator 200 is held fixed
relative to shaft
24 186, then the form 116 will be forced into a concave shape. As can be
appreciated,
by variably positioning strut actuators 196 and 198 relative to one another,
and
26 relative to shaft 186 (and thus the associate truss module 120 of Fig. 3),
a variety of
27 curved shapes for form 116 can be achieved. While truss modules 118 and 120
are
28 depicted as each having eight struts, a lesser or greater number of struts
can be
29 used. The number of struts used can depend on the anticipated final
structure to be
formed using the apparatus. For example, the shape of the concrete structure
to be
31 produced, and the anticipated hydrostatic forces from the liquid concrete,
will
32 determine whether a lesser number of struts can be used (a large number of
struts
33 will accommodate more complex geometries, and will also resist greater
hydrostatic
34 toads).
22 Case Ru09-POs
CA 02394057 2002-07-18
1 Turning now to Fig. 6, a plan view of the truss module 120 of Fig. 2 is
2 depicted in a plan view, but without the strut system depicted in Fig. 5.
That is,
3 Fig. 6 can be considered as the truss module 120 depicted in Fig. 1 minus
the strut
4 system depicted in Fig. 5. Fig. 6 allows the space frames 152 and 150 of
Fig. 2 to
be seen more clearly. The components of the truss module depicted in Fig. 6
6 include the end frames 144 and 142, the actuator frame 136, and the space
7 frames 152 and 150 which place the respective end frames 144 and 142 in
spaced-
8 apart relationship from the actuator frame 136. End frames 144 and 142 are
9 provided with connection brackets 199, allowing the apparatus 100 (Fig. 1 )
to be
connected to adjacent, similar apparatus and therefore produce an integral
concrete
i 1 forming system (as will be described further below). Each space frame 150,
152 is
12 pivotally connected to respective end frame 142, 144 by pins 238 at
brackets 199,
13 and each space frame 150, 152 is pivotally connected to the actuator frame
136 by
14 pins 239. Further, each space frame 150, 152 is preferably comprised of
adjustable
length links 234, 236, allowing the end frames 142 and 144 to move in
directions P
i 6 and P' relative to the actuator frame 136 (similar to movement of the
strut
17 actuators 196 and 198 relative to the shaft 186, as indicated in Fig. 5).
To achieve
18 this movement of end frames 142 and 144 relative to actuator frame 136,
each
19 space frame 150 and 152 can comprise adjustable links. Specifically, each
space
frame 150, 152 can include an upper forward adjustable link 236 (proximate the
21 associate form, in this case form 116 of Fig. 2), and an upper distal
adjustable
22 link 234 (distal from form 116). Adjustable links 234 are preferably two-
part
23 adjustable links, having first part 234a and second part 234b which are
pivotally
24 connected to space frame cross member 247 by pivot pin 241. The use of a
two-
part adjustable link 234 allows a greater range of adjustability of the space
26 frames 150, 152. Each space frame 150 and 152 is also provided with a
27 complementary lower forward adjustable link (not seen in Fig. 6) and a
lower two-
28 part distal adjustable link (not seen in Fig. 6), to thereby generate
adjustable,
29 generally "box-shaped" (i.e., three dimensional) space frames 150, 152
between the
respective end frames 142, 144 and the actuator frames 136 and 176 (Fig. 3).
31 Preferably, the adjustable links 234, 236 are configured to be secured into
their
32 adjusted positions by pins, screws, clamps or other means which prevent
relative
33 movement between the sliding members of the adjustable links. Each space
34 frame 150, 152 can also be provided with cross brace 247 and diagonal brace
23 Case RU01-P06
CA 02394057 2002-07-18
1 members 246 to provide additional structural rigidity to the space frames
150, 152 to
2 thereby resist the hydrostatic forces imposed on the space frames by liquid
concrete
3 placed between the forms 114 and 116 (Fig. 1 ), which are imparted to the
space
4 frames via the actuators 196, 198 and 200 (Fig. 3). It will be appreciated
that space
frames 146 and 148 of truss module 118 (Fig. 2) can be constructed similarly
to
6 space frames 150 and 152 depicted in Fig. 6. The space frames 146, 148, 150
7 and 152 (Fig. 2), in conjunction with the actuator frames 134, 136, and the
end
8 frames 138, 140, 142 and 144, generally provide support for the deck modules
110
9 and 112 (Fig. 1 ), as described in more detail below.
Turning briefly to Fig. 10, a plan view of truss modules 118 and 120 is
11 depicted, showing how the space frames 146 and 148 of truss module 118
articulate
12 about actuator frame 134 to accommodate the convex shape of form 114, while
13 space frames 150 and 152 of truss module 120 articulate about actuator
frame 136
14 to accommodate the concave shape of form 116. However, it will be
appreciated
that the form ends of forms 114 and 116 will not align if the forms 114 and
116 are of
16 the same length, due to the greater radius of form 116 than form 114. This
situation
17 can be addressed by the use of a form extender 299 which can be pivotally
attached
18 to module 120. The use of extender forms 299 increase the arc length of the
outer
19 form 116 to match-up with the arc length of the inner form 114.
The truss module structure 120 depicted in Fig. 6 supports the deck support
21 system 204, and in the same manner the truss module structure 118 depicted
in
22 Fig. 1 supports the deck support system 202. As seen in Fig. 6, the deck
support
23 system 204 (which supports deck 112 of Fig. 1) comprises translatably
associated
24 deck support members 240 and 242 (two each) which are supported on space
frames 150 and 152. Deck support members 240 are fixed to the end frames (142
26 or 144), and deck support members 242 are fixed to the actuator frame 136.
Deck
27 support members 240 and 242 are supported by space frame cross members 247,
28 and are constrained by brackets 244. A similar configuration is employed
for deck
29 support system 202 (Fig. 2). Turning to Fig. 7, the truss module 120 of
Fig. 6 is
depicted in a rear view, but a number of the space frame components have been
31 removed for clarity. Fig. 7 shows how the deck support members 240, 242 are
32 supported on end frames 142 and 144, cross members 147, and actuator frame
136.
33 In the view depicted in Fig. 10, it will be appreciated that the deck
support members
34 240 and 242 of truss module 120 (see Fig. 6) will be been translated away
from one
24 Case RU01-P06
CA 02394057 2002-07-18
1 another due to the expansion of the space frames 150 and 152, while the deck
2 support members of the deck support system 202 of truss module 118 (see Fig.
2)
3 will be translated closer to one another.
4 The deck support systems 202 and 204 (Fig. 2) can be used in conjunction
with an adjustable-area decking system. Turning to Fig. 10, a plan view of the
truss
6 modules 118 and 120 of Fig. 2 are shown, but the truss modules 118 and 120
are
7 shown in Fig. 10 as being adjusted into a curved shapes, and with adjustable-
area
8 deck plate systems 110 and 112 laid on top of the deck support systems (202
9 and 204, Fig. 2). Each deck plate system 110 and 112 (Fig. 10) includes a
plurality
of under-deck plates 294 which are preferably hingedly connected to the truss
t 1 modules 118 and 120, and are placed in spaced-apart relationship from one
another.
12 The under-deck plates 294 can be perforated to allow water and concrete to
fall
13 away from the work surface. Placed over the gaps between the under-deck
14 plates 294 are a series of over-deck plates 292 which are preferably
hingedly
connected to the truss modules 118 and 120. The over-deck plates 292, in
16 combination with the under-deck plates 294, form a fan-type work deck
system
17 110, 112, which can accommodate the expanded, or contracted, or curved, or
18 straight shapes of the truss modules 118, 120 by relative movement of the
deck
19 plates 292 and 294 to one another. The deck plates can be fabricated from
metal,
such as expanded steel grating, or from a non-metallic material such as fiber
21 reinforced plastic (°FRP"), which provides less friction between the
upper-deck plates
22 and the lower-deck plates. A non-metallic deck plate material also allows a
degree
23 of flexibility in the deck plates (within the plane of the deck plates) to
accommodate
24 changes in geometry of the associated truss module on which the work deck
is
supported. in addition to the fan-type deck plate systems 110 and 112, the
truss
26 modules can be provided with telescoping handrail systems 166 and 168 to
allow the
27 handrails at the outer edges of the work decks 110, 112 to also accommodate
the
28 change in size of the truss modules 118, 120 as they are placed in
different
29 configurations. As seen in Fig. 3, the work decks 110 and 112 are supported
by, but
not fixed to, the deck support systems (respectively, 202 and 204) so that the
work
31 decks (110, 172) are slidably disposed with respect to (i.e., can move in
directions P
32 and P' relative to) the truss modules (respectively, 118, 120), but in
conjunction with
33 the respective forms 114 and 116. That is, the work decks 110, 112 are free
to
34 translate along with respective forms 114 and 116 relative to respective
truss
25 Case RU01-P06
CA 02394057 2002-07-18
1 modules 118 and 120. Hinged connection 162 (between work deck 110 and
2 form 114) and hinged connection 164 (between work deck 112 and form 116)
allow
3 the work decks 110 and 112 to stay in a relatively fixed position with
respect to the
4 forms (respectively, 114 and 116). In this way, as the forms 114 and 116 are
translated in directions P and P' (Fig. 3), the work decks 110 and 112 stay in
close
6 proximity to the associated form (114 or 116), thus eliminating a gap
between the
7 form and the work deck, as results in prior art concrete forming apparatus.
8 Turning to Fig. 8, a side elevation detail of attitude control module 130 of
9 Fig. 1 is shown. As described above, the attitude control modules 130, 132
(Fig. 1)
can also be considered as reaction force members to facilitate pulling the
forms
1 I 114, 116 away from the face of the concrete structure "W" using the
actuators 196,
l2 198 and 200. As shown in Fig. 8, attitude control module 130 is connected
to truss
13 module 118 at flange 178. Attitude control module 130 comprises main frame
248,
14 which supports upper attitude control actuator 260 and lower attitude
control
actuator 264. Actuators 260 and 264 engage respective attitude positioning
shafts
16 ("attitude positioners") 254 and 256, which can be threaded shafts (similar
to
17 shaft 184, Fig. 3). When shafts 254 and 256 are threaded, then actuators
260
18 and 264 can be jack-screw actuators, similar to actuator 200, described
above.
19 Actuators 260 and 264 are preferably set in a fixed position in frame 248.
Positioning shafts 254 and 256 are depicted as being fitted with wheels 266,
which
21 allow the attitude module 130 to track along the finished concrete wall
"W".
22 Wheels 166 can be replaced with pads to reduce the number of moving parts,
but
23 wheels 166 can cause less damage to the face of the wall "W" as the
apparatus 100
24 moves upward. Further, a combination of wheels and pads can be used. In
this
2~ instance the wheels can be spring-loaded so that they are biased towards
the climb-
26 rod 99, and therefore contact the formed wall "W" when the forms 114, 116
translate
27 outward and away from the formed concrete wail. However, when the forms 114
28 and 116 are translated towards the formed wall "W", the spring-loaded
wheels will be
29 pressed into the attitude control modules 130, 132, and the pads will
contact the
formed wall. In another embodiment, the wheels 26 of the attitude control
31 modules 130, 132 can be replaced with caterpillar tractor-type treads,
which allows
32 the reaction force of each of the attitude control modules to be spread
over a larger
33 surface area of the formed waN "W". As is apparent, radial attitude control
26 Case RU01-P06
CA 02394057 2002-07-18
1 module 132 of Fig. 1 can be constructed similarly to attitude control module
130 of
2 Fig. 8 {described above).
3 The attitude control modules 130 and 132 can be attached to the actuator
4 frames 174, 176 (Fig. 3), end frames 138, 140, 142, 144, Fig. 2), and/or the
space
frames (146, 148, 150, 152, Fig. 2). The attitude control modules 130 and 132
can
6 also be an integral part of the truss modules 118, 120 so that they are not
"attached
7 to" the truss modules, but are part of the truss modules. In this latter
instance, the
8 attitude control module frame 248 is but an extension of the truss module
118, and
9 connection flanges 178 are not present. Attitude control modules 130 and 132
can
also be a modular or integral extension of yoke 106.
11 In operation, attitude control actuators 260 and 264 can be used to
12 individually position the radial attitude positioning shafts 254 and 256,
and thereby
13 alter the position of the apparatus 100 with respect to the climb rod 99
(Fig. 1).
14 Further, the attitude control actuators 260 and 264 (in radial control
modules 130
and 132) can be used in conjunction to cause the attitude positioning shafts
254
16 and 256 to push the forms 114 and 116 towards or away from the evolving
wall "W".
17 Turning now to Fig. 9, a side elevation detail of the yoke jacking system
108
18 of Fig. 1 is depicted. The yoke jacking system 108 is connected to the
first and
19 second arms 268 and 270 of the yoke 146 by flanges 262 and 274. As
depicted, the
yoke jacking system 108 comprises a yoke actuator frame 258 which supports
upper
2I and lower climb actuators 272. Climb actuators 272 can be annular screw
jacks or
22 hydraulic jacks which can alternately grip the climb pipe 99 to effect
upward
23 movement the yoke 106 in direction "Y° along the axis of the climb
pipe 99. Climb
24 actuators 272 can be operated in discrete fashion to effect a "jump-form"
type
operation of the concrete forming apparatus 100, or they can be operated in a
26 continual fashion to effect a continuous "slip-form" casting mode. Turning
again to
27 Fig. 3, as was described previously, the yoke 106 of Fig. 1 is attached to
the truss
28 modules 118 and 120 by yoke flanges 180.
29 Preferably, yoke 106 is pivotally attached to lower yoke flanges 180, and
is
adjustably connected to upper yoke flanges 180. This is depicted in Fig. 8,
which
3 l shows a ball joint type pivot hinge 273 which is placed between the lower
yoke
32 attachment bracket 180 and the lower end of the yoke arm 286. The yoke
33 positioning device further comprises an actuator 275 which causes relative
34 movement between the yoke 106 and the truss module 118. The preferred
direction
2~ Case RU01-P06
CA 02394057 2002-07-18
1 of movement is into and out of the plane of the sheet on which the figure is
drawn.
2 In this way, in a side view of the truss module 118 of Fig. 8, the yoke 10fi
can be
3 moved pivotally in either a clockwise or a counterclockwise rotational
direction
4 relative to the lower pivot connection 273. Since the yoke is anchored to
the climb
rod 99 (Fig. 9), the truss module 118 will be moved (rather than the yoke),
allowing
6 sway control of the apparatus 100 as the yoke actuators 272 move the
7 apparatus 100 in the upward "Y" direction. As can be appreciated, a similar
8 arrangement as that shown in Fig. 8 can be provided for truss module 120. In
this
9 way the climbing device 108 can be plumbed or adjusted in directions "R1" or
"R2"
(Fig. 3) with the attitude control modules and, in plan view, in directions
orthogonal to
1 I "R1" and "R2" (i.e., into and out of the plane of the sheet on which Fig.
3 is drawn)
12 with the tangential or sway control effected by actuator 275 acting about
the lower
13 ball joint type pivot hinge 273 referenced to a predetermined reference
point, such
14 as a point on the ground, by using yoke adjustment devices. The yoke
adjustment
devices can be made additionally adjustable in the "R1" and "R2" directions to
16 augment the attitude control effected by the attitude control modules 130
and 132,
17 for example, with threaded nuts on a threaded shaft, wherein the nuts are
placed
18 between each yoke arm {268, 270) and each flange 180 in conjunction with
sway
19 control devices 273 and 275 so that the nuts can be used to urge the yoke
arms in a
direction ("inward" or "outward") relative to the flange 180. 1t will be
appreciated that
21 a further means of tangential or sway control (i.e., in a direction into
and out of the
22 plane of the sheet upon which Fig. 3 is drawn) can be accomplished in a
global or
23 system sense by attitude control modules 130, 132 of associated forming
24 apparatus 100 oriented with a vector component in the direction of the sway
of
climbing device 108 into or out of the plane of the sheet upon which Fig. 3 is
drawn.
