Note: Descriptions are shown in the official language in which they were submitted.
CA 2,895,219
Agent Ref: 11874/00002
1 METHOD AND SYSTEM OF USING STANDARDIZED STRUCTURAL COMPONENTS
2
3 Cross-Reference to Related Applications
4 The present application claims benefit of priority of U.S. Non-
Provisional Application
Ser. No. 13/719,561 entitled "METHOD AND SYSTEM OF USING STANDARDIZED
6 STRUCTURAL COMPONENTS" and filed on December 19, 2012, which is a
continuation-in-
7 part of and claims benefit of U.S. Non-Provisional Application Ser. No.
12/964,380 entitled
8 "PANELIZED STRUCTURAL SYSTEM FOR BUILDING CONSTRUCTION" and filed on
9 December 09, 2010, which claims the benefit of U.S. Provisional
Application Ser. No.
61/288,011 filed on Dec. 18, 2009.
11
12 Technical Field
13 The present disclosure relates to a method and system for constructing
and assembling
14 buildings using panelized and modular structural system.
16 BackEround
17 A building's structure must withstand physical forces or displacements
without danger of
18 collapse or without loss of serviceability or function. The stresses on
buildings are withstood by
19 the buildings' structures.
Buildings five stories and less in height typically use a "bearing wall"
structural system to
21 manage dead and live load vertical forces. Vertical forces on the roof,
floors, and walls of a
22 structure are passed vertically from the roof to the walls to the
foundation by evenly spreading
23 the loads on the walls and by increasing the size and density of the
framing or frame structure
24 from upper floors progressively downward to lower floors, floor-to-
floor. For ceilings and floor
spans, trusses are used to support loads on the ceilings and floors and to
transfer these loads to
26 walls and columns.
27 Where vertical bearing elements are absent, for example at window and
door openings,
28 beams are used to transfer loads to columns or walls. In buildings
taller than five stories, where
29 the walls have limited capacity to support vertical loads, concrete
and/or
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structural steel framing in the form of large beams and columns are used to
support the
structure.
Lateral forces (e.g., wind and seismic forces) acting on buildings are managed
and
transferred by bracing. A common method of constructing a braced wall line in
buildings
(typically 5 stories or less) is to create braced panels in the wall line
using structural
sheathing. A more traditional method is to use let-in diagonal bracing
throughout the wall
line, but this method is not viable for buildings with many openings for
doors, windows, etc.
The lateral forces in buildings taller than five stories are managed and
transferred by heavy
steel let-in bracing, or heavy steel and/or concrete panels, as well as
structural core elements
such as concrete or masonry stair towers and elevator hoistways.
There is a need for a panelized and modular system for constructing and
assembling
buildings without relying on concrete and/or structural steel framing, heavy
steel let-in
bracing, and heavy steel and/or concrete panels.
Summary
A method and system disclosed herein provides generating an architectural
diagram
describing an architectural layout of a building, wherein one or more walls of
the building are
designated as standardized structural walls, automatically positioning cach of
the
standardized structural walls to a geometric grid, and mapping (or "placing"),
using a
computer, one or more of a plurality of standardized structural components,
including
standardized panels, standardized columns, and standardized trusses to
coordinates of the
geometric grid.
In some implementations, articles of manufacture are provided as computer
program
products. One implementation of a computer program product provides a computer
program
storage medium readable by a computer system and encoding a computer program.
Another
implementation of a computer program product may be provided in a computer
data signal
embodied in a carrier wave by a computing system and encoding the computer
program.