26 As an example, the attitude control modules stabilizing yokes 106B and 106D
in
27 localized directions "R1" and "R2" along the short sides of system 350 of
Fig. 12,
28 especially near the comers, can accomplish the sway control of yokes 106A
29 and 106C along the long sides of system 350. In a like manner, the attitude
control
modules stabilizing the yokes 106A and 106C in localized directions "R1" and
"R2"
31 along the long sides of system 360, especially those nearest the corners,
can
32 accomplish the sway control of yokes 1068 and 106D along the short sides of
33 system 350.
2g Case RU01-P06
CA 02394057 2002-07-18
1 As previously discussed, Fig. 10 shows how the truss modules 118 and 120
2 can be configured using the adjustable struts (155, 156, 206, 208, 158, 160,
210,
3 212, etc. of Fig. 2) and the space firame adjustable links (234, 236),
described
4 above, for placing the apparatus 100 in a radial arc shape. By connecting
several
so-shaped apparatus 100 together, a closed-circle concrete forming apparatus
can
b be formed, and the assemblage of the discrete concrete forming apparatus
into the
7 closed-circle concrete forming apparatus can then be used to generate a
vertical
8 silo.
9 In addition to the standard concrete forming apparatus 100 depicted in Figs.
6
through 10, specialized concrete forming apparatus can be provided, in
accordance
11 with the present invention. Fig. 11 depicts one such specialized apparatus
300. The
12 apparatus 300 of Fig. 11 is shown in a plan view, and the yoke ( 106, Fig.
1 ) and
13 work-decks 110, 112 {Fig. 1 ) have been removed for clarity. The apparatus
300 of
14 Fig. 11 is specially constructed to form corners of a concrete structure,
and includes
a first truss module 318 which supports forms 314a and 314b, and a second
truss
16 module 320 which supports forms 316a and 316b. As can be seen, truss
17 module 318 is longer than truss module 320. Accordingly, shortened truss
modules
18 (similar to module 120 of Fig. 2, but having only a single set of upper and
lower
19 struts) can be connected to end frames 142 and 144 of truss module 320 in
respective areas A1 and A2, so that the end frames of the shortened truss
21 module 320 wilt align with the end frames 138 and 140 of truss module 318.
Truss
22 module 318 essentially comprises two of the truss modules 118 {Fig. 2)
joined
23 together at a truss pivot assembly 338. That is, truss module 318 comprises
space
24 frame and strut assemblies 346 and 348 which are joined together at truss
pivot
assembly 338. Truss sub-module 346 supports form section 314a, and truss sub-
26 module 348 supports form section 314b. Form sections 314a and 314b are
hingedly
27 joined at hinge 340, allowing the form sections 314a and 314b to form a
sharp angle,
28 rather than a curved shape (as in Fig. 10). Likewise, truss module 320
comprises
29 standard space frames 150 and 152, as described above, but space frame 150
supports form section 316a, while space frame 152 supports form section 316b.
31 Form sections 316a and 316b are hingedly joined at hinge 339, allowing the
form
32 sections 316a and 316b to form a sharp angle. The form sections 314a, 314b,
316a
33 and 316b together form a corner area °C°. If a sharp outside
comer is not desired,
34 then a rounding form can be placed between form sections 316a and 316b to
round
29 Case RU01-P06
CA 02394057 2002-07-18
1 the comer. Each space frame 346, 348 of truss module 318 of the comer
forming
2 apparatus 300 can be articulated at least 45 degrees about a centerline "CL"
which
3 joins form hinges 340 and 339, and likewise each space frame 150, 152 of
truss
4 module 320 can be articulated at least 45 degrees about the centerline "CL".
In this
way comers of varying angles can be produced with the corner forming
6 apparatus 300.
7 Since actuator frame 337 of truss module 320 of Fig. 11 does not have a
8 corresponding actuator frame in the truss module 318, the yoke assembly
(such
9 as 106 of Fig. 1 ) which is used to lift the apparatus 300 upward along the
climb rod
t0 (e.g., climb rod 99 of Fig. 1) is preferably located where two actuator
frames
11 correspond (i.e., where two actuator frames are located adjacent one
another
12 between truss modules). Turning to Fig. 12, a plan view of a system 350 of
a
13 concrete structure forming apparatus in accordance with the present
invention is
t 4 depicted. The system 350 is generally configured to produce a rectangular,
vertical
l5 concrete structure. The system 350 comprises four corner forming apparatus
300A,
16 300B, 300C and 300D. ft is noted that comer forming apparatus 300A and 3008
are
17 joined along the long-dimensioned side of the rectangular form 350 by
straight
18 forming apparatus 100A, 1008, 100C, 100D, and so on. At the short-
dimensioned
19 sides of the rectangular form 350, truss modules 318A and 318D of corner
forming
20 apparatus 300A and 300D are joined directly together. However, the truss
21 modules 320A and 320D of comer forming apparatus 300A and 300D are not
joined
22 directly together, but instead are provided with supplementary truss
modules 120N
23 and 120M. Likewise, whereas truss modules 318A and 318D are joined to
24 respective straight forming apparatus 100A and 1002, supplementary truss
25 modules 120P and 120Q are provided to allow the outside truss modules 320A
26 and 320D of corner-forming apparatus 300A and 300D to connect to the
straight
27 forming apparatus 100A and 1002. As can also be seen in Fig. 12, each
concrete
28 forming apparatus .that comprises part of the overall system 350 is not
necessarily
29 provided with a yoke. Specifically, along the long-dimensioned sides of the
30 rectangular shape 350 only every other straight forming apparatus is
provided with a
31 lifting yoke (e.g., apparatus 100A and 100C are provided with respective
yokes 106A
32 and 106C, while forming apparatus 1008 and 100D are not provided with
yokes).
33 However, along the short-dimensioned sides of the rectangular form 350,
34 yokes 1068 and 106D are connected to respective inner truss modules 318A
30 Case RU09-P06
CA 02394057 2002-07-18
1 and 318D, as well as to respective outer supplemental truss modules 120N
2 and 120M. As can be seen by the example provided in Fig. 12, the number and
3 location of yokes provided in any concrete forming system which includes
concrete
4 forming apparatus of the present invention will be governed by
considerations such
as the thickness of the concrete structure being formed and the final shape of
the
6 structure. The number and location of yokes will also be governed by: (1)
resolving
7 the hydrostatic forces of concrete exerted on the forms (114, 116) over the
span of
8 the truss modules (118, 120) to the yokes (106); (2) the gravity loads
supported by
9 each truss module 118, 120 (e.g., the loads on the work decks 110, 112); and
(3) the
stability of the overall concrete-forming system as the weight of the system
bears on
11 the climb rods (99).
t 2 Although I have described above a specific embodiment of a concrete
forming
13 apparatus of the invention, it will be appreciated that another embodiment
of the
14 present invention provides for a concrete forming module (such as 102 of
Fig. 1 )
which can be used to retract concrete forms away from a concrete structure (or
a
16 partial concrete structure) which has been formed, or to move concrete
forms into
17 place to form a concrete structure. The module 102 includes a concrete form
(114,
18 Fig. 1 ) and a first actuator frame 134. The module 102 further includes a
first form-
19 translating actuator 200 which is supported by the actuator frame 134. A
first
elongated form-translating member (shaft 184), which is engaged by the form
2 t translating actuator 200, has a first end connected to the form 114. The
form-
22 translating actuator 200 is configured to move the form-translating member
184
23 relative to the actuator frame 134, to thereby translationally move the
form 114
24 relative to the actuator frame 134. Preferably, the module 102 further
includes a
second actuator frame 174 which is spaced-apart from the first actuator frame
134,
26 and connected to the first actuator frame, by a main frame 248. In this
case the
27 module 102 has a second form-translating actuator (200) supported by the
second
28 actuator frame 174, and a second elongated form-translating member (shaft
188)
29 having a first end connected to the form 114 proximate a lower edge of the
form (the
>~rst translating member 184 being connected to the form 114 proximate an
upper
31 edge thereof). The second form-translating member 188 is engaged by the
second
32 form-translating actuator 200 (lower), and the second form translating
actuator
33 (lower 200) is configured to move the second form-translating member (188)
relative
34 to the second actuator frame 174. Preferably, when two form translating
actuators
3 I Case RU07-P06
CA 02394057 2002-07-18
1 (200 upper and lower) are provided, the first and the second form
translating
2 members (184, 188) are each connected to the form 114 by a hinged connector
3 (e.g., pin 192), allowing the form to "tilt°, such as indicated by
116a in Fig. 3.
4 The concrete forming module 102 can further include a first space frame
(146,
Fig. 2) connected to the first side of the actuator frame 134, and a second
space
6 frame 148 connected to the second side of the actuator frame. A first end-
frame 138
7 can be connected to the first space frame 146 distal from the actuator frame
134,
8 and a second end-frame 140 can be connected to the second space frame 148
distal
9 from the actuator frame 134. A work deck 110 (Fig. 1 ) can be supported by
the
actuator frame 134 and the first and second end frames (138, 140).
11 Yet another embodiment of the present invention provides for a concrete
12 forming module (such as module 102) which can be used to shape a semi-
flexible
13 concrete form into a curvilinear shape to thereby allow casting of various
geometries
14 of structures, all using the same form module. The concrete forming module
102
includes a semi-flexible concrete form (such' as form 114, which can be made
of
16 steel of a sufficient thinness that it can be resiliently deformed into a
desired shape).
17 The module 102 includes an actuator frame (such as frame 134, Fig. 2), and
a form-
18 shaping actuator supported by the actuator frame. The form-shaping actuator
can
19 be any of actuators 196, 198 or 200. The module 102 further comprises an
elongated form-anchoring member (such as shaft 184) having a first end
connected
21 to the form 114 at an anchor point (e.g., at pin 192, Fig. 3). The form-
anchoring
22 member 184 is connected to the actuator frame 134. This connection of the
form-
23 anchoring member 184 to the actuator frame 134 can be either a fixed
connection, or
24 a moveable connection. The module 102 further includes a form-shaping
member
(such as strut 155, 156, 206 or 208 of Fig. 2) having a first end connected to
the
26 form 114 (as at form support members 222, 224, 226 or 228 of Fig. 5), and a
second
27 end connected to the form shaping actuator (e.g., 196, 198 or 200). The
connection
28 of the form-shaping member (e.g., strut 155, 156, 206 or 208) to the form
shaping
29 actuator (e.g., 196, 198 or 200) can either be direct, as in the case of
actuators
196, 198 (Fig. 3), or indirect, as in the case of actuator 200 (where the
connection is
31 through the form-anchoring member (shaft 184)). The form-shaping actuator
32 (196, 198 or 200) is configured to produce relative movement between the
second
33 end of the form-shaping member (e.g., the end of strut 155 which is closest
to the
32 Case RU01-P06
CA 02394057 2002-07-18
1 actuator frame 134, as seen in Fig. 2) and the anchor point (e.g., pin 192,
Fig. 3) to
2 thereby urge the form 114 into a curvilinear shape.
3 In this latter embodiment the form-shaping actuator can be configured to
4 move within the actuator frame to effect movement of the second end of the
form-
s shaping member (e.g., strut 155) relative to the anchor point (e.g., pin
192).
6 Specifically, actuator 196 or 198 can be used in the manner described above,
7 wherein the "form-anchoring member" (shaft 184) is held stationary by
actuator 200,
8 so that actuation of the jack-screw actuator (196 or 198) causes the
actuator
9 196, 198 to move within the actuator frame 134 on guides 194 (Fig. 3).
Alternately,
the form-shaping actuator can be configured to move the elongated anchor
member
11 relative to the actuator while the actuator remains stationary. This can be
12 accomplished by using actuator 200 to move the "form anchoring member"
13 (shaft 184) relative to the actuator frame 134.
14 t will now describe how the apparatus described above can be operated.
I) Mobilization-Demobilization
16 Concrete forming apparatus of the present invention, such as apparatus 100
17 of Fig. 1, will typically be mobilized to and from a construction site in a
state of
18 advanced assembly. Several standard modules 102, 104 can be connected in a
19 chain (as in modules 100A, 1108, 100C of Fig. 12) and transported in a
straight
format on a semi-trailer with the opposed form faces (114, ~ 16) set closely
together
21 and the actuator shafts (184, 186, 188, 190 of Fig. 3) retracted fully into
the actuator
22 frames (134, 136, 174, 176) to minimize the width of the module pair (102,
104).
23 Yokes 106 can be shipped in halves (e.g., arms 268 and 270 of Fig. 9
shipped
24 separately), with the jacking subassembly 108 attached to one of the frame
halves-
Climb pipes 99 (Fig. 1 ) can be stacked as pipe. Attitude control modules 130
26 and 132 (Fig. 1 ) and other components can be stacked on pallets.
27 II) Set-Up
28 Each module chain (comprised of severs! standard apparatus modules
29 102, 104 in opposed pairs) can be lifted as a unit off of a semi trailer
onto the
foundation "F" (Fig. 1 ) or nearby on a flat, level surface. These module
chains can
31 then be manually configured, module-by-module, into the intended geometric
format
32 that will effect the reinforced concrete wall or shell segment of the
structure, or an
33 entire structure such as shown in Fig. 12. Actuation of the modules 102,
104 into the
34 desired geometry is accomplished by setting struts (155, 156, 206, 208,
158, 160,
33 Case RUO~-P06
CA 02394057 2002-07-18
1 210 and 212) to a predetermined length and setting strut actuators (196,
198) to the
2 predetermined location along actuator shafts (184, 186, 188, 190). The
adjustable
3 links (234, 236, Fig. 6) of the space frames (146, 148, 150, 152, Fig. 2)
are allowed
4 to telescope relative to one another during this actuation process to set
the form
geometry. Extender form adaptors such as 372 {Fig. 10A) and end-of wall
6 adaptors (not shown, and which are used to closed the open ends between
forms
7 114 and 116 to constrain concrete between the forms when the forms are not
8 arranged in a closed shape, as in Fig. 122) can then be attached to the
required form
9 ends. Any required incremental length modules (e.g., 120M, 120N, 120P and
120Q
of Fig. 12) are inserted within and between the various module chains to
effect the
I 1 exact curvilinear structural length desired. The adjustable (inks 234, 236
(Fig. 6) of
12 the truss modules 118, 120 can then be locked in place to freeze the
structural
13 shape. These module chains are then lifted into place straddling the
foundation
14 dowel rebar (which typifies the base of most reinforced concrete
structures), and
IS typically also a form height of completely-installed horizontal structure
reinforcing
16 steel ("rebar") (since there is little or no access to install this
reinforcing steel after
17 the forms 114, 116 are in place). As these module chains and individual
modules
18 are landed on the foundation, they can be rough-leveled. The free ends of
the
19 module chains and individual modules are then pinned together with pins at
common
end frame anchor flanges 199 (Fig. 6), adjoining work deck panels (such as
296, Fig.
21 10) are set in place, and the adjoining handrail is attached together.