Other implementations arc also described and recited herein
Brief Descriptions of the Drawings
FIG. 1 illustrates a stud for use as a framing member in horizontal truss
panels;
FIG. 2 illustrates a track for use as a framing member in horizontal truss
panels;
FIGS. 3 and 3.1 illustrate a V-Braced horizontal truss panel;
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FIGS. 4, 4.1, and 4.2 illustrate various open horizontal truss panels;
FIG. 5 illustrates a truss for attachment to horizontal truss panels;
FIG. 6 illustrates a structural column assembly for attaching horizontal truss
panels to
one another;
FIGS. 7 and 8 show the manner of attaching a horizontal truss panel such as
shown in
FIGS. 3, 3.1,4, 4.1, and 4.2 to the structural column assembly of FIG. 6;
FIG. 9 shows a unified horizontal truss panel wall line having open and V-
braced
horizontal truss panels in a Unified Truss Construction System (UTCS) wall
line;
FIG. 10 illustrates the truss of FIG. 5;
FIG. 11 shows the truss/stud hangar of FIG. 6;
FIG. 12 illustrate a portion of the structural column assembly of FIG. 6;
FIG. 13 illustrates trusses connected to horizontal truss panels;
FIG. 14 illustrates trusses connected to horizontal truss panels to form a
UTCS open
span assembly creating a wall line;
FIG. 15 illustrates a UTCS building section formed as an assembly of multiple
floors
of a UTCS structure;
FIG. 16 shows alignment of the structural column assemblies of FIG. 6 in a
building;
FIG. 17 illustrates a three-dimensional view and a two-dimensional view of the
floor-
to-floor sections of a section of this building;
FIG. 18 shows the transfer of forces to the structural column assemblies of
FIG. 6;
FIG. 19 illustrates an examplc block diagram of a system for using the
standardized
structural components;
FIG. 20 illustrates an alternative example block diagram of a system for using
the
standardized structural components;
FIG. 21 illustrates an example flowchart of a method of using the standardized
structural components;
FIG. 22 illustrates example of structural panel names generated by the system
disclosed herein;
FIG. 23 illustrates example flowchart of a method for using specialized code
to track
building construction progress;
FIG. 24 illustrates an example flowchart of a method for using machine control
files
to control the manufacturing of the standardized structural components;
FIG. 25 illustrates an example geometric grid used by the method and system
disclosed herein;
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FIG. 26 illustrates an example plan view of a geometric grid with various
standardized structural components along the grid lines;
FIG. 27 illustrates an example elevation view of a building structure using
various
standardized structural components;
FIG. 28 illustrates a three-dimensional view of a structure generated using
various
standardized structural components; and
FIG. 29 illustrates an example computing system that can be used to implement
one
or more components of the method and system described herein.
Detailed Descriptions
The Unified Truss Construction System (UTCS) disclosed herein is a unique,
new,
and innovative structural system for single and multistory buildings, based on
standardized
structural panels. The system employs a limited number of configurations of
uniquely
engineered, light gauge metal framed vertical wall panels (horizontal truss
panels), light-
gauge-metal floor and ceiling trusses, cold rolled square or rectangular steel
tubing (structural
columns), and unique connecting plates and clips.
Unlike conventional approaches to designing and engineering a building's
structure,
where many different assemblies (walls, columns, beams, bracing, strapping,
and the
fasteners that fasten them together) are employed to manage vertical live load
and dead load
forces, and lateral forces, UTCS manages these forces through a limited number
of uniquely
designed standardized horizontal truss panels, which are assembled with
structural columns
and trusses. This unique assembly ot elements effectively supports and
transfers vertical and
lateral forces from the walls, floor, ceiling, and roof to UTCS' redundant and
dense column
system. Accordingly, columns absorb these vertical and lateral forces such
that UTCS is not a
vertical bearing wall structural system and eliminates the need for "hot
formed" structural
steel (weighted steel or "red iron") and concrete as part of a building's
structural system.
UTCS framing members are made from specially designed computerized roll
forming
machines. These machines manufacture framing studs or members from cold rolled
steel
commonly referred to as "coiled steel." Each stud is cut to size, pre-drilled
for fastening
screws, with countersinks at the assembly screw head area, pre-punched for
chasing
mechanical, electrical, and plumbing ("MEP") assemblies and rough-ins, pre-
punched for
passing vertical and horizontal bracing, and labeled for assembly. The
machines read stud
specifications from CAD files.
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Horizontal truss panels and the trusses used in UTCS are constructed with
framing
members roll formed from light gauge steel, such as 18 to 14 gauge steel,
depending on
building height and code requirements. There are two profiles of framing
members used in
the horizontal truss panels, a stud 10 illustrated in FIG. 1 and a track 12
illustrated in FIG. 2.
The stud 10 and the track 12 are each rolled from light gauge steel, such as
18 to 14 gauge
steel.
Each of the stud 10 and the track 12 includes a web 14, flanges 16, and lips
18 formed
as illustrated in FIG. 1. The flanges 16 extend in the same direction at
substantially right
angles from opposing sides of the web 14, and the lips 18 extend inwardly from
ends of the
flanges 16 such that the lips 18 parallel the web 14. The stud 10 and the
track 12 differ
mainly in that the flanges 16 of the track 12 are slightly higher than the
flanges 16 of the stud
10, and the web 14 of the track 12 is slightly wider than the web 14 of the
stud 10. These
relative dimensions allow the stud 10 to slide into or through the track 12
without the need to
compress the flanges 16 of the stud 12, which affects its structural
performance.
UTCS employs a limited number, such as two, configurations of horizontal truss
panels. These horizontal truss panels are the structural wall elements of
UTCS. If only two
such configurations are used, they are (a) a V-braced horizontal truss panel
20/22 shown in
FIG. 3 or FIG. 3.1, which contains a "V" shaped brace ("V-brace"), and (b) an
open
horizontal truss panel 24 shown in FIG. 4, which does not contain a V-brace.
An open horizontal truss panel 24 is generally used in any area of a building
having
large openings (windows, doors, pass-throughs, and the like) in a UTCS
structure. The open
horizontal truss panel 24 is engineered to support and transfer vertical live
(occupancy, for
example) and dead load forces (e.g., drywall, MEP assemblies, insulation, and
the like) from
floor and ceiling assemblies attached either to or proximate to each panel
within a building
("Local Forces"). The V-braced horizontal truss panel 20/22 is engineered to
support vertical
local forces and lateral forces acting on the structure (wind and seismic, for
example).
As shown in FIG. 3, the V-braced horizontal truss panel 20 has atop track 26
and a
bottom track 28. Inboard of the top track 26 is a continuous horizontal brace
comprised of
back-to-back (web-to-web) tracks 30 and 32, (referred to as double horizontal
bracing),
which are anchored by fasteners 34 such as bolts or screws to side studs 36
and 38 at the
sides of the V-braced horizontal truss panel 20. The top track 26 and the
bottom track 28 are
also anchored by fasteners 34 to the side studs 36 and 38. The area between
the continuous
horizontal brace formed by the tracks 30 and 32 and the top track 26 contains
vertical angled
webbing 40 made from studs. This braced area in FIG. 3 acts as a truss
attachment area 42
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within the V-braced horizontal truss panel 20 for the attachment of trusses
106 discussed
below, and supports and transfers forces exerted on the V-braced horizontal
truss panel 20 to
the structural columns discussed below and attached to each of the side studs
36 and 38 of the
V-braced horizontal truss panel 20.
The V-braced horizontal truss panel 20 also has two inboard studs 44 and 46
and a
center stud 48 anchored by fasteners 34 to the top and bottom tracks 26 and 28
and to the
tracks 30 and 32. The side studs 36 and 38 pass through end cutouts 50 in the
ends of the web
14 and in the lips 18 of the tracks 30 and 32 such that the flanges 16 of the
studs 36 and 38
abut the flanges 16 at the ends of the tracks 26, 28, 34, and 36. These end
cutouts 50 are
shown in FIG. 2. The fasteners 34 are at these abutment areas. Similarly, the
inboard studs 44
and 46 and the center stud 48 pass through interior cutouts 52 of the webs 14
and lips 18 of
the tracks 30 and 32 such that an exterior of the flanges 16 of the studs 36
and 38 and of the
center stud 100 abut the interior of the flanges 16 of the tracks 26, 28, 34,
and 36. These
interior cutouts 52 are also shown in FIG. 2. The fasteners 34 are at these
abutment areas.
The five vertical studs 36, 38, 44, 46, and 48, for example, may be spaced 24"
on center. The
point at which the inboard studs 44 and 46 and the center stud 48 pass through
the tracks 30
and 32 is a hinge connection (i.e., a single fastener allows for rotation).
The studs of the V-
braced horizontal truss panel 20 also serve to support drywall, conduit,
wiring, plumbing
assemblies, etc.
The V-braced horizontal bliss panel 20 also contains a continuous V-shaped
bracing.
This V-Bracing is unique in its design and engineering. The two legs of the V-
brace are V-
brace studs 54 and 56 such as the stud 10 shown in FIG. 1. The V-brace stud 54
is anchored
to the side stud 36 just below the tracks 30 and 32 and to the bottom track 28
by the fasteners
34 and passes through an interior cutout 58 in the web 14 of the inboard stud
44. This interior
cutout 58 is shown in FIG. 1. The web 14 of the V-brace stud 54 abuts one
flange 16 of each
of the studs 36 and 44 and the track 28. These abutment areas receive the
fasteners 34 as
shown.
Similarly, the V-brace stud 56 is anchored to the side stud 38 just below the
tracks 30
and 32 and to the bottom track 28 by the fasteners 34 and passes through the
interior cutout
58 in the inboard stud 46. The web 14 of the V-brace stud 56 abuts one flange
16 of each of
the studs 38 and 46 and the track 28. These abutment areas receive the
fasteners 34 as shown.
The attachment of the V-brace studs 54 and 56 to the studs 36 and 38 and to
the track
28 require that the ends of the V-brace studs 54 and 56 be angles as shown in
FIG. 3. These
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angled ends permit multiple fasteners 34 to be used to anchor the V-brace
studs 54 and 56 to
their corresponding side studs 36 and 38.
The V-brace studs 54 and 56 are positioned with their webs perpendicular to
the webs
of the studs 36, 44, 48, and 38 of the V-braced horizontal truss panel 20.