After the entire
22 segment length (or whole structure length) of modules 102, 104 are in place
and
23 pinned together, the modules are then fine-Leveled (or set to a desired
wall slope) by
24 shimming under each flange of the end frames (e.g., 142, 144) and under the
actuator frames (134, 136). Yoke modules 106 are then lowered into place at
their
26 prescribed support location along the jump-slip form system (see Fig. 12,
for
27 example) and are attached and plumbed radialiy to a reference point, such
as the
28 end frame pairs (140, 144 of Fig. 2), specifically, the lower pair of
actuator frames
29 (174, 176) or at the frame support paints (180, Fig. 3). The yokes 106 are
then
plumbed tangentially to the truss modules 118, 120 by adjusting the upper
support
31 point (proximate upper flange 180) relative to lower support point
(proximate lower
32 flange 180). Next, a climb pipe 99 (Fig. 1 ) is lowered down through the
yoke jacking
33 assembly 108 to the foundation °F". The initial climb pipe 99, as
well as subsequent
34 spliced climb pipes, can be sized to stick up above the top of the yoke 106
by
34 Case RU01-P06
CA 02394057 2002-07-18
1 several form heights, so as to reduce the frequency of splicing subsequent
climb
2 pipes. The climb pipe 99 is plumbed tangentially (into or out of the plane
of the
3 sheet upon which Fig. 3 is drawn), and plumbed radially (in directions "R1"
and "R2"
4 of Fig. 3) (or set to a predefined radial slope for sloped walls),
inherently by its
reference to the bores on the upper and lower yoke jacks (272, Fig. 9) through
which
6 the climb pipe 99 has been placed. Next, modular power and control units are
7 mounted along the work decks (110, 112, Fig. 1) and connected to the truss
module
8 actuators (196, 198, 200), the attitude control module actuators (260, 264,
Fig. 8),
9 yoke jacks 272, and GPS or other geometric monitoring and control systems.
Any
other support subsystems such as, but not limited to, welder leads, cutting
torch gas
! 1 lines, and climate control lines (forms can be provided with a climate
control system
12 to facilitate hot and cold weather concreting) can also be attached between
modules
13 102 and 104 at this time. The final activity before beginning construction
of the
14 reinforced concrete structure is to prepare the forms with a release agent,
and
I S globally actuate the forms 1 i4, 116 into place relative to the support
truss
16 structures 118 and 120. To insure a proper pre(oad between the forms (114,
116)
17 and support truss modules (118, 120) on the initial concrete lift (when in
discrete
18 casting mode), the bottom back edge of the forms (114, 116) at their middle
and
19 ends is preferably braced to the concrete foundation "F" (Fig. 1 ) with
concrete
anchors. Subsequent preload (for the discrete casting mode) is accomplished by
21 thrusting the bottom edge of the form face 114, 116 against the top edge of
the
22 evolving concrete structure (such as wall "W", Fig. 1 ) after it has
achieved adequate
23 strength. The preload can compensate for deflection or "bulging" of the
24 forms 114, 116 due to the hydrostatic forces of the liquid concrete as it
is deposited
between the forms.
26 111) Operation
27 There are two primary modes of operation of the apparatus of the present
28 invention: discrete casting and continuous casting, which are performed by
the
29 apparatus to achieve either vertical segmental casting of discrete concrete
segments, or casting of the entire structure all-at-once. I will now describe
each of
31 these modes separately.
32 a) Discrete Casting Mode
33 The set-up (described above) will have generally prepared the apparatus 100
34 for casting the first lift or jump of concrete, lifts being typically the
form height in
3 5 Case RU01-P06
CA 02394057 2002-07-18
I classical jump-forming, but in the case of the "jump-slip machine"
(apparatus 100,
2 or 350 for example), the forms on subsequent lifts are overlapped somewhat
with the
3 previous pour to allow preioading of the forms against the cured concrete,
and to
4 effect smoother, less noticeable, horizontal joints than is typically the
case for prior-
s art jump forming wherein the forms are placed directly above one another
(with no
6 overlap). Prior to pouring concrete, any block-outs (e.g., door, windows,
etc.) or
7 embedments are placed between the forms 114 and 116, and fastened to the
form
8 faces with fasteners, and any spreaders (as discussed below) are attached to
the
9 forms 114, 116. The first "lift" is then poured into the void area 90 (Fig.
1) between
the forms (114, 116) by way of a concrete pump truck trunk or a concrete
bucket,
11 and then vibrated until the form height is achieved. Although the support
truss
12 modules (118 and 120) and yoke system 106 will generally be relatively
rigid and will
13 have been preloaded by the actuators (196, 198 and 200) relative to the
form
14 modules (114, 116) to achieve tight geometric thickness control of the
concrete
l5 section, even tighter dimensional tolerances at the top of forms 114, 116
can be
16 achieved by placing rigid steel spreaders at stiffener members (170, 222,
224, 226
17 and 228, Fig. 5) at the top of the forms around the perimeter of the forms
before
18 pouring. While sufficient time passes to cure the just-poured concrete to a
specified
19 minimum strength before releasing the forms 114, 116 for the next lift,
reinforcing
steel ("rebar") can be placed for the next lift of concrete. Access to place
reinforcing
21 and pour concrete is provided on both sides of the evolving structural
section on the
22 work decks 110, 112. The work decks 110, 112 can be supplied with concrete
and
23 reinforcing steel, and other materials, by way of individual equipment such
as mobile
24 cranes and concrete pump trucks or, more preferably, it can be supplied
with a
specialized modular tower crane which is located so that the swing of the boom
of
26 the crane has sufficient access to all parts of the segment or whole
structure (e.g.,
27 structure 350 of Fig. 12). Being modular in nature, the tower crane will be
able to
28 self-increment its height. At such time as the reinforcing steel for the
second lift is in
29 place and the first lift has attained adequate strength, the forms 114, 116
are
released away from the cured concrete, and can also be tilted as described in
31 association with Fig. 3 (see tilted form 116a). End-of-wall adapters and
end-of-
32 segment adaptors (which close the open the ends of forms 114, 116 to
constrain
33 concrete between the forms when the forms are not arranged in a closed
34 configuration as depicted in Fig. 12) are also then released from the
apparatus 100,
36 Case RUO!-P06
CA 02394057 2002-07-18
1 and rotated away from the cast concrete, and any end-of-segment end plates
281 (a
2 moveable end-of segment adapter) are lifted to the next level. Before
raising the
3 jump-slip system 100, the forms (114, 116) are preferably cleaned and oiled
by
4 personnel on the work-decks 110, 112 for the next lift. (Cleaning before
raising the
machine to the next level prevents loose concrete and oil from contaminating
the
6 cold joints.) The top edge of the cured concrete of the first lift is also
cleaned of any
7 loose concrete so that the bottom edge of the forms 114, 116 will interface
cleanly
8 with this edge and form a tight overlap. The jump-slip machine (100 of Fig.
1, or 350
9 of Fig. 12) can then be raised to the next level by activating the yoke
jacks 272
(Fig. 9). As the control of the system is intended to be automated, an
operator can
I 1 instruct a programmable logic controller ("PLC") to execute the lift, and
all forms will
12 automatically be raised to the predetermined elevation. Elevation can be
monitored
13 through an array of GPS sensors that locate the forms 114, 116 in three
dimensions
14 to thereby maintain the intended structure geometry. Following the initial
lift, there
will now be sufficient room between the form system (truss modules 118 and
120)
16 and the foundation "F" to attach the attitude control modules 130, 132
(Fig. 1) using
17 anchor flanges 178 (Fig. 3). This arrangement of mounting the attitude
control
18 modules 130, 132 immediately below the yoke module 106 provides a rigid
19 mounting, and will result in high dimensional control of the evolving
structure by the
modules 130, 132. _ However, due to openings or obstructions in the resulting
21 structure where the radial attitude control modules 130, 132 cannot thrust
off of the
22 structure, the attitude control modules may need to be mounted to the truss
modules
23 118, 120 adjacent to the yoke arms 268, 270 (Fig. 9) on nearby actuator
frames
24 (frames 134, 136 of an adjacent apparatus 100), or on the end frames (138,
140,
142, 144, Fig. 2)), or on the spaces frames (146, 148, 150, 152, Fig. 2). Once
the
26 attitude control modules 130, 132 are attached, they can then be connected
to the
27 power and control system, and the PLC can be instructed to effect a full
radial
28 alignment of the jwmp-slip system by way of simultaneously or iteratively
actuating
29 these attitude control modules (130, 132) using actuators 260, 264 (Fig.
8). This
radial alignment, in combination with the yoke-climb pipe 99 tangential or
sway
31 alignment and vertical progression (height of climb module 108), generally
fully
32 aligns the jump-slip machine in three dimensions along the entire form
perimeter.
33 The form modules 114, 116 are then actuated back into the structure-forming
34 position, and the bottom edge of the forms are pre-loaded against the top
edge of
37 Gase RU01-P06
CA 02394057 2002-07-18
1 the first concrete lift over a specified overlap distance that will not
overload the just-
2 poured concrete. Again, any block-outs or embedments can be inserted and
3 fastened at this time, and spreaders can be attached to the form tops.
Concrete is
4 then poured again, as described above, and the discrete casting process is
repeated
until the full structure height is effected. Climb pipe 99 can be periodically
spliced
6 onto the existing climb pipe with threads and/or welds. Because the intended
7 structure height may not be a precise multiple of the "effective form height
" (i.e., the
8 actual height of the forms 114, 116 minus the overlap), the final pour may
be poured
9 to only some fraction of the effective farm height.
t 0 b) Continuous Casting Mode
11 The set-up, described above, will generally have prepared the jump-slip
12 machine (100 of Fig. 1, 350 of Fig. 12, for example) for continuous-mode
casting.
i3 Typically the jump-slip standard module pairs (102, 104) will be delivered
to the
14 construction site as described in the "set-up°, above, but they will
have form liners,
such as plywood, attached to the form faces 114, 116 to allow a continuous
release
16 of the concrete as it is formed. During the set-up, the forms 114, 116 will
have been
17 actuated into a format that is relieved downward (i.e., the tops of forms
114 and 116
I S will be slightly tilted towards one another, opposite of the direction of
tilt indicated by
19 form 116a in Fig. 4). This will allow a smooth transition of the form past
the
concrete, which will be in various stages of setting-up and curing as the
structure is
21 being formed. As with the discrete casting mode described above, prior to
pouring
22 concrete any block-outs or embedments are placed within the forms and
fastened to
23 the form faces 114, 116 in the first form height. Unlike the discrete
casting mode, in
24 continuous casting operation subsequent block-outs or embedments can be
inserted
in between the forms 114, 116 amongst the continuous process of installing
rebar
26 and pouring concrete. Continuous casting is initiated with the pouring of
nearly the
27 full form height, and any final geometric changes to the structural width
are made at
28 this time while the concrete is in a fluid state by moving the individual
strut
29 actuators 196, 198 in or out using actuators 200, and, to a limited extent,
moving the
3o strut actuators in or out relative to the actuator shafts 184, 186, 188,
190 by
31 actuating the actuators 196 and/or 198. Reinforcing ("rebar") is installed
essentially
32 continuously and simultaneously with the pouring of concrete. The
reinforcing
33 progression should stay above the forms 114, 116 a sufficient distance to
allow
34 inspection of the reinforcing before it is cast in concrete. In an
automatic control
3g Case RU01-P08
CA 02394057 2002-07-18
1 mode, the PLC can be pre-set to activate simultaneously all yoke jacks 272
to effect
2 a continuous upward progression of the jump-slip system 100 at a
predetermined
3 rate, which can be modified at any time to slow-down or speed-up tfie
casting
4 process to match the rate at which the personnel are installing the
reinforcing and
concrete, or depending on variances in concrete curing times. As the jump-slip
6 system gets high enough off the foundation, the radial attitude control
modules
7 130, 132 can be attached (as described above) and connected to the power and
8 control system. The radial attitude control modules 130, 132 can then become
an
9 active part of the PLC-conirolted alignment system and, together with the
tangential
control and elevation control, they can continuously maintain the jump-slip
11 system 100 in the predetermined geometry within the allowed tolerances.
When the
i 2 height of the evolving structure permits, fixed or trolley-type swing
scaffolds can be
13 attached to the lower actuator frames (174, 176, Fig. 3) and the end frames
(138,
14 140, 142, 144, Fig. 2) to allow any required finishing of the slip-formed
concrete
surface. The continuous casting process then proceeds as described above until
the
16 desired structure height is achieved. As with discrete casting mode, Gimb
pipe
17 segments 99 are periodically spliced on to the previous climb pipe to
maintain the
18 yoke jacks 272 with a climb member to effect vertical or near vertical
progression of
19 the apparatus 100.
I~ Take-down
21 After the concrete structure has been formed, the jump-slip form system
22 (comprising a plurality of connected apparatus 100, or variations thereof
such as
23 comer forming apparatus 300A of Fig. 12) can then be lifted down from the
24 completed reinforced concrete segment (or the completed whole structure) in
module chains with a mobile crane or specialized tower crane. Near the ground
the
26 radial alignment control modules (130, 132) and any swing scaffolds are
preferably
27 removed from the truss modules 118 and 120. Then the yokes 106 can be
lifted to
28 the ground. The protruding climb pipes 99 can then be cut off flush with
(or recessed
29 into) the formed structure and patched over. The remainder of the take-down
is
essentially the reverse of "set-up", described above.
31 The apparatus described above, and variations thereon described in my U.S.
32 Patent application serial number 101131,838, as well as alternate
embodiments
33 described below, can be used to fabricate vertical concrete building
support
34 structures ("building support structures"). These building support
structures allow
39 Case RUO~-PO6
CA 02394057 2002-07-18
I high-rise buildings to be constructed which avoid many of the problems
described
2 above with respect to prior art high-rise buildings and their methods of
construction.
3 I will now describe additional methods and apparatus of the present
invention which
4 can be used to construct such building support structures and the resultant
buildings.
I will also describe the buildings themselves, which include many advantageous
6 aspects over prior art high-rise buildings. By "high-rise building" I mean a
structure
7 for housing people andlor equipment, and which is by standard definition 12
or more
8 stories high. A "story" is generally considered to be approximately 3-4
meters ( 10-13
9 feet) in height. While each story of such a building is typically defined by
a floor and
a ceiling, in some instances a floor and associated ceiling can be spaced
apart by
11 multiple stories. For example, the lobby of a high-rise office building can
span 6
12 meters (approx. 20 feet) or more in height, thus making the lobby a "two-
story" (or
13 more) lobby. In some applications (such as an industrial plant) a high-rise
building
14 can have sections where there are no defined floors or ceilings. Although
the
I S methods and apparatus of the present invention are particularly useful for
16 constructing high-rise buildings, they can be used to equal effect to
construct
17 buildings that do not fit the above definition of "high-rise building".