Also, the V-brace
studs 54 and 56 run continuously from immediately below the tracks 32 and 34
through the
inboard studs 44 and 46 to the apex of a "V" at substantially the middle of
the bottom track
28. The connection at the apex of the V-bracing is facilitated by an apex
plate 60 and
additional fasteners 34, which interconnect the V-brace studs 54 and 56 and
the center stud
48. The plate 60, the bottom track 28, and the stud 48 and the V-brace studs
54 and 56 are
interconnected by the lower three fasteners as shown in FIG. 3. The inboard
stud 46 is also
attached by fasteners 34 to the top track 26 and to the tracks 30 and 32 at
the point where the
inboard stud 46 passes through the interior cutouts 52 in the tracks 30 and
32. The apex plate
60 may be formed from a material such as 18-14 gauge cold roll steel.
The connections of the V-brace studs 54 and 56, to the side studs 36 and 38,
to the
center stud 48, and to the track 28 are moment connections and improve the
lateral structural
performance of the V-braced horizontal truss panel 20.
These connections facilitate the transfer of most of the lateral forces acting
on the V-
braced horizontal truss panel 20 to the structural column of the system
(discussed in further
detail below).
The V-braced horizontal truss panel 20 also contains a track 62 providing
horizontal
bracing. The track 62 is located, for example, mid-way in the V-Brace formed
by the V-brace
studs 54 and 56. The track 62 has the end cutouts 50 to accommodate the
inboard studs 44
and 46, has the interior cutout 52 to accommodate the center stud 48, and is
anchored by
fasteners 34 to the inboard studs 44 and 46 and to the center stud 48. The
track 62 contributes
to the lateral-force structural performance of the V-braced horizontal truss
panel 20.
The V-braced horizontal truss panel 20 may contain other bracing and backing
as
necessary for building assemblies like drywall, cabinets, grab bars and the
like. The V-braced
horizontal truss panel 20 is used as both interior (demising and partition)
structural walls and
exterior structural walls. The V-braced horizontal truss panel 20/22 may also
accommodate
windows and pass-throughs, although the space is limited as can be seen from
the drawings.
The V-braced horizontal truss panel 22 of FIG. 3.1 has the same construction
as the
V-braced horizontal truss panel 20 of FIG. 3 except that the V-brace stud 54
forming half of
the V-brace of FIG. 3 is replaced by two studs 64 and 66 whose lips 18 abut
one another, and
the V-brace stud 56 forming the other half of the V-brace of FIG. 3 is
replaced by two studs
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68 and 70 that may or may not abut one another. Thus, the studs 64, 66, 68,
and 70 form a
double V-brace for the V-braced horizontal truss panel 22 of FIG. 3.1 to
provide extra
strength.
As shown in FIG. 4, the open horizontal truss panel 24 has a top track 80 and
a
bottom track 82. Inboard of the top track 80 is a continuous horizontal brace
comprised of
back-to-back (web-to-web) tracks 84 and 86, (referred to as double horizontal
bracing),
which arc anchored by fasteners 34 such as bolts or screws to side studs 88
and 90 at the
sides of the open horizontal truss panel 24. The top track 80 and the bottom
track 82 are also
anchored by fasteners 34 to the side ,Auds 88 and 90. The area between the
continuous
horizontal brace formed by the tracks 84 and 86 and the top track 80 contains
vertical angled
webbing 92 made from studs. This braced area in FIG. 4 acts as a structural
truss 94 for the
open horizontal truss panel 24, and supports and transfers forces exerted on
the open
horizontal truss panel 24 to the structural columns discussed below and
attached to each of
the side studs 88 and 90 of the open horizontal truss panel 24.
The open horizontal truss panel 24 also has two inboard studs 96 and 98 and a
center
stud 100 anchored by fasteners 34 to the top and bottom tracks 80 and 82 and
to the tracks 84
and 86. The side studs 88 and 90 pass through end cutouts 50 in the ends of
the web 14 and
of the lips 18 of the tracks 84 and 86 such that the flanges 16 of the studs
88 and 90 abut the
flanges 16 at the ends of the tracks 80, 82, 84, and 86. These end cutouts 50
are shown in
FIG. 2. The fasteners 34 are at these abutment areas. Similarly, the inboard
studs 96 and 98
and the center stud 100 pass through interior cutouts 52 of the webs 14 and of
the lips 18 of
the tracks 84 and 86 such that the flanges 16 of the studs 96 and 98 and of
the center stud 100
abut the flanges 16 of the tracks 80, 82, 84, and 86. These interior cutouts
52 are also shown
in FIG. 2. The fasteners 34 are at these abutment areas. The five vertical
studs 88, 90, 96, 98,
.. and 100, for example, may be spaced 24" on center. The point at which the
inboard studs 96
and 98 and the center stud 100 pass through the tracks 84 and 86 is a hinge
connection (i.e., a
single fastener allows for rotation). The studs of the open horizontal truss
panel 24 also serve
to support drywall, conduit, wiring, plumbing assemblies, etc.