18 Turning now to Fig. 13, a side elevation view of a high-rise building 10 in
19 accordance with an embodiment of the present invention is depicted. The
building
includes a plurality of "floors" 11, and rests on a foundation "F". Turning to
Fig. 14, a
2I plan sectional view of the building 10 of Fig. 13 is depicted. The building
10 includes
22 a vertically oriented building support structure 20 which is supported on
the
23 foundation ("F", Fig. 13) and supports the "floors" 11. By "floor" I mean a
building
24 space defined by a floor surface 12 and a ceiling surtace. Typically, in
office and
residential buildings, a concrete slab will define the ceiling surface of a
first floor, as
26 well as the floor surface of the next higher vertically oriented floor. As
will be
27 described further below, multiple (or single) floors can be contained in a
building
28 module which can, be supported by the building support structure 20. The
building
29 support structure 20 depicted in Fig. 14 has a perimeter wall 22 which (as
depicted)
consists of 4 wall segments arranged in a square closed-shape when viewed in
the
3 I horizontal cross section depicted in Fig. 14. The perimeter wall 22 has an
outward-
32 facing outer surtace 220, and an inward-facing inner surface 22i. The
perimeter wall
33 22 defines an open inner area 21 (i.e., the entire area bounded by the
inner surface
34 22i of perimeter wall 22). The support structure 20 depicted in Fig. 14
further
Case RU01-P06
CA 02394057 2002-07-18
1 includes interior walls 24. As depicted, the "interior walls" 24 can be
considered as
2 two intersecting walls, each wall having a first end and a second end in
contact with
3 the inner surface of the perimeter wall 22. In this way, each interior wall
24
4 bifurcates the open inner area 21 of the building support structure 20. The
building
support structure 20 further includes a floor diaphragm 32 which is disposed
within
6 the open inner area 21 and is connected to the building support structure 20
at the
7 inner surface 22i of the perimeter wall 22. The floor diaphragm 32 can be
used for
8 multiple purposes, described below. For example the floor diaphragm 32 can
9 provide walkways to allow people to access elevator shafts 28 which can be
placed
in the open inner area 21. In this case, openings (not shown) can be provided
in the
11 perimeter wall 22 to allow personnel to move from the floor surface 12 to
the
12 walkways or hallway floor panels 32. As can be seen, the floor diaphragm 32
does
13 not need to have contiguous contract with the perimeter of the inner
surface 22i of
14 the perimeter waN 22, but can have void areas. When multiple floor
diaphragms
have void areas which align, then a continuous, open vertical passageway 26
can be
l6 formed through the building 10. These open vertical passageways 26 can be
used
17 to receive service passageways (not shown). Examples of "service
passageways"
18 include, without limitation, water pipes, electrical conduits, HVAC air
ducts,
19 stairways, elevator shafts 28, etc. Thus, some or al! of the utilities for
the building
can be placed in the inner open area 21 ~of the building support structure 20.
This is
21 a particularly advantageous arrangement since the utilities will thus be
protected by
22 the perimeter wall 22. For example, if a fire is burning in the primary
floor space 12,
23 the utilities (which can include water for extinguishing the fire) located
in the inner
24 area 21 will not be affected to the point where they can no longer fulfill
their function.
Turning to Fig. 15, a partial side sectional view of the building 10 depicted
in
26 Figs. 13 and 14 is shown. Fig. 15 depicts the top several floors 11 (or
"stories") of
27 the building 10. The building support structure 20 is visible, as are the
elevator
28 shafts 28, the floor diaphragms 32, and the open vertical passageways 26.
In one
29 embodiment, floor slabs for each floor can be attached to the perimeter
wall 22 of
the building support structure 20. In a preferred embodiment, depicted in Fig.
15,
31 one or more floors 11 (actually, sections of floors) are provided in the
form of a
32 "building module" 58. Turning briefly to Fig. 19, a detail of the upper
right comer of
33 the building 10 depicted in Fig. 15 is shown. Two building modules 58 are
shown in
34 side view. The upper building module 58 includes floors n, n-1 and n-2,
which are
4 i Case RU01-P06
CA 02394057 2002-07-18
I defined by floor slabs 12. The lower building module 58 includes floors n-3,
n-4. and
2 n-5, which are also defined by floor slabs 12. Building modules 58 can be
3 juxtaposed to the outer surface of the perimeter wall 22, and can be
attached to the
4 perimeter wall in a number of different manners, as will be described
further below.
Generally, the building modules 58 are attached to the building support
structure 20
6 in a cantilevered fashion. That is, the building modules 58 are cantilevered
off of the
7 perimeter wall 22. Supports 60 (such as steel cables or metal rods, for
example) can
8 be attached to the floor slabs and the perimeter wall 22, as well as to
module interior
9 walls 53, to provide additional support for the building module 58 from the
building
support structure 20. As can be seen, floor "n-3" is actually defined by a
space
11 between the upper and lower building modules 58. A facade 52 covers the
outward-
12 facing ends of each building module 58. The facade can include windows and
other
13 design panels which provide the building 10 with its outward appearance.
14 A building in accordance with the present invention is not limited to the
use of
building modules (such as modules 58 of Fig. 15) for the primary useable space
of
16 the building. Rather than modularize the useable space, a separate "floor"
can be
17 attached to the building support structure of the present invention. For
example, the
18 modules 58 of Fig. 15 can be considered as separate floors. I will use the
19 expression "floor" to include any type of structure which is attached to
the building
support structure and provides useable space. Typically, a "floor" will be a
concrete
21 panel (typically pre-stressed) which defines the floor space of an office
or an
22 apartment. A "floor" can also include a steel structure (either solid plate
steel, a steel
23 frame, or a combination thereof). Other types of "floor" configurations can
also be
24 used (wood structures, composite structures, etc.) The "floor" does not
need to be a
continuous panel, but can have openings (such as a work deck in a process
plant).
2b In any event, "floors" are attached to the outer surtaces of the building
support
27 structure of the present invention by being supported in a cantilevered
manner. This
28 can be accomplished by using tension rods or cables (60, Fig. 19) or simple
angular
29 bracing which attached at a first end to the outer surface of the building
support
structure, and as a second end to the "floor". Such angular bracing can be
provided
31 below a floor (to put the bracing in compression), above a floor (as in
Fig. 15) to put
32 the bracing in tension, or a combination. A notable feature of the present
invention is
33 that a first, lower floor or building module attached to a building support
structure of
34 the present invention does not necessarily (and preferably does not) bear
any load of
42 Case RU01-P06
CA 02394057 2002-07-18
I a second, higher floor or building module. That is, floors or building
modules
2 attached to the building support structure of the present invention are not
dependent
3 on one another for support. Preferably, for two vertically adjacent floors
or building
4 modules, a first one of the floors or building modules will bear 10% or less
of the
weight of the immediately adjacent floor or building module above it. This
feature
6 allows each floor or building module to be individually designed, in shape
and
7 functionality, independent of the shape and functionality of the other
floors or building
8 modules.
9 As can be seen in Fig. 19, a gap 56 can be provided between adjacent
building modules 58. This gap 56 can allow slight rotational movement (i.e.,
1 I clockwise or counterclockwise, as viewed in Fig. 19) of one building
module 58 with
I Z respect to the other. For example, if wind or seismic loads deflect the
upper portion
13 of the building 10 of Fig. 13 in a right-ward direction (i.e., producing
clockwise
14 rotation of the upper portion of the building 10), then the gap 56 of Fig.
19 will tend to
I S be reduced. This arrangement allows flexibility of the building 10, which
allows the
16 building to more easily accommodate seismic and wind loads. As will be
described
17 further below, a stop-element can be placed in the gap 56 so that after a
preselected
18 amount of building deflection is encountered, further deflection will be
resisted. For
19 example, an elastomeric compound can be placed in the gap area 56. As the
building deflects in the manner just described and the building modules 58
come
21 closer together at the outward-facing ends (at facade 52), the elastomeric
compound
22 will be compressed, thus resisting further deflection of the building. A
flexible facade
23 element (not shown), such as a bellows, an elastic sheet, or a sliding
sheet
24 arrangement, can be provided at facade elements 56 in order to cover the
gap 56
and resist intrusion of ambient air and rein into the area between building
modules
26 58.
27 Turning to Fig. 16, a side view of the upper portion of building support
28 structure 20 of Fig. 14 is shown. Fig. 16 shows how openings 30 can be
formed in
29 the perimeter wall 22, allowing access to the floor diaphragms 32 (only one
of which
is shown in Fig. 16). The openings 30 can be, for example, personnel openings
at
31 the location where a building module (58, Fig. 19) is located juxtaposed to
the outer
32 surface of the perimeter wall 22, to thereby allow personnel to move
between the
33 building module and the open inner area 21 within the building support
structure 20.
34 For example, if stairways andlor elevator shafts are located in the open
inner
43 Case RUOf-P06
CA 02394057 2002-07-18
1 area 21, then personnel can move from residential or office building modules
to the
2 elevators or stairs. Likewise, the openings 30 can allow service personnel
to access
3 utilities and the like which can be located in service passageways
(conduits, pipes,
4 ducts, etc.) placed in the inner open area 21. In another embodiment,
described
more fuNy below, the openings 30 can be vehicle openings to allow vehicles
access
6 to the inner open area 21, in which vehicle ramps can be located to allow
vehicles to
7 move upward or downward in the building to vehicle parking spaces on
designated
8 parking floors. The access openings 30 can also be used to provide utilities
from
9 service passageways within the inner open area 21 to the building modules
supported on the building support structure 20.
11 Turning to Fig. 17, a detail of the upper left corner of the building
support
12 structure 20 depicted in plan view in Fig. 14 is shown. Fig. 17 depicts a
cross
13 sectional plan view of the comer of perimeter wall 22, showing one
embodiment of
i4 how the perimeter wall 22 can be configured. As shown, the perimeter wall
22
includes a cast, reinforced concrete central support shell 36 which can be
cast using
16 the apparatus described above with respect to Figs. 1-12. The perimeter
wall 22
17 further includes an outer coating 34 of ceramic or other fire protec~ve
material on the
t 8 exterior of the concrete shell 36, as well as an inner coating 35 of
ceramic or other
19 fire protective material on the interior of the concrete shell 36. As the
concrete shell
36 is cast, post tension tendon ducts 38 can be placed in the concrete shell
36. The
21 post tension tendon ducts 38 can be provided with a ceramic or other heat
protective
22 lining 37.
23 Turning to Fig. 18, a side elevation, sectional view of the comer of the
building
24 support structure 20 of Fig. 17 is shown. The building support structure 20
is
supported on a foundation "F", which is located in a subterranean location
(beneath
26 the surface 41 of the surrounding terrain). The foundation "F" can include
a spread
27 foundation or pile cap 47 which is supported on piles or caissons 40. in
order to
28 maintain the concrete in the perimeter wall 22 of the support structure 20
in constant
29 compression, even during earthquakes and under wind loads, the perimeter
wall
(and any interior walls within the support structure 20) are preferably post-
tensioned.
31 Accordingly, the perimeter wall 22 can include post-tension tendon ducts
38, in
32 which post-tension tendons 44 can be placed. The process of post-tensioning
33 concrete structures is welt known in the art, and need not be described in
detail.
34 Generally, in post-tensioning, one end of a post-tension tendon is
typically anchored
44 Case RU09-P06
CA 02394057 2002-07-18
1 at one end or side of a concrete structure, and the other end of the tendon
is
2 connected to a jack, such as a hydraulic jack, at the other end or side of
the
3 structure. The jack putts on the tendon until a predetermined tension is
achieved in
4 the tendon, at which time the tendon is anchored to the structure at the
jacking end.
The jack can then be removed, or can be left in place for later adjustment of
the
6 tension in the tendon. Accordingly, post-tension tendons 44 can pass from
the top of
7 perimeter wall 22, where a post-tension anchor (or jack) 48 is located, to
the bottom
8 of the perimeter wall. Preferably, the post-tension tendons 44 pass through
the
9 foundation pile cap 47 in order to additionally secure the perimeter wall 22
to the
foundation "F". The lower ends of tendons 44 are connected to jack {or post-
tension
11 anchor) 46. That is, the post-tensioning jack can be either item 48 at the
top of the
12 perimeter wall 22, or item 46 at the bottom of the perimeter wall 22 (and
thus the
13 post-tension anchor is alternately item 46 or item 48). Further, items 48
and 46 can
14 both be post-tensioning jacks. In an alternative arrangement, an
intermediate post-
tension jack/anchor 50 can be provided so that as the perimeter wall is
evolved
16 upward, it can be post-tensioned. The lower post-tensioning jack/anchor 46
can be
t 7 accessed via a tunnel 42 which provides a crawl-space 43. In addition to
post-
I S tensioning the perimeter wall 22, the foundation 47 can also be post-
tensioned by
19 providing foundation post-tensioning ducts 49 and foundation post-
tensioning
tendons 45.
21 Of particular note is how the building support structures of the present
22 invention handle the relatively Large out-of-plane bending and associated
high
23 transverse shears and rotational deflections due to the force couple
reactions
24 created when supporting the horizontally cantilevered dead and live loads
of a "floor"
or building module. The building support structure of the present invention
can be
26 described as a "thick shell structure", versus a "thin shell structure."
These
27 expressions are well understood in the art of designing structures.
Generally, load
28 analysis of a thin. shell structure does not take into account the
thickness of the
29 support member, whereas load analysis of a thick shell structure does.
Since thin
shell concrete structures are not suited to handle large transverse shears,
they must
31 be thickened significantly. to receive these force couples. This
"thickening" can be
32 effectively accomplished in several ways: (1) by centering the force couple
reactions
33 along an inherent stiffened section of the wall as occurs at a corner or
where an
34 orthogonal wall butts into the wall (see wall intersects that occur along
lines a, b, c
45 Case RU01-POfi
CA 02394057 2002-07-18
1 and a', b' and c' of Fig. 14), (2) by thickening the wall several fold along
its height
2 and width to enable it to handle these large force couple reactions anywhere
along
3 its face (e.g. see the perimeter wail 622 of Fig. 38 which is made "thick"
by providing
4 concrete-saving voids 623), (3) by providing thickened horizontal sections
of the wall
where these large forces are reacted to the wall, thus transferring this load
laterally
b in beam action to adjacent, orthogonal walls or intermediate stiffener walls
(e.g. at
7 the threshold diaphragm level 632 of the support structure of Fig. 38), or
(4) by
8 reacting the force couple reactions at discrete floor levels where the floor
9 diaphragms stiffen the wall and transfer these loads to adjacent orthogonal
wails.
The building support structure of this invention can be designed to handle
these
I 1 couple force reactions in any of the four ways mentioned above. Methods 1
and 4
12 are the least desirable because they unnecessarily constrain the location
of where
13 building modules and floors can be attached to the support structure.
Method 2
14 alone, or in combination with method 3, provide the means to attach
building
modules or floors virtually anywhere on the outer surface of the building
support
16 structure of the present invention.
17 It is not common practice to cantilever floors or building modules from the
18 frame structure of prior art thin-shell building support structures, since
there is no
19 standard load path to react the large out of plane bending and transverse
shear
loads in the vertical load bearing or column members of those structures. That
.is,
21 the columns and shear cores of prior-art high-rise buildings are
principally designed
22 to handle axial loads, and not large bending loads along the columns or
shear cores.
23 The fourth method (described above) would be the only logical means of
handling
24 these force couple reactions from the cantilevered modules within the
context of the
prior art, but the typical floor diaphragm in the prior art is not designed to
handle
26 these types of loads.
27 There are examples of relatively thick shell "towers" in the prior art, but
there
28 are no prior art examples of a thick shell type building which cantilevers
the usable
29 space (a "floor" or building module) from a thick shell support structure.
Accordingly,
the present invention includes a building having a building support structure
which is
3I a thick shell concrete structure. The building support structure can be a
closed form
32 structure having a perimeter wall (such as wall 22 of Fig. 14), or it can
be an open
33 shape structure (described below). The building includes "floors" that are
supported
34 in a cantilevered manner from the building support structure.
46 Case RU01-Pa6
CA 02394057 2002-07-18
1 Figs. 13 and 14 depict a high-rise building 10 which is essentially square-
Z shaped in a horizontal cross section (Fig. 14). The building support
structure 20 of
3 Fig. 14 is also depicted as being essentially square-shaped in a horizontal
cross
4 section. However, there is no requirement that either the building, or the
building
support structure, of the present invention be essentially square-shaped in a
6 horizontal cross section. Turning to Fig. 20, a side elevation view of
another high-
? rise building 62 in accordance with the present invention is depicted. The
building 62
8 is supported on foundation "F°, and includes floors 63 which are not
all of the same
9 width. The side profile of the building 62 can be described as a "double
hourglass"
shape. Since the primary support for the floors of a building in accordance
with the
11 present invention is provided by an inner building support structure, fewer
constraints
12 are placed on the side profile shape of the resultant building. In the
prior art, most of
13 the support for the floors of a high-rise building is provided by steel
members located
14 at the outer periphery of the building. Accordingly, these prior art
buildings have side
t 5 profiles which are generally straight. While some prior art high-rise
buildings have a
16 stepped shape, the steps are generally limited to narrowing the horizontal
cross
17 section of the building as the height is increased. That is, prior art high-
rise buildings
18 generally do not have upper floors that are wider than lower flOOrs. Two
horizontal
i 9 cross sections of the building 62 of Fig. 20 are depicted in Figs. 21 and
22. In Fig.
21, the floor 63a is essentially elliptical in a horizontal cross section,
while in Fig. 22
21 the floor 63b is essentially circular in a horizontal cross section.
However, both
22 floors 63a and 63b are supported by the same building support structure 20,
which is
23 essentially square in a horizontal cross section.
24 Turning to Fig. 23, a horizontal cross section of another building 64 in
accordance with the present invention is depicted. The building 64 includes a
26 building support structure 66 which includes an outer perimeter wall 68.
Outer
27 perimeter wall 68 forms a closed shape that is generally circular in a
horizontal cross
28 section. The building support structure depicted in Fig. 23 further
includes an inner
29 perimeter wall 72, and radial spoke interior walls 70 which connect the
outer
perimeter wall 68 to the inner perimeter wall 72. The outer perimeter wall 68,
inner
31 perimeter wall 72, and radial spoke interior walls 70 define primary open
inner areas
32 74, in which floor diaphragms can be located (similar to floor diaphragms
32 of Fig.
33 14). The inner perimeter wall 72 further defines a secondary open inner
area 75 in
34 which service passageways, such as elevator shafts 73, utility conduits,
and other
47 Case RU01-P06
CA 02394057 2002-07-18
1 services can be located. The building support structure 66 depicted in Fig.
23 thus
2 provides additional structural support over the building support structure
20 of
3 Fig. 14, due primarily to the presence of the inner perimeter wall 72. The
inner
4 perimeter wall 72 of building support structure 66 also provides an
additional level of
protection for service passageways located within the secondary open area 75.
6 Accordingly, in the event the integrity of the outer perimeter wall 68 is
compromised,
7 service passageways located within the secondary open area 75 will still be
8 protected by inner perimeter waA 72.
9 Building 64 of Fig. 23 includes building modules 76 which are supported by
building support structure 66. Building modules 76 are depicted as producing a
floor
I 1 in an octagonal shape when viewed in a horizontal cross section of the
building 64.
12 However, it will be appreciated that the building modules supported by the
building
13 support structure 68 can produce horizontal cross sectional shapes of any
shape,
14 including, by way of example only, rectangular, circular, and elliptical
shapes.
The building support structure 20 shown in Figs. 15 and 18 depict a building
16 support structure having a perimeter wall 22 of constant thickness and
horizontal
17 cross sectional shape throughout the entire height of the building 10.
However, this
18 is not a requirement of the present invention. That is, the thickness of
the perimeter
19 wall of the building support structure, as viewed in a horizontal cross
section, can
vary with the height of the building support structure. Further, the
horizontal cross
21 sectional area of the building support structure can also vary with the
height of the
22 building support structure. This is depicted in Fig. 24, which shows a side
elevation
23 sectional view of a building support structure 80 supported on a foundation
"F°, in
24 accordance with the present invention. As depicted in Fig. 24, the building
support
structure 80 includes a bottom, first section 80a having perimeter walls of a
first
26 thickness, and a middle, second section 80b having perimeter walls of a
second
27 thickness, the second thickness being less than the first thickness. The
building
28 support structure .80 further includes an upper, third section 80c which
has a
29 horizontal cross sectional area less than the horizontal cross sectional
area of the
first and second sections 80a and 80b of the building support structure 80.
The
3l upper section 80c of the building support structure 80 can be supported on
the
32 middle section SOb by an intermediate building support structure platform
81. Since
33 the lower section 80a of the building support structure 80 supports the
bulk of the
34 weight of a building supported by the building support structure 80, the
thickness of
4g Case RUO~-P06
CA 02394057 2002-07-18
1 the perimeter walls of section 80a are preferably thicker than the perimeter
walls of
2 sections 80b and 80c. Likewise, since the greatest moments (overturning
forces)
3 due to wind and seismic loads will be encountered where the building support
4 structure 80 is jointed to the foundation "F", the horizontal cross
sectional area of
section 80a is preferably greater than the horizontal cross sectional area of
either
6 section 80b or 80c.
7 Figs. 14 and 23 depict building support structures (respectively, structures
20
8 and 6fi) which have horizontal cross sections of a closed shape
(speciflcaliy, a
9 square shape (Fig. 15), and a round shape (Fig. 23)). By "closed shape" I
mean a
shape defined by a wall (or wails) that enclose an area. Fig. 26 depicts yet
another
11 closed shape of a horizontal cross section of a building support structure
84, being a
12 triangular shape. Other closed shapes can also be used, including without
limitation,
13 a rectangle, an ellipse, and a pentagon. In addition to having a horizontal
cross
14 section of a closed shape, building support structures in accordance with
the present
invention can also have a horizontal cross section of an open shape. By "open
t 6 shape° I mean a shape defrned by a wall (or walls) which does not
enclose an area.
17 Fig. 25 depicts one example of a horizontal cross section of a building
support
18 structure 82 which is an open shape. Building support structure 82
essentially
19 includes two intersecting straight walls (not unlike interior walls 24 of
the building
support apparatus 20 of Fig. 14). The building support structure 82 of Fig. 25
does
21 not include a perimeter wall which encloses an area, and so the shape can
be called
22 an "open shape". As indicated in Fig. 23, a building support structure in
accordance
23 with the present invention can include a plurality of perimeter walls
(walls 68 and 72),
24 as well as interior walls (70). in addition to closed shapes and open
shapes, a
building support structure in accordance with the present invention can have a
26 horizontal cross section of a combined opened and closed shape. An example
of
27 such a shape is depicted in Fig. 27, which depicts a horizontal cross
section of a
28 building support structure 86. The building support structure 86 includes
the closed
29 shape triangular perimeter wall 84 of Fig. 26, as well as a secondary,
inner triangular
closed perimeter wall 83. Attached to the apexes of the outer triangular
perimeter
31 wall 84 are three open shape extensions 87, which project outward from the
apexes
32 of the triangular wall 84. The configuration depicted in Fig. 27 can
provide greater
33 support for floors or floor modules supported on the outward-facing
surfaces of the
34 perimeter wall 84, and can also provide greater resistance to overturning
moments
49 Case RU01-P08
CA 02394057 2002-07-18
1 (due to wind or seismic loads, for example). Common to all of these building
support
2 structures, and to a building support structure in accordance with the
present
3 invention, is that they include a floor support wall or walls defining floor
support
4 surfaces. For example, the building support structure 20 of Fig. 14 includes
floor
support wall 22 (perimeter wall 22) defining a floor support surface (outward-
facing
6 surface 220). Further, floors (or building modules, or both) are supported
from the
7 floor support surface in a cantilevered manner.
8 Turning to Fig. 28, an isometric diagram depicts how the building 10 of Fig.
13
9 can be constructed according to the present invention. The building support
structure 20 is evolved upward in direction "X", and can be produced using the
I 1 apparatus 100 of Fig. 1, and other apparatus described herein. As the
building
12 structure 20 evolves upward, building modules 58 can be lowered into
position for
13 attachment to the outward-facing surface of the perimeter wall 22. Cranes
88 can be
14 used to lower the building modules 58 into place. Although cranes 88 are
depicted
as being supported by the perimeter wall 22, a preferred embodiment for
placing a
16 crane is described further below. The configuration depicted in Fig. 28
allows
17 building modules 58 to be constructed at an off site location and then be
brought to
18 the building construction site for mounting on the building support
structure. Cranes
19 88 can move upward in direction "U" as building modules 58 are added to the
support structure 20..
2i Yet another building that can be constructed according to the present
22 invention is depicted in a side elevation view in Fig. 29. The building 400
of Fig. 29
23 has a centrally located building support structure 420 which has a
perimeter wall
24 422. Turning briefly to Fig. 30, a cross sectional diagram of the building
400 is
depicted, and it can be seen that the perimeter wall 422 is a closed shape
having an
26 outer surface 422o that is generally rectangular (square) and an inner
surface 4221
27 that is generally round. Openings 430 in the perimeter wall do not extend
the height
28 of the structure 420 (i.e., they are located similarly to opening 30 in
building support
29 structure 20 of Fig. 16). Therefore, the horizontal cross sectional shape
of building
support structure 420 is a closed shape, notwithstanding the suggestion in
Fig. 30
31 that the building support structure 420 is two separate parts. Returning to
Fig. 29,
32 the perimeter wall 422 defines an inner open area 450 within the building
support
33 structure, with floor diaphragms 432 allowing access from the building
modules to
34 the open inner area 450. The building support structure 420 is supported by
a
50 Case RU01-P06
CA 02394057 2002-07-18
1 foundation "F", which is shown in detail in Fig. 28A. Tip foundation "F"
includes a
2 pile cap 404 which is supported on piles or caissons 70. Access tunnels 403
are
3 defined in the pile cap 404 to allow workers to access post-tensioning jacks
andlor
4 anchors. Preferably, the perimeter walls 422 are past-tensioned to the
foundation
"F" using post-tension tendons 406d. Further, the pile cap 404 is preferably a
post-
6 tensioned concrete structure having orthogonaliy oriented horizontal post-
tensioning
7 tendons 406a and 406c, as well as vertical post-tensioning tendons 406b. As
8 depicted, the foundation "F" is located a distance below the ground level
"G" of the
9 surrounding terrain.
Supported on the building support structure 420 are a plurality of building
11 modules. A variety of different types of building modules are depicted.
Between the
12 foundation "F" and the ground level "G", parking floor building modules
410, 411 and
13 415 are supported, at least partially, on the perimeter wall 422. Three
different types
14 of parking floor module are depicted, although typically only one
configuration will be
used. Parking floor module 410 is a purely cantilevered design, wherein the
entire
16 floor module is supported by the perimeter wall 422. Floor module 411 is
supported
17 at a first end by the perimeter wall 422, and at a second end by support
499, which
18 can be anchored to a subterranean retaining wall 402. Subterranean
retaining wall
19 402 can be anchored to the surrounding ground by tendons 413. Floor module
411
can be of a lighter design than floor module 4'10 due to the fact that floor
module 411
21 is supported at both ends. Finally, floor module 415 is similar to floor
module 411 in
22 that it is supported at both ends, the support at the second end being a
column 498
23 which rests of the bottom of the retaining structure 402. The various
levels in the
24 subterranean parking area 408 can be accessed via the inner open area 450,
as will
be described more fully below.
26 In general, each building module contains at least one floor slab 412 which
is
27 located at the level of an access opening (430, Fig. 30) to allow movement
of people
28 and/or vehicles from the building modules into and out of the inner open
area 450.
29 Building modules 458a and 458c (Fig. 29) are two-story, two-floor modules,
and
building module 458b is a four-story, four-floor module. The reasons for
having
3 I building modules of~ different story counts is that the modules can be
fabricated by
32 different entities, or can have different design specifications. For
example, the four-
33 story module 458b can be a module of office space intended to be leased out
to a
34 single entity, in which case the teasing entity can have preconfigured the
office
5 ) Case RU01-P06
CA 02394057 2002-07-18
1 layout (walls, etc.) for all four floors. On the other hand, two-story
modules 458a and
2 458c can all be leased to different entities, in which case each leasing
entity can
3 desire to preconfigure its own module. Building module 458f is a three-
story, three
4 floor module, and module 458d is a four-story, one floor module. One use of
building
module 458d can be as a ballroom. Building modules 458e are two-story, two
floor
6 modules, but have floor slabs 412 which extend farther from the perimeter
wall 422
7 than do the floor slabs of the other building modules. Building modules 458e
thus
8 can provide the building 400 with a side profile having a certain amount of
relief (as
9 compared to the side profile of building 10 of Fig. 13, for example).
Preferably, the
building modules are 6 stories (approx. 18-24 meters, or 60-78 feet) or less
in height,
11 and are also preferably not more than one-fifth of the height of the
overall height of
12 the building support structure to which they will be attached.
13 Turning briefly to Fig. 30, davits (or cranes) 492 can be supported from
the
14 building support structure (or the apparatus used to for the building
support
structure). These davits can be used to lift building modules (such as modules
458a-
16 g of Fig. 29) into place. Moreover, the davits allow building support
modules to be
17 lifted into place in a highest-first mode. That is, with respect to Fig.
29, a first
18 building module 458a can be lifted in place and attached to the building
support
19 structure 420. "hereafter, a second building module 458c (immediately
underneath
module 458a) can be lifted in place and attached to the building support
structure
21 420. One advantage of this arrangement is that should the second module
slip
22 during installation, it will not damage any modules beneath it (there
preferably being
23 no modules beneath it when the second module is being installed).
24 Between each building module and the adjacent building module a gap 56 is
preferably provided, so that the building modules are not in direct contact
with one
26 another. Preferably, a compressible or moveable element 418 is provided in
the gap
27 area 56 to seal the area between adjacent modules. The compressible or
moveable
28 element can be, for example, a solid elastomeric member, or a hollow
extruded
29 resilient member. As described above, the gap 56 is provided between
adjacent
modules to allow a given amount of desirable "sway" (movement in directions
"Y°) to
31 the building 400. When sway reaches a certain point, the gap 56 on one side
of the
32 building will be closed, and the structure will then stiffen to resist
additional
33 undesirable sway. However, since the building support structure 420 will
sway about
34 a pivot point located at the foundation "F", any building module located at
or below
52 Case RU09-P06
CA 02394057 2002-07-18
1 the ground level "G" can encounter resistance from the surrounding terrain,
resulting
2 in buckling of the floor slab in the building module. To address this
problem, a
3 variety of solutions can be employed. For example, with respect tea the
parking level
4 building modules 410, 411 and 415, it will be seen that each floor slab can
move
laterally (i.e., in directions "Y") without becoming compressed (and thus
buckling).
6 With respect to building modules located at the ground level "G", one
solution is
7 indicated by building module 458h, which is placed directly on a separately
8 supported concrete slab 424. As can be seen, building module 458h is not
rigidly
9 connected to the perimeter wall 422. However, a flexible coupling can be
provided
between the module 458h and the perimeter wall 422 to provide access from the
I 1 module to the open inner area 450 (via an opening, not shown). Another
solution to
12 the ground level building module situation is indicated by module 458g,
which is a
13 two-story, two floor module. As can be seen, module 4588 is not attached at
the
14 ground level "G", but is in fact attached to the perimeter wall 422 one
story up from
i 5 the ground level, creating a space 497 between the module 458g and the
ground
16 level "G°. A facade element 496 can be attached to the outward-
facing end of the
17 module 4588, and the facade element 496 can approach (but preferably not
directly
18 contact) the ground "G". A flexible element (nat shown) can be inserted in
the area
19 between the bottom edge of the fagade element 496 and the ground "G" to
allow
relative movement between the facade element 496 and the ground "G". As is
21 apparent, other configurations can also be provided which will reduce the
chance for
22 building modules located at and below the ground level "G" to become
damaged due
23 to movement of the building support structure 420.