The open horizontal truss panel 24 also contains a track 102 performing
horizontal
.. bracing. The track 102 is located, for example, mid-way between the tracks
82 and 86. The
horizontal bracing track 102 includes the end cutouts 50 through which the
side studs 88 and
90 pass, has three interior cutouts 52 through which the inboard studs 96 and
98 and the
center stud 100 pass, and is anchored by fasteners 34 to the side studs 88 and
90, to the
inboard studs 44 and 46, and to the center stud 48. The flanges 16 of the
studs 88, 90,96, 98,
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and 100 abut the flanges 16 of the track 102. The fasteners 34 are applied to
these abutment
areas. The open horizontal truss panel 24 is engineered to handle vertical
local forces.
The open horizontal truss panel 24 is designed to accommodate windows, doors,
and
pass-throughs. The open horizontal truss panel 24, for example, may be 20'
wide or less.
.. FIGS. 4.1 and 4.2 illustrate open horizontal truss panels with one or more
openings for
windows, doors, and pass-throughs. FIG. 4.1 illustrates typical chase openings
104 through
which MEP assemblies may be passed. These chase holes 104 may be formed in the
V-
braced horizontal truss panels 20 and 22 as well. FIG. 4.2 illustrates several
open horizontal
truss panels with openings for doors.
The open horizontal truss panel 24 may contain other bracing and backing as
necessary for building assemblies like windows, doors, pass throughs, drywall,
cabinets, grab
bars and the like. The open horizontal truss panel 24 is used as both interior
(demising and
partition) structural walls and exterior structural walls.
The horizontal truss panels described above arc tall enough to accommodate the
floor
.. to ceiling areas of buildings, and to accommodate attachment of trusses,
such as a truss 106
shown in FIG. 5. The truss 106 is attached to the truss attachment area 42 and
includes a top
stud 108 and a bottom stud 110 interconnected by an angled webbing 112 made
from studs
such that the angled webbing 112 is attached to the top and bottom studs 108
and 110 by the
fasteners 34. The truss 106 is attached to the truss attachment area 42 of a
horizontal truss
.. panel 114 by use of truss/stud hangars 116 and the fasteners 34. Although
the horizontal truss
panel 114 is shown as the V-braced horizontal truss panel 20/22, the
horizontal truss panel
114 can be any of the horizontal truss panels described herein. The truss/stud
hangars 116 are
discussed more fully below in connection with FIG. 11.
The truss hangars 116 may be formed from a material such as 18-14 gauge cold
roll
.. steel.
The truss 106 is also shown in FIG. 10. Trusses used in UTCS are made from the
studs 10. These trusses have the top and bottom studs 108 and 110 and the
internal angled
webbing 112. The trusses 106 do not have side or end Webbing connecting their
top and
bottom chords 108 and 110. The truss 106 may be formed from light gauge steel,
such as 18
.. to 14 gauge steel. The gauge and length f the truss 106 varies depending on
application and
width of floor span.
FIG. 6 illustrates a structural column assembly 130 that includes a structural
column
132 having a top plate 134 and a bottom plate 136 welded to the top and bottom
of the
structural column 132 so that the top plate 134 covers the top of the
structural column 132
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and the bottom plate 136 covers the bottom of the structural column 132. The
structural
column 132, for example, may be four sided, may be hollow, and may vary in
wall thickness
depending on building height and code requirements. The top plate 134 and the
bottom plate
136 are shown in FIG. 6 as being linear in the horizontal direction and are
used where two
walls are joined side-by-side so as to share a common linear horizontal axis.
However, the
top plate 134 and the bottom plate 136 may be "L" shaped plates when two walls
are to be
joined at a corner such that the horizontal axes of the two walls are
perpendicular to one
another.
One or more bolts 138 arc suitably attached (such as by welding or casting) to
the top
plate 134. The bolts 138 extend away from the top plate 134 at right angles.
Each end of the
bottom plate 136 has a hole 140 there through. Accordingly, a first structural
column 132 can
be stacked vertically on a second structural column 132 such that the bolts
138 of the top
plate 134 of the second structural column 132 pass through the holes 140 of
the bottom plate
136 of the first structural column 132. Nuts may then be applied to the bolts
138 of the top
plate of the second structural column 132 and tightened to fasten the first
and second
structural columns 132 vertically to one another.