24 Near the top of the building support structure 420, diaphragms 495 can be
formed to seal off a void 414 within the inner open area 450 of the support
structure
26 420. This void area 414 can be used to hold water or the like, to thus
facilitate fire
27 fighting and also to provide an inertial mass to resist sway of the
building 400 due to
28 seismic forces. A.roof cap 416 can be placed over the uppermost diaphragm
495
29 not only for aesthetic reasons, but also to cover and protect the anchors
of the post-
tensioning tendons 4064.
31 Turning to Fig. 30, a horizontal cross section through building modules
458c
32 of building 400 is depicted. As can be seen, there are floor modules 458c
attached
33 to the building support structure 420 at this level. A fire resistant
material 423 can be
34 placed around the outer surface of the perimeter wall 422 to protect post-
tensioning
53 Case Ru01-POs
CA 02394057 2002-07-18
I tendons, and structural steel 445 in the wall 422, as weN as the service
passageways
2 placed within the inner open area 450 defined by the perimeter wall 422. A
floor
3 diaphragm 432 can be placed within the inner open area 450, and access
openings
4 430 can allow people to move from the building modules 458c to the inner
open area
450, and visa versa. Service passageways placed within the inner open area 450
6 can include a stairwell 436, elevator shafts 494, and utility ducts 442
which can
7 contain utilities such as electrical conduits, water pipes, HVAC air ducts,
and
8 telecommunications cables. The utility ducts 442 can be accessed by access
doors
9 434. Post-tensioning tendons 438 can be used to support the floor modules
458c
from the perimeter wall 422 of the building support structure, as will be
described
11 more fully below.
12 Turning to Fig. 31, a detail of the building support structure 420 depicted
in
13 Fig. 30 is shown. Embedded within the perimeter wall 422 is a vertically
ascending
14 spiral of reinforcing steel ("rebar"), horizontal reinforcing steel 448,
and post-
tensioning tendon conduits 444. Climb pipes 446 can also be incorporated
within the
16 perimeter wall 422, which function as climb pipe 99 of Fig. 1, described
above and
17 described more fully below. The building module support tendons 438 can
also be
I S embedded within the perimeter wall 422, and can be provided with post-
tension jack
19 attachment connections 452, which can be accesses via the access opening
430.
While the building modules can be attached to the building support structure
21 using conventional means such as bolting or welding together steel plates,
or a slot-
22 and-flange configuration, an alternate (or additional) means of securing
the building
23 modules to the building support structure can employ post-tension tendons.
Fig. 32
24 depicts a side elevation cross section of the upper right corner of the
perimeter wall
422 of Fig. 30, and shows one manner of connecting the building module 458c to
the
26 building support structure 420 using post-tensioning tendons. The following
27 discussion will make reference not only to Fig. 32, but Fig. 33 (being a
detail of the
28 building module/perimeter wall junction 465), and Fig. 34 (being a cross
section of
29 the building module/perimeter wall junction depicted in Fig. 33). With
reference to
Fig. 32, a post-tension tendon duct 460 is located in the perimeter wall 422.
During
31 fabrication of the building module 458c, a hollow module chord 480 is
fabricated into
32 the floor element of the module. A bundle of cables (tendon) 438 (Fig. 34)
are
33 anchored inside the hollow module chord 480 with end-anchor 462 (Fig. 32)
and
34 intermittent shear plates 464, as well as fire resistant grout 468. The
cables 438
54 Case RU01-P06
CA 02394057 2002-07-18
1 protrude beyond the left end (as seen in Fig. 32) of the building module
chord 480 so
2 that they can be received within tendon duct 460. As the module 458c is
lifted into
3 place (as in Fig. 28, for example), cables 438 dangling from the building
module
4 chord 480 are inserted into tendon duct 460 and pulled into the duct with a
lead line
until the module 458c is in place. Anchor block 452 is inserted around the end
of the
b tendon 438, and the anchor block 452 is seated within a capture seat 453 in
7 preparation for tensioning the building module 458c to the building support
structure
8 420. The pasition of the module 458c relative to the building support
structure 420
9 can be set according to survey, and with the aid of vertical adjuster 478
(Fig. 34) and
lateral adjuster 482 (which together act on the fluted duct extender 476), as
well as
11 variable thickness shims {not shown) at the junction 465. As the cables 438
are
12 tensioned at anchorage 452, adjusters 478 and 482 temporarily counter react
any
13 cable side thrust due to misalignment as well as the gravity loads of the
module 458c
14 as the crane support of the module 458c is released during the tensioning
process.
After the initial phase of tensioning is accomplished, grout 470 can be
injected into
16 the open area of chord 480 through an appropriately located orifice 472. If
it is
17 desired that the cable 438 be readily removable in the future to replace a
module (as
18 in the case of replacing a damaged module or upgrading a modular processing
plant,
i 9 for example) the tendon duct 460 can be plugged at the bell end of duct
extender
476 (Fig. 34) prior to assembly of the module 458c onto the support structure
420 so
21 that fire resistant permanent grout 470 does not ingress into tendon duct
460. After
22 grout 470 sets up, a protective but light strength grout 474 can be
injected from
23 anchor 452 such that it fills the entirety of duct 460 and the area in the
extension
24 tube 476 around cable 438. This type of grout allows the cable 438 to be
removed
without damage in the future. If however, it is desired that the grout 474 be
26 permanent, then grout 470 can be allowed to flow and set-up throughout
ducts 460
27 and 476, as well as in the area 470. In this way, the grout can act as a
secondary
28 protection in the event the anchor 452 were affected by fire or explosion.
Anchor
29 452 is afforded fire protection with a grout cast over it within capture
seat 453, as
well as drywall, cement, or plaster protection 454.
31 Turning now to Fig. 35, a plan view of an apparatus 500 of the present
32 invention which can be used to construct the building support structure 420
of the
33 building 400 of Fig. 31 is depicted in a plan view. Fig. 36 depicts a side
elevation
34 sectional view of the apparatus 500. The apparatus 500 of Fig. 35 should be
55 Case RU01-P06
CA 02394057 2002-07-18
1 compared to the apparatus 350 of Fig. 12, described above. It will be
apparent that
2 the apparatus 350 of Fig. 12 includes ganged apparatus 100 (Fig. 1 ) having
yokes
3 106A, 1068, etc., interspersed with sets of truss modules (100B, 100D, etc.)
not
4 having yokes, and corner forming apparatus 300A, 3008, etc. Of note is that
the
apparatus 350 includes opposing first and second concrete forms (e.g., 114a
and
6 116a) which are joined by yokes, resulting in an open inner area 351. By
contrast,
7 the apparatus 500 of Fig. 35 includes truss modules 502a, 502b, 502c and
502d
8 which are connected by comer-forming truss modules 520a, 520b, 520c and
520d.
9 Truss modules 502a, 502b, 5D2c 502d, 520a, 520b, 520c and 520d support
outside
concrete form 514, which is arranged in the shape of a square (to form the
square
I 1 outer surface of building support structure 420 of Fig. 31 ). However,
whereas each
12 of the outer truss modules of the apparatus 350 of Fig. 12 generally has a
13 corresponding inner truss module supporting an inner concrete form, in the
14 apparatus 500 the truss modules 502a, 502b, 502c 502d, 520a, 520b, 520c and
520d do not have corresponding inner truss modules. Rather, the apparatus 500
16 includes an insert concrete form. 516, which is depicted here as being
circular in
17 shape and is (or can be) inserted into the open inner area 450 which is
defined by
18 the outer concrete forms 514. Further, whereas opposing parallel concrete
forms
19 (e.g., 114a and 116a) of the apparatus 350 of Fig. 12 are generally joined
by a yoke
(e.g., 106A) which is oriented essentially orthogonal to the forms, in the
apparatus
21 500 of Fig. 35 the yokes (503a, 503b, etc.) do not span befinreen opposing
parallel
22 concrete forms 514. In the configuration depicted in Fig. 35, the yokes
(503a, 503b,
23 etc.) join the truss modules that support form 514 near the outer corners
of the
24 apparatus 500.
in general, the apparatus 500 includes a plurality of inward-facing concrete
26 forms 514 arranged adjacent to one another and in a closed-perimeter
formation.
27 Although the closed-perimeter shape is depicted in Fig. 35 as being a
square, other
28 shapes can also be employed, such as, by way of example only, a rectangle,
a
29 circle, and ellipse, and a hexagon. The apparatus 500 further includes a
plurality of
truss modules 502a, 502b, 502c 502d, 520a, 520b, 520c and 520d, which are
31 preferably (but not necessarily) connected to one another to form an
integral
32 assembly of truss modules. Each truss module is associated with a
respective
33 inward-facing concrete form 514. The truss modules can support a work deck
510,
34 which can be confrgured similarly to the work deck 110 of Fig. 10. The
apparatus
56 Case 81101-P06
CA 02394057 2002-07-18
1 500 also includes a plurality of actuator devices, which are not shown in
Fig. 35 but
2 can be similar to the actuator devices 196, 198 andlor 200, described above
with
3 respect to Fig. 3. Each actuator device is mounted on a respective truss
module
4 502a, 502b, 502c 502d, 520a, 520b, 520c and 520d, and is configured to
translationally move the associated inward-facing concrete 514 form with
respect to
6 the respective truss module. Apparatus 500 includes an insert concrete form
516
7 which is arranged in a closed-perimeter shape (here, a circle, but other
shapes can
8 also be used). The insert concrete form 516 is configured to be located
within the
9 closed-perimeter formation produced by the plurality of inward-facing
concrete forms
514. As depicted, apparatus 500 further includes a yoke system 506, which
11 connects truss modules 502a, 502b, 502c 502d, 520a, 520b, 520c and 520d to
the
12 insert concrete form 516. The apparatus 500 further includes a plurality of
climbing
13 devices (508a through 508h of Fig. 35, of which 508a through 508d can be
seen in
14 Fig. 36) which are attached to the yoke system 506. The climbing devices
508a,
508b, etc. are configured to engage associated climb rods (in Fig. 35, climb
rods
16 99a-99h) to thereby move the apparatus 500 along the climb rods, generally
(but not
17 necessarily) in an upward direction.
18 The yoke system 506 depicted in Figs. 35 and 36 includes yoke arms 503a
19 through 503h, which are each connected to a truss module (e.g., 502a, 502b,
etc.)
at a first end, and each support a climbing device (e.g., 508a through 508d,
Fig. 36)
21 at a second end. Orthogonally oriented yoke arms which are located near a
22 common comer (e.g., arms 503g and 503a, Fig. 35) are joined together by the
23 climbing devices (e.g., 508c and 508d), as well as by a corner connecting
24 member 504a which connects the climbing devices (all of which can be seen
in side
view in Fig. 36). The yoke system 506 includes four corner connecting members
26 504a thought 504d. Generally parallel yoke arms which are located on the
same
27 side of the apparatus 500 are connected together by side connecting members
512a
28 through 512d.
29 The apparatus 500, as viewed in Fig. 36, can also include a plurality of
attitude positioners 531 configured to contact a portion of a building support
structure
31 (such as structure 420) formed by the apparatus. Attitude positioners 531
can
32 function similarly to attitude positioners 254, described above with
respect to Fig. 8.
33 The attitude positioners 531 (Fig. 36) can be supported by the truss
modules, or they
34 can be supported by attitude control modules 530, which can function
similarly to
$7 Case RU01-P06
CA 02394057 2002-07-18
1 attitude control module 130 of Fig. 8. Each attitude positioner 531 can have
an
2 associated attitude control actuator 533 (similar to actuators 260 and 264
of Fig. 8).
3 The attitude control actuators 533 are supported by a respective associated
truss
4 module, and can be supported either directly by the truss module, or
indirectly by the
S frame of the attitude control modules 530.
6 As suggested by Fig. 36, the attitude positioners 531 can also be used as
7 force reactors to allow the truss modules 502b and 502d to push the concrete
forms
8 514 away from the outer face of the evolving structure 420. However, the
insert
9 concrete form 516 is not configured to retract from the wall in the same
manner, and
so a method of freeing the insert form 516 from the evolving structure 420 is
11 preferably provided. One method is indicated in Fig. 36, which shows how
the insert
12 concrete form 516 has a slight outward taper to the form as a function of
height. In
13 this manner, once the insert form 516 is broken free of the structure face
by moving
14 the form 516 upward slightly, there will be a separation between the form
and the
face of the structure allowing the form 516 to move freely upward. However,
once
16 the insert form is moved to the location for the next casting, there will
be a slight gap
17 between the top of the evolving structure 420 and the bottom of the insert
form 516.
18 This is depicted in Fig. 37A, which is a detail from Fig. 36 and shows the
area at the
19 top of the evolving structure 420, the bottom of the insert form 516, and
the gap 535
there between. In order to plug the gap 535 so that the next level of the
structure
21 420 can be poured without concrete running out of the gap, an inflatable
elastomeric
22 seal or bladder 524 can be provided, which is oriented opposite the inward
facing
23 form 514 and is attached to the insert form 516 by a rigid perimeter plate
526. The
24 bladder 524 can be inflated compartmentally or in total via orifices 528.
The sea!
524 can be inflated to expand and meet the concrete 420, thus sealing the gap
535.
26 This is depicted in Fig. 378, which shows the bladder 524' in the inflated
position.
27 Another method to facilitate upward movement of the insert form (and which
28 can provide additional benefits, described below) is to provide the insert
concrete
29 form with a lift system, allowing the insert concrete form to be moved
vertically with
respect to the inward-facing concrete forms. That is, while climbing devices
508a-h
31 can move the whole apparatus 500 upward (including the insert concrete form
516),
32 the concrete form lift device allows independent movement of the insert
concrete
33 form 516 (i.e., in direction "X", Fig. 36). In the embodiment depicted in
Figs. 35 and
34 36, the insert concrete form lift system includes a plurality of lift
devices 523a-d
g$ Case RU01-P06
CA 02394057 2002-07-18
1 supported on the yoke system 506 (and specifically in the example shown, on
the
2 comer connecting members 504a-d of the yoke system 506). The lift system
further
3 includes lift members 522a-d which are connected to the insert concrete form
516
4 and are engaged by the plurality of Lift devices 523a-d. The lift devices
523a-d can
be, for example, jack screws, and the lift members 522a-d can be threaded rods
6 which are engaged by the jack screws. Other types of lift devices can also
be used,
7 such as, by way of example only, a winch, a hydraulic cylinder, and a rack
and pinion
8 gear drive.
9 Turning now to Fig. 38, a horizontal cross section of another concrete
building
support structure 620 in accordance with the present invention is depicted.
The
! I support structure 620 includes a perimeter wall 622 which is made of
hollow-core
12 wall segments. More specifically, the perimeter wall 622 defines elongated,
vertically
13 oriented hollow chambers 623 which are disposed between the perimeter wail
outer
14 surface 622o and the perimeter wall inner surface 622i. The chambers 623
are
separated by a web 633, and preferably span the vertical height of the support
16 structure 620. The use of the elongated hollow chambers has several
benefits.
17 Mainly, the use of the chamber 623 reduces the weight of the support
structure 620,
18 as well as the quantity of concrete required to build the structure. The
elongated
19 chambers 623 can also be used to house service passageways, such as
electrical
conduits, pipes, air ducts, communications cables, elevator shafts, and, in
large
21 chambers, stairwells. When tension cables are used to mount the building
modules
22 to the perimeter wall 622 similar to Fig. 32, then preferably the tension
cables pass
23 through the web portion 633 of the wall 622, rather than through the open
chambers
24 623.
2S Fig. 39 depicts a partial side elevation view of the support structure 620
of Fig.
26 38. As can be seen, openings 630 can be formed in the perimeter wall 622 at
27 selected open chambers 623. The perimeter wall 622 defines an open inner
area
28 650 (Fig. 38). As; with the building support structure 20 of Fig. 14, the
open inner
29 area of the building support structure 620 can be provided with floor
diaphragms and
service passageways. Access openings 630 (Fig. 39) can provide access from
31 building modules supported on the perimeter wall outer surface 6220 to
chamber
32 623 and/or the open inner area 650. When an access opening 630 is provided
to
33 allow ingress and egress for the central area 650, and when the access
opening 630
59 Case RUO~-P06
CA 02394057 2002-07-18
! is located at one of the elongated chambers 623, then an access platform or
2 threshold diaphragm 632 is formed within the hollow chamber 623.
3 Turning to Fig. 40, a plan view of a structure forming apparatus 600 that
can
4 be used to form the building support structure 620 of Fig. 38 is depicted.
In general,
the apparatus 600 is similar to the apparatus 350 of Fig. 12. That is,
apparatus 600
6 includes a plurality of the structure forming apparatus 100 (Fig. 1) and
four of the
7 comer-forming apparatus (300, Fig. 11 ) connected together in a square
shape. In
8 order to more clearly show special features included in the apparatus 600 of
Fig. 40,
9 many of the details already shown in Figs. 1-12 have been removed (for
example,
the truss modules are not shown in Fig. 40). The apparatus 600 includes an
inward-
I 1 facing concrete form 614 (similar to form 114 of Fig. 1 ) and an outward-
facing
12 concrete form 616 (similar to form 116 of Fig. 1 ). The apparatus 600 also
includes
13 an outer work deck 610 and an inner work deck 612 (similar to respective
work
14 decks 110 and 112 of Fig. 10j. A yoke system (comprising yokes 606a, 606b,
606c,
I S etc.) allows the entire apparatus 600 to move upward along climb rods 99.
In order
16 to form the hollow chambers 623 in the structure 620 of Fig. 38, insert
concrete
17 forms 618 are provided. Insert forms 618 are depicted as cylindrical forms,
and are
18 suspended in the area between the outer form 614 and the inner form 616
such that
19 the insert form 618 is spaced-apart from inward-facing forms 614 and 616.
More
specifically, an outer rail 627, and an inner rail 628; suspend the insert
form 618 by
21 brackets 611. The outer and inner rails 627 and 628 can be attached to the
upper
22 edge of respective outer and inner concrete forms 614 and 616 or more
typically the
23 yoke system 606 as shown in Figure 43. Operation of these forms 614, 616
can be
24 much like that of the insert concrete form depicted in Figures 36 and 36
wherein lift
systems 522 and 523 are employed to translate the insert form 618 upward.
26 Release mechanisms include relief type insert forms as well as elastomeric
forms as
27 given in Figure 42. In order to form periodic access platforms (632, Figs.
38 and 39)
28 in selected elongated chambers (623, Fig. 39j, a specialized platform
forming insert
29 form 695 can be provided. The operation of the platform insert forms 695
will be
described more fully below.
31 Turning to Fig. 41, a partial side sectional view of the structure forming
32 apparatus 600 of Fig. 40 is depicted. The apparatus 600 is depicted in the
process
33 of constructing the building support structure 620 of Figs. 38 and 39. The
view
34 depicted in Fig. 41 shows only one side of the perimeter wall 622, and the
section is
60 Case RU01-P06
CA 02394057 2002-07-18
1 taken through one of the hollow chambers 623 in which access platforms 632
are to
2 be formed. In Fig. 41 truss module assemblies 602 and 604 are visible, and
are
3 shown supporting respecfive concrete forms 614 and 616, as well as
respective work
4 decks 610 and 612. Yoke 606a connects the truss modules 602 and 604, and
climbing devices 608, supported by the yoke 606a, allow the apparatus 600 to
climb
6 upward along (and descend along) the climb rods 99. The platform-forming
insert
7 form 695 is supported by lifting devices, such as jack screws 640, which can
climb
8 along climb rods 99, allowing the platform insert form 695 to be raised and
lowered
9 independently of forms 614 and 616.
Apparatus 800 can also be provided with one or more cranes 648. Crane 648
11 can be used to lift materials (such as buckets of concrete and reinforcing
steel) to the
12 work area, and can also be used to lift building modules for attachment to
the
13 outward-facing surface of the perimeter wall 622 (similar to the depiction
in Fig. 28).
14 The crane 648 can also be used to lift building materials (such as service
I S passageways, utility conduits, pipes, air ducts, stairway assemblies, and
elevator
16 shafts, for example) into the open inner area 650, as well as into the
hollow
l 7 chambers 623 (Fig. 38). As depicted in Fig. 41, the crane 648 is supported
by the
18 yoke system, which includes yoke 606a and climbing devices 608. A crane
support
19 member 642 is supported on the steel flanges which support the climbing
devices 608, and a crane base support 644 is supported on the crane support
21 member 642. In one configuration, the crane support member 642 can be
22 connected to other crane support members by rails 691, allowing the crane
to move
23 on rollers 652 along the top of the perimeter wall 622 (i.e., in a
direction into and out
24 of the sheet on which the figure is drawn). A rotational bearing 689
mounted on the
crane base support 644 can allow the crane 648 to rotate clockwise or counter-
26 clockwise (as viewed from above). in one variation, the crane support
member 642
27 can be circular in shape, and the crane can thus rotate on the crane
support member
28 using rollers. As. the apparatus 600 progresses upward while constructing
the
29 building support structure 620, additional lengths of climb rod can be
attached to the
tops of the existing climb rods 99. While Fig. 41 depicts the crane 648 as
being
31 supported on the yoke system (indirectly through rails 691 and crane
support
32 member 642), in one variation the crane 648 can be supported directly from
the
33 climb rods 99. This latter arrangement allows the crane 648 to move
vertically
34 independent of the yoke system (606a, 606b, etc., Fig. 40) and the truss
modules
Case RU01-POfi
CA 02394057 2002-07-18
1 602 and 604. In this case stability of the crane 648 can be accomplished by
2 maintaining the crane relatively close to the yokes 606a, 606b, etc. and
therefore
3 relying on the attitude control system (e.g., attitude control modules such
as 130 and
4 132 of Fig. 1 ) of the forming apparatus 600 (Fig. 41 ), or by utilizing a
separate
S attitude control type system for the crane 648 which can be similar to the
attitude
6 control device 130 described above with respect to Fig. 8.
7 As depicted in fig. 41, the platform insert form 695 is configured to
contact
8 the inward-facing concrete forms 614 and 616 at diametrically opposed
locations.
9 This allows the insert form 616 to essentially "block out" the opening 630
(Fig. 39)
that will allow ingress and egress for the open area 650 from the outer
surface 6220
11 of the perimeter wall 622. Fig. 42 depicts a side elevation sectional view
of a
12 specialized platform-forming insert form 695A that can be used in the
apparatus 600
13 of Fig. 40. The insert form 695A includes side panels 687 (which block out
the sides
14 of an access opening, such as opening 630 of Fig. 39), and bracing 660
which
stiffens the side panels. In the example depicted in Fig. 42, the insert form
695A is
16 provided with separate lifting members 662, rather than using the climb
rods 99 of
17 Fig. 40. The insert concrete form 695A includes rigid back-plates 658, and
vertically
t 8 oriented expansible bladders 656 fitted over the back-plates 658 so as to
form a
19 sealed chamber 661 there between. The sealed chambers 661 can be filled
with a
fluid (such as hydraulic fluid) to cause expansible bladders 656 to expand
outward
21 and contact the inward-facing concrete forms 614 and 616 (Fig. 40). This
will
22 prevent liquid concrete entering the area where the access opening (630,
Fig. 39) is
23 to be formed. After a concrete pour is made and the concrete has set to a
sufficient
24 self-supporting hardness, the fluid can be released from the sealed
chambers 661,
allowing the expansible bladder 656 to relax, thus facilitating upward
movement of
26 the insert form 695A.
27 While Fig. 39 depicts the access openings 630 as being periodically formed
in
28 the perimeter wall; 622 along selected hollow chambers 623, in one
variation the
29 access openings 630 can be formed in solid sections of perimeter wall 622.
In this
variation the platform-forming insert form 695A of Fig. 42 is preferably
provided with
31 a lift device (connected to lifting members 662) to allow the insert form
695A to be
32 raised out of the area between the inward-facing forms 614 and 616 (Fig.
40), to
33 thereby allow solid perimeter wall sections to be formed. In the variation
wherein the
34 access openings 630 are periodically formed along selected hollow chambers
623 in
62 Case RU01-P06
CA 02394057 2002-07-18
1 the perimeter wall 622 (as in Fig. 39), then provisions need to be made to
fiorm the
2 hollow chamber 623, with periodic access openings 630, and access platforms
632.
3 In this latter variation, the platform-forming insert 695A (Fig. 42) can be
rigidly
4 connected to the inward-facing forms 614 and 616 in the same manner that the
chamber-forming insert forms 618 (Fig. 40) are rigidly connected to forms 614
and
6 616 by rails 627 and 628 (Fig. 38). Further in this variation, the
expansible
7 bladders 656 (Fig. 42) can be configured to retract a distance "T" (Fig. 41
) from the
8 inward-facing forms 614, 616 when fluid pressure is relieved from the sealed
9 chamber 661 (Fig. 42). When the bladder 656 (Fig. 42) is thus retracted, a
void area
of thickness "T" will thus be provided between the insert form 695A and the
inward-
11 facing forms 614, 616, allowing liquid concrete to fill this area and form
perimeter
12 waif components of thickness "T" (Fig. 38) between the surfaces (6220,
622i) of the
13 wall 622 and the hollow chamber 623. In this way, the insert form 695A of
Fig. 42
14 can be used to alternately form the hollow chamber 623, or the access
opening 630
(Fig.39).
16 When the access opening 630 (Fig. 39) is formed within one of the hollow
17 chambers 623, then an access platform concrete form is preferably provided
to form
18 the lower surface of the access platform (632, Fig. 38). Fig, 41 depicts
access
19 platform lower forms 693, which can be placed in the evolving hollow
chamber 623
to thus provide a form for the lower surface of the access platforms 632.
Access
21 platform lower forms 693 can either be permanent forms (i.e., left in place
after the
22 access platform 632 is formed), or removable forms (i.e., removed after the
concrete
23 which forms the access platform 632 has hardened sufficiently to allow the
form 693
24 to be removed).
Turning now to Fig. 43, a side elevation sectional view of a building support
26 structure forming apparatus 700 in accordance with another embodiment of
the
27 present invention is depicted. Apparatus 700 can be used to construct a
building
28 support structure 720, which can be similar to the building support
structure 420 of
29 Fig. 30. Apparatus 700 of Fig. 43 is also depicted in a partial side
elevation view in
Fig. 44, which will be discussed concurrently with Fig. 43. The apparatus 700
of
31 Figs. 43 and 44 is similar to the apparatus 500 of Fig. 36, except as will
be described
32 below. Structure forming apparatus 700 includes inward-facing forms 714,
which are
33 supported by respective truss module systems 702 {similar to truss module
system
34 102 of Fig. 1 ), which include attitude control modules 730A (similar to
attitude control
(3 Case RU01-P06
CA 02394057 2002-07-18
1 module 130 of Fig. 1 ). Truss module systems 702 are connected to one
another by
2 yoke 706A. Insert form 695A (of Fig. 42) is supported between forms 714 by
support
3 rods 662, which are in turn engaged by lift devices 740, which allow the
insert form
4 695A to be moved in direction "X" independently of forms 714. Lift devices
740 are
attached to a yoke cross member 746, which is connected to the left and right
arms
6 of yoke 706A. A crane 748 (Fig. 44), similar to crane 648 of Fig. 41, can be
mounted
7 on a crane support base 744, which is in turn supported by a crane support
member
8 742. Crane support member 742 is in tum supported on yoke-connecting members
9 781, which rest on top of yoke 706A, as well as on top of an adjacent yoke
7068
(Fig. 44). Crane rails 791 are connected to crane support member 742, and
allow
11 crane 748 to move in directions "Y" (Fig. 44) with respect to the evolving
building
12 support structure 720. The yokes (706A and 706B) on which the yoke-
connecting
13 members 781 rest are not provided with climb devices {such as yoke 606a of
Fig. 41,
14 which has climb devices 608). Rather, the yoke-connecting members 781 are
I S connected to an intermediate yoke 706C, which supports the climbing device
708.
16 Climbing device 708 can be used, either alone or in conjunction with
adjacent
17 climbing devices, to move the apparatus 700 vertically along climb rods 99.
Yoke
I 8 cross member 746 can be mounted on insert form rails 715, allowing the
insert form
19 695A to also be moved horizontally in directions "Y" (Fig. 44)
independently of
movement of the crane 748 in directions "Y". It wiH be appreciated that a
system as
21 depicted in Figs. 43 and 44 can also be used in the apparatus 600 of Fig.
40,
22 wherein yokes 606a and 606b of Fig. 40 are replaced with yokes 706A and
7068 of
23 Fig. 44. Consequently, an intermediate yoke (such as yoke 7068 of Fig. 44)
will be
24 placed between yokes 606a and 606b of Fig. 40.
One example of the usefulness of the apparatus 700 of Figs. 43 and 44 is
26 depicted in Fig. 45, which is a side elevation sectional view similar to
Fig. 43. In
27 Fig. 45 the evolving building support structure 720 has perimeter walls 722
which
28 define an inner open area 750. When the yoke 706A is moved into or out of
the
29 plane of the sheet on which the figure is drawn, then a crane (such as
crane 748 of
Fig. 44) can be used to lower a service passageway module 730 into the open
area
31 750. The service passageway module 730 can then be connected to other
service
32 passageway modules 730, which have been previously placed in the open area
750
33 between perimeter walls 722. Alternately, a service passageway module 730
can be
34 placed on top of the evolving structure, and the next vertical casting of
perimeter
64 Case RU01-P06
CA 02394057 2002-07-18
t walls can then be cast around the passageway module 730, essentially using
the
2 sides of the module 730 as inner concrete forms. The service passageway
3 module 730 can include any or all of the service passageways previously
mentioned,
4 including staircases, elevator shafts, utility conduits, pipes, etc. In this
way, the
construction of a building (such as building 400 of Fig. 29) can be performed
in a
6 modularized manner, allowing building modules (e.g., 458a, 458b, 458c, etc.)
and
7 service passageways modules (730, Fig. 45) to be constructed aff-site and
brought
8 to the building construction site.
9 The apparatus 700 (as well as other apparatus described herein) allow for
the
construction of buildings having certain advantageous ingress-egress features.