The top and bottom plates 134 and 136 arc slightly wider than the track 12
used for
the horizontal truss panel 20/22/24 and vary in thickness depending on
building height and
code requirements. The through-bolting provided by the bolts 138 and holes 140
permit the
structural columns 132 to be connected to one another vertically and to other
assemblies
within a building (roof, foundations, garages, etc.).
The structural columns 132 are connected to horizontal truss panels 20/22/24
by way
of stud sections 142 of the stud 10. The stud sections 142 are welded or
otherwise suitably
fastened to the top and bottom of the structural column 132. A stud section
144 is fastened by
weld or suitable fastener at about the middle of the structural column 130
such that its web 14
faces outwardly. This stud section 144 is a "hold-off' to keep the studs 36,
38, 88, and 90 of
the horizontal truss panels from deflecting. Unification plates such as 154
may or may not be
used at this location.
The material of the structural column 132, for example, is cold rolled steel.
The
structural column 132 may be hollow and have a wall thickness that varies
depending on
application and code. The material oi the plates 134 and 136 and for the truss
hangars 144
and 146, for example, may be 18-14 gauge cold roll steel.
FIGS. 7 and 8 shows the manner of attaching a horizontal truss panel such as
the
horizontal truss panels 20, 22, and 24 to the structural column assembly 130.
A unified
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horizontal truss panel is created when the structural column assembly 130 is
attached to the
horizontal truss panel 20/22/24 using four truss hanger unification plates
150, which have a
stud insertion projection for attachment of the trusses 106 discussed in
further detail below,
and two flat unification plates 154, all of which are attached by fasteners 34
to the side stud
36 and 38 of the horizontal truss panel 20/22/24 and the stud sections 142.
The stud sections
144 as shown in FIG. 7 act to "hold-off studs 36 and 38 so that these studs do
not deflect
through the space between the side studs 36 and 38 and the structural column
132.
Unification plates such as 154 may or may not be used at this location.
In a UTCS structure, a section or length of wall is assembled by attaching a
number
(depending on wall length) of horizontal truss panels together using the
structural column
assemblies 130. The open horizontal truss panels 24 are used as a wall
section(s) in buildings
where there are larger openings like windows, doors, and pass-throughs. The V-
braced
horizontal truss panels 22/22 are used as wall section(s) generally throughout
the rest of the
structure so as to provide dense lateral support of the structure. FIG. 9
shows a horizontal
truss panel wall line having open and V-braced horizontal truss panels 24 and
20/22 in a
UTCS wall line.
As indicated above, the truss 106 is attached to the horizontal truss panel
20/22/24 by
way of the truss/stud hangars 116 and the fasteners 34 located at the inboard
studs 44 and 46
and the center stud 48. The truss/stud hangar 116 is shown in FIG. 11 and
includes a stud
.. insertion projection 152 to be received within the top stud 108 of the
truss 106 as illustrated
in FIG. 5 and, when inverted 180 degrees as illustrated in FIGS. 5 and 8,
within the bottom
stud 110 of the truss 106. The truss/stud hanger 116 also includes L-shaped
flanges 172 used
to fasten the truss/stud hangers to the top track 26 and, inverted, to the
horizontal bracing 30
and 32 of the horizontal truss panels.
The trusses 106 are connected to the horizontal truss panels 20/22/24 by
inserting the
end of the top stud 108 of the truss 106 into the insertion projection 152 and
fastening by
fasteners 34, and connecting by fasteners 34 the L-shaped flanges 172 to the
web 14 and
flange 16 of the top track 26 and by connecting by fastener 34 a projection
tab 176 of the
truss hangar 116 to the top flange 16 of the stud 108. The bottom stud 110 of
the truss 106 is
connected by inverting the truss/stud hanger 116 by 180 degrees, inserting the
end of the
bottom stud 110 of the truss 106 into the insertion projection 152 and
fastening by fasteners
34, connecting by fasteners 34 the L-shaped flanges 172 to the web 14 of the
tracks 30 and
32, and by connecting by fastener 34 the projection tab 176 to the bottom
flange 16 of the
stud 110.
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A truss 106 is also attached at each of the structural columns 132 by way of
an
insertion projection 152 on the unification plate 150. The end of the top stud
108 of the truss
106 is inserted over the insertion projection 152 of the unification plate 150
and fastened with
fasteners 34 to the web 14 of the stud 108. The projection tab 176 is fastened
by a fastener to
the top flange 16 of the stud 108. The bottom stud 110 of the truss 106 is
connected by way
of insertion of the end of the stud 110 over the insertion projection 152 of
an unification plate
150 that is rotated 180 degrees. Fasteners 34 arc used to connect the
insertion projection 152
to the web 14 of the stud 110. The projection tab 176 is attached by way of a
fastener to the
bottom flange 16 of the stud 110.
FIG. 13 illustrates the trusses 106 connected to horizontal truss panels
20/22/24.
FIG. 14 illustrates the trusses 106 connected to horizontal truss panels
20/22/24
forming a UTCS open span assembly where the horizontal truss panels 20/22/24
are
assembled with the trusses 106 to create a wall line. The trusses 106 support
a floor and
ceiling assembly.
Attaching the trusses 106 to the horizontal truss panels in this manner
incorporates the
truss 106 into the horizontal truss panels 20/22/24, eliminating the "hinge-
point" that exists ,
where a wall assembly sits on a floor, or where a ceiling assembly sits on top
of a wall. This
connection unifies the trusses 106 and horizontal truss panels 20/22/24, in
effect enabling the
entire wall and floor system to act together as a "truss." This configuration
facilitates the
transfer of forces on the floor, ceiling, and horizontal truss panels 20/22/24
to their attached
structural column assemblies 130. Accordingly, vertical and lateral forces arc
not transferred
vertically horizontal truss panel to horizontal truss panel. When subflooring
and drywall are
incorporated into the building, the entire system acts as a "diaphragm."
FIG. 15 illustrates a UTCS building section formed as an assembly of multiple
floors
of a UTCS structure. In a UTCS building or structure, the horizontal truss
panels 20/22/24 are
laid out such that the structural column assemblies 130 on one floor line up
vertically with
the structural column assemblies 130 on the floor below, and so on, down to a
foundation.
FIG. 16 shows this alignment of the structural column assemblies. FIG. 16 also
illustrates the density of the structural column assemblies 130 in a UTCS
structure.
FIG. 17 illustrates a three-dimensional view and a two-dimensional view of the
floor-
to-floor joints of this assembly. It shows that horizontal truss panels
20/22/24 do not contact
or bear on each other, as is otherwise typical in "bearing wall" and steel and
concrete
structures. The horizontal truss paneis on one floor of a UTCS structure do
not carry load
from the floor above. This load is instead transferred to and carried by the
structural column
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assemblies 130. Each "floor" or elevation of the structure dampens and
transfers its vertical
live and dead load forces to the structural column assemblies 130, where they
arc dampened
and transferred vertically to the foundation of the building.
The V-braced horizontal truss panels 20/22 dampen and transfer the lateral
forces
acting on the building to the redundant structural column assemblies 130 in
the structure.
This transfer of forces is illustrated in FIG. 18. The blow up portion of FIG.
18 also illustrates
that the panels do not bear on each other vertically and that the forces
(arrows) arc not
transferred vertically from one panel to the other. Rather the vertical and
lateral forces are
transferred laterally to the structural column assemblies 130. This type of
load transfer is
.. facilitated by the unique design and assembly of the system. Both the
horizontal truss panels
20/22/24 and the trusses 106 act as a unified truss system.
UTCS may employ horizontal truss panels of varying widths from 20' to 2', the
most
common being V-braced horizontal truss panels 20/22 measuring 8' and 4'. These
panels lead
to a significant redundancy of the structural column assemblies 130 within the
structure. Each
.. open horizontal truss panel 24 acts to support and mitigate only those
vertical local forces
proximate to their attached structural column assemblies 130. The V-braced
horizontal truss
panels 20/22 act to support vertical local forces as well as lateral forces
acting on the
structure. Because of the unique manner in which the horizontal truss panels
20/22/24
transfer vertical and lateral forces and the redundancy of the structural
column assemblies
130 in the system, there in no need to configure panels differently from floor-
to-floor. Only
the width and gauge of the tracks 12, the studs 10, and V-brace vary,
depending on building
height and code requirements.
Interior non-structural partition walls that separate spaces within a UTCS
building are
constructed from light gauge steel (typically 24-28 gauge) and are typical in
Type I and Type
II steel frame construction.
UTCS is extremely efficient in managing vertical and lateral forces on a
building.
With UTCS the need to build a bearing wall structure or heavy structural core
is eliminated,
vastly reducing costs over traditional construction practices. UTCS saves time
as well
because the structure of a building is erected from a limited number of pre-
assembled panels.
This also dramatically reduces the cost of engineering the structure of
buildings.
UTCS is unique and innovative. It can be built on nearly any foundation system
including slabs, structured parking, retail and commercial buildings. UTCS
employs a
framing technology that is based on a system-built, panelized approach to
construction.
UTCS uses panelized building technology and innovative engineering to
significantly reduce
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the cost of design, material, and erection of a building. UTCS technology and
engineering is
a new structural system and method of assembling single and multistory
buildings.
Certain modifications of the present invention have been discussed above. For
example, although the present invention is particularly useful for
constructing and assembling
buildings without relying on concrete and/or structural steel framing, heavy
steel let-in
bracing, and heavy steel and/or concrete panels, it can also be applied to
buildings having
concrete and/or structural steel framing, heavy steel let-in bracing, and
heavy steel and/or
concrete panels. Other modifications will occur to those practicing in the art
of the present
invention.
FIGS. 1-18 and the accompanying disclosure illustrate using a limited number
of
configurations for standardized structural components. Specifically, the
standardized
structural components allow for providing integration between architectural
and structural
design of building structures, production of components for such building
structures, and the
eventual erection of such building structures using the standardized
structural components.
The following disclosure illustrates various methods and systems for using
these standardized
structural components. Specifically, the system and method disclosed below
eliminates the
implementation inefficiencies, unnecessary costs, lack of coordination,
unnecessary delays,
and other problems associated with conventional building design and
construction projects.
The fully integrated method and system disclosed below provides an integrated
platform for design, manufacturing, and construction of building structures.
Furthermore, the
system disclosed herein also provides an active design functionality that
assists in
determining how other elements and building components, such as, rough-ins,
finishes,
windows, stairs, elevators, etc., relate to and are automatically sized and or
located in relation
to the structure of a building. The automation and coordination provided by
the system
enables greater design efficiency, better overall coordination and time and
cost savings on
architecture, structural engineering, mechanical, electrical and plumbing
(MEP) engineering,
manufacturing, and construction.
FIG. 19 illustrates an example block diagram of a system 1900 for using the
standardized structural components disclosed above. Specifically, the system
1900 includes a
computer aided design (CAD) software module 1902 that is used to generate a
design file
1904 for a building. An example of the CAD software 1902 is the Revit
architectural design
software from Autodesk. The design dile 1904 may be generated in a format,
such as
AutoCAD DWG file, DXF file, JPEG file, BMP file, GIF file, TXT file, etc. In
one
implementation of the system 1900, the design file 1904 also includes
designation of one or
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more walls 1906 of the building as standardized structural panel walls. For
example, such
designation of the walls may be provided by the architect during the design
phase of a
building.
The system 1900 also includes a database 1908 that stores structural details
for
various standardized structural components 1910. For example, the database
1908 includes
records that provide the definition of the trusses, the truss components, and
other
standardized structural components 1910 discussed above in FIGS. 1-18.
Furthermore, these
records may also include other characteristics of these standardized
structural components
1910, such as their dimensions, lateral and vertical load bearing capacities,
shear capacities,
the identification of studs that attach to the particular panels, etc. While
system 1900
illustrates the database 1908 as being separate from the CAD software module
1902, in one
implementation, the database 1908 may be integrated with the CAD software
module 1902.
Alternatively, the database 1908 may be accessible to the CAD software module
1902 via a
plug-in to the CAD software module 1902 that is designed to access the
database 1908. Such
an implementation allows the database 1908 to be located remotely on a
database server
accessible to a large number of users of different CAD software modules.
The system 1900 includes a geometric grid module 1912 that uses the design
file
1904 and the standardized structural components 1910 as its input. The grid
module 1912
may be configured to reside in the CAD software module 1902 as an add-in. A
designer
generating a building design using the CAD software module 1902 may select to
activate the
grid module 1912. Alternatively, the grid module 1912 may be configured to be
automatically activated when the CAD software module 1902 is active. The grid
module
1912 generates a geometric grid based on the one or more of the standardized
structural panel
walls 1906, wherein the grid identifies the coordinates for each of the
standardized structural
panel walls 1906. In one alternative implementation, the geometric grid
generated buy the
grid module 1912 exists in each of x, y, and z planes. Yet alternatively, the
geometric grid
may be set up as a network of multiple grids at various angles to account for
the angles
typical in building designs. The geometric grid also allows the activation of
several grids at
various angles to one another to allow for the design of angled buildings,
where active grids
snap the standardized structural components to precise grid coordinates.
Subsequently, the grid module 1912 automatically positions one or more of the
standardized structural panel walls 1906 along grid lines such that the
standardized structural
panel walls 1906 end substantially close to the grid line intersections. In
this manner, the
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locations and lengths of the standardized structural panel walls 1906 are
aligned to the lines
of the geometric grid.
Subsequently, the system 1900 employs a mapping solutions module 1914 that
analyzes the wall lines as mapped to the geometric grid using structural
performance and
other data associated with standardized structural components 1910 to
determine the position,
direction, etc., of the standardized structural components 1910 along the grid
lines. In one
implementation