11 Turning to Fig. 46, a plan sectional view of a building 800 in accordance
with the
12 present invention is depicted. The view depicted in Fig. 46 can correspond
to a
13 section at any of the subterranean building module parking levels 408
depicted in
14 Fig. 29, as well as above-ground parking levels. More specifically, the
building 800
includes building support structure 820 similar to building support structure
620 of
16 Fig. 38. The building support structure 820 defines an inner, open area
850. The
17 building support structure 820 further supports a building module 858 which
includes
I 8 vehicle parking areas 839. The perimeter walls 822 of the building support
structure
19 820 defines vehicle openings 840 therein at the location where the building
module
858 is located juxtaposed to the outer surface of the perimeter walls 822, to
thereby
21 allow vehicles to move between the building module 858 and the open inner
area
22 850 within the building support structure 820. The building support
structure open
23 inner area can be provided with service passageways, such as staircases 834
and
24 elevator shafts 836. Pedestrians can move between the parking areas 839 and
the
service passageways (stairs 834, andlor elevators 836) via personnel openings
830
26 in the perimeter wall 822. Dividing walls 837 separate the vehicle
passageways 840
27 from the pedestrian areas (near elevators 836 and stairs 834). A vehicle
ramp, such
28 as the spiral or helical ramp 842, can be located within the open inner
area 850 of
29 the building support structure 820 to allow vehicles "V" to ascend and
descend within
the open inner area of the building support structure. This configuration of
providing
31 a helical ramp 842 within the open inner area 850 allows vehicles to
quickly move
32 upward or downward through the parking levels, rather than having to
traverse each
33 floor 812 in moving from one level to the next. For example, if an
individual has a
34 pre-assigned parking space 839 on the third lower level, then the
individual can drive
65 Case RU01-P06
CA 02394057 2002-07-18
1 directly down to the third lower level, bypassing the first and second lower
levels. It
2 will be appreciated that vehicle openings 840 can be accesses by one or more
3 openings (not shown) in the outer facade 801 of the building module 858 to
allow
4 vehicles to enter the building 800. Further, if vehicle openings in the
outer facade
801 are provided on a lobby level of the building 800 (for example, where
building
6 module 458h of Fig. 29 is located at ground level "G" in Fig. 29), then the
dividing
7 walls 837 (Fig. 46) can be extended to the outer facade 801, and parking
spaces 839
8 will not be provided on the lobby level. Vehicles can also be provided
access to the
9 building 800 through exterior ramps (not shown) that lead to an upper level
above
the lobby level, or to a lower level below the lobby level. When vehicle
access to the
t I parking levels is provided on a level other than the lobby level, and
parking levels are
i 2 located both above and below the lobby level, then vehicle openings 840
into the
13 inner area 850 at the lobby level can be eliminated, such that vehicles
bypass the
i 4 lobby level when moving between the upper and lower parking levels.
While the apparatus described above with respect to Figs. 1-12, 35-36 and
16 40-45 can be used to form building support structures in accordance with
the present
17 invention, other apparatus can be used as well. Figs. 47A through 50 depict
two
18 alternate apparatus that can be used to construct building support
structures of the
19 present invention. Taming to Fig. 47A, a plan view of one such apparatus
900 in
accordance with the present invention is depicted. The building support
structure
21 forming apparatus 900 differs primarily from the apparatus 500 (Fig. 36)
and 600
22 (Figs. 40 and 41 ) in that the apparatus 900 does not include a yoke system
(such as
23 yoke system 506 of Fig. 36). In Fig. 47A, apparatus 900 is depicted as
forming the
24 building support structure 420 of Fig. 31. Inward-facing concrete forms
914a-d are
used to farm the outer surtace 4220 of the perimeter wall 422 of structure
420, and
26 an insert form (not shown, but similar to insert form 516 of Fig. 35) can
be used to
27 form the inner surface 4221 of perimeter wall 422. The insert form can be
supported
28 by the form trusses 902a-d by slideable brackets, allowing the form trusses
to move
29 translationally white keeping the insert form in place. Forms 914a-d are
each
supported on respective form trusses 902a-d. Each form truss 902a-d is
moveably
31 supported at each end by a support collar (collars 906a-d). Each support
collar is
32 mounted on a vertical lift tower (lift towers 904x-d). Fig. 48 depicts a
side elevation,
33 sectional view of the apparatus 900 of Fig. 47A, showing the apparatus 900
forming
34 the support structure 420. The lifting towers 904a-d can be supported on a
platform
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1 919, which can be the foundation for the building support structure 420, ar
can be a
2 "structure step" (i.e., a platform attached to the evolving support
structure 420 at a
3 vertical location above the location of the foundation).
4 The assembly of forms 914a-d, form trusses 902x-d, and support collars
906a-d is configured to climb upward (in direction "X") along the lifting
towers
6 904a-d, and can also move downward in the opposite-X direction. This
climbing
7 (and descending) motion can be effected in a number of different manners.
For
8 example, the lifting towers 904a-d can have a rack (not shown) fitted to
them, and a
9 driven pinion (not shown) can be fitted to the support collars 946a-d and
can engage
the rack to drive the support collars along the climbing towers. In another
11 arrangement, a hoist can be mounted to the top of the lifting towers 904a-d
and can
t2 be attached to the support collars 906a-d (such as by cables) to hoist {and
lower) the
13 support collars. Accordingly, the apparatus 900 includes a lifting device
(not shown)
14 configured to lift the support coNars 906a-d with respect to the lifting
towers 904a-d.
As depicted in Fig. 48, the lifting towers 904a-d can be periodically braced
against
16 the evolving structure 420 for lateral support by supports 916. Also as
depicted in
17 Figs. 47A and 48, at least one of the lifting towers 904d can be sited to
support a
18 crane 910. The crane 910 can be used to facilitate the construction of the
building
19 support structure 420, as well as the construction of building modules or
floors
cantilevered from the outer surface 4220 of the perimeter wall 422.
Preferably, the
21 crane 910 is a self-lifting crane, which uses a crane lifting device 912 to
move the
22 crane upward along lifting tower 9044.
23 The structure forming apparatus 900 of Fig. 48 further includes form
actuators
24 918, which are located at the junction between the form trusses 902a-d and
the
support collars 906a-d. The form actuators 918 are configured to move the
truss
26 forms 902a-d (and consequently, the associated forms 914a-d) laterally with
respect
27 to the support collars 906a-d. This is depicted in Fig. 47B, which is
similar to the
28 plan view of the apparatus 900 depicted in Fig. 47A, except that in Fig.
47B the
29 forms 914a-d, and respective form trusses 902x-d, are depicted as being in
retracted
positions 914a'-914d' and 902a'-902d'. Preferably, at least one form actuator
918 is
31 located at each junction where a farm truss 902a-d (Fig. 47A) meets a
support collar
32 906a-d. However, form actuator 918 can be located only at a single end of a
form
33 truss, and the other end can be fttted to a follower (such as a rail). The
form
34 actuators can be any type of device configured to move one object
translationally
67 Case RU01-P06
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1 with respect to the other, including, without limitation, a rack-and-pinion
2 configuration, a hydraulic cylinder, and a worm-screw drive. This
configuration
3 (depicted in Figs, 47A through 48) allows the forms 914a-d to thrust against
the
4 lifting towers 904a-d in order to free the forms fram the just-formed
structure
S segment so that the forming apparatus 900 can be moved upward to form the
next
6 segment.
7 Another apparatus 950 that can be used to form building support structures
of
8 the present invention is depicted in plan view in Fig. 49. Fig. 50 depicts a
side
9 elevation, sectional view of the apparatus 950 of Fig. 49, but with the
forms retracted
from the position shown in Fig. 50. Fig. 49 depicts the apparatus 950 forming
a
11 building support structure 420 (the building support structure described in
Fig. 31 ).
12 As can be seen, the apparatus 950 of Figs. 49 and 50 is essentially a
hybrid of the
13 combined apparatus 900 (Figs. 47A and 48) and 500 (Figs. 35 and 36).
Specifically,
14 the apparatus 950 includes a yoke system 956 (Fig. 49) (not present in the
1 S apparatus 900 of Fig. 48, but present in the apparatus 500 of Fig. 35), as
well as the
t 6 collar-truss configuration of apparatus 900 (which is not present in the
apparatus
17 500). More specifically, the apparatus 950 of Figs. 49 and 50 includes
inward-facing
18 forms 964a-d which are supported on form trusses 952a-d. Each truss form
952a-d
19 is moveably supported at each end by a support collar 968a-d, similar to
the manner
in which form trusses 902a-d of Fig. 47A are moveably supported by the support
21 collars 906a-d. Further, the apparatus 950 includes form actuators 970
(Fig. 50)
22 which are configured to move the form trusses 952a-d laterally with respect
to the
23 support collars 968a-d, in the same manner that actuators 918 of Fig. 48
move form
24 trusses 902a-d. The apparatus 950 includes a yoke system 956, which
includes
2S yoke arms 956a-d. Yoke arms are fitted with climbing devices 958 (Fig. 50)
which
26 are configured to engage climb rods 99 and move the apparatus 950 in the
upward
27 °X" direction. The yoke system 956 is suspended above, and connected
to, the
28 support collars 968a-d via yoke spacers 954a-d. Accordingly, the yoke
system
29 moves the whole apparatus 950 along the climb rods 99, while allowing the
form
trusses (and the forms) to move laterally and independently of the yoke arms
31 956a-d .
32 The apparatus 950 of Fig. 50 can further include attitude control modules
974
33 which are connected to the support collars 968a-d. The attitude control
modules 974
34 include attitude positioners 961 (similar to attitude positioners 254!266
of Fig. 8).
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1 The attitude control modules 974 can also slideably engage the form trusses
952a-d.
2 Thus, the attitude control modules 974 can maintain the attitude positioners
961 in
3 contact with the evolving structure 420 as the forms 964a-d (and form
trusses
4 952a-d) are moved away from the outer face 4220 of the structure 420, as
depicted
in Fig. 48.
6 Although the apparatus 900 and 950 are depicted in respective Figs. 47
7 and 49 as being configured to form a four-sided closed shape support
structure 420,
8 these apparatus can be configured to form a closed shape support structure
having
9 only three sides (such as support structure 26 of Fig. 84), or more than
four sides.
i0 Yet another embodiment of the present invention provides for a method of
! 1 constructing a building (as for example, but not limited to, buildings 10,
400 and 800
12 of respective Figs. 13, 19 and 46). The method includes forming a vertical
concrete
13 building support structure (as for example, but not limited to, building
support
14 structures 20, 66, 80, 82, 84, 86, 420, 620 and 820 of respective Figs. 14,
23, 24, 25,
26, 27, 30, 38, and 46). The building support structure can be farmed using
the
16 apparatus of the present invention, described above. Exemplary apparatus
include
17 apparatus 100, 350, 500, 600 and 700 of respective Figs. 1, 12, 35, 41 and
43. The
18 method also includes attaching, preferably in a cantilevered manner, a
plurality of
19 vertically-arranged building modules to the building support structure.
Exemplary
building modules include modules 58, 458a-h and 858 of respective Figs. 15, 29
and
21 46. The method can further include providing a gap between vertically
adjacent
22 building modules, as depicted by gap 56 between building modules 458c and
458e
23 on the right side of building 400 of Fig. 29.
24 In one embodiment the building support structure can be formed so as to
have a perimeter wall which, in a horizontal cross section, comprises a closed
shape
26 defining an outer surface and an open inner area. For example, building
support
27 structure 620 (Fig. 38) has a perimeter wall 622 which, when viewed in a
horizontal
28 cross section as in Fig. 38, forms a closed shape (essentially, a spuare
having
29 truncated comers) having an outer surface 622o and an inner surface 622i.
The
inner surface 6221 of the building support structure 620 defines the open
inner area
31 650. In this configuration the building modules can be attached to the
building
32 support structure by supporting them in a cantilevered fashion from the
outer surface
33 of the perimeter wall. The building modules can be attached to the building
support
34 structure using conventional methods such as welding, brackets, andlor
steel
69 Case RU01-P06
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1 beams. However, the method of the present invention also provides for
supporting
2 the building modules from the outer surface of the perimeter wall by
attaching the
3 building modules to the building support structure using a post-tension
tendon which
4 passes through the perimeter wall, as depicted in Figs. 32-34 and described
above.
The method can further include forming a plurality of floor diaphragms in the
6 open inner area. For example, floor diaphragm 432 is formed in the open
inner area
7 450 of the building support structure 420 of Fig. 30. One method of forming
the floor
8 diaphragm was described above with respect to Fig. 41, wherein an insert
form 695
9 is placed between wall forms 614 and 616, and a concrete wall segment 622 is
poured. Afterwards, the insert form 695 is moved upward with respect to the
side
11 forms 614 and 616, and a floor diaphragm form 693 is placed in the open
area 623
12 between the walls 622. Concrete is then poured between the side forms 614,
616
13 and on top of the diaphragm form 693 to form the floor diaphragm 632. Two
such
14 diaphragms 632 can be cast in relative proximity to define a containment
space or
vessel which can be used for storing liquids such as water or for storing bulk
solids,
16 similar to the manner in which solids or liquids are stored in a silo or
bin. In this way,
17 multiple containment vessels can be constructed in direct vertical
proximity or with
18 space there between provided for material reclaiming (for example,
reclaiming bulk
19 solids via a gravity-type conical reciaimer or other means).
This method of constructing a building can also include attaching building
21 modules in a cantilevered manner from the inside surface of the perimeter
wall, as
22 well as from other interior walls of the building support structure. For
example,
23 balconies or offices overlooking a central atrium within inner open area
(such as area
24 650 of the support structure 620 of Fig. 38).
The method of constructing a building can also include forming a plurality of
26 access openings through the perimeter wall to allow passage between the
building
27 modules and the open inner area. For example, access openings 430 can be
28 formed in building .support structure 420 of Fig. 30, and access openings
fi30 can be
29 formed in building support structure 620 of Fig. 39. The access openings
can be
formed using a concrete insert form in the manner described above with respect
to
31 Figs. 40-42. While the access opening can also be formed by cutting holes
in the
32 perimeter wall, the method of using concrete insert forms is less time
consuming and
33 does not result in wasted concrete, as would result by cutting openings in
the wall
34 after the wall is formed.
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1 The building constructing method of the present invention can also include
2 installing service passageways in the open inner area. For example, in Fig.
30
3 service passageways, including stairways 436 and elevator shafts 494, are
depicted
4 as being installed in the open inner area 450 of the building support
structure 420.
Other service passageways that can be installed (not depicted in Fig. 30} can
include
6 electrical conduits, pipes (such as water pipes), air ducts, and
communications
7 cables. Water pipes can include not only water for drinking and sanitary
uses, but
8 also water for fire fighting purposes, and waste-water (i.e., sewage) pipes.
Other
9 types of service passageways can include pipes for conducting fre fighting
foam.
These latter types of service passageways can be installed in the utility
ducts 442 of
11 Fig. 30, for example. When the building is a commercial processing
building, then
12 material handling service passageways (or example, conveyors) can also be
located
13 within the open inner area. In one embodiment the service passageways can
be
14 provided in the form of service passageway modules (e.g., service
passageway
modules 730 of Fig. 45), in which event the service passageways are installed
in the
16 open inner area by connecting together a plurality of the service
passageway
17 modules in the manner depicted in Fig. 45. When the apparatus for
constructing the
18 building includes a crane (such as crane 648 of apparatus 600 of Fig. 41 ),
then the
t9 crane can be used to lower the service passageways modules into the open
inner
area within the building support structure. Alternately, the crane can lower a
service
21 passageway module into place, and then the next vertical stage of the
building
22 support structure can be formed around the just-placed module.
23
24 While the above invention has been described in language more or less
specific as to structural and methodical features, it is to be understood,
however, that
26 the invention is not limited to the specific features shown and described,
since the
27 means herein disclosed comprise preferred forms of putting the invention
into effect.
28 The invention is, therefore, claimed in any of its forms or modifications
within the
29 proper scope of the appended claims appropriately interpreted in accordance
with
the doctrine of equivalents.
31
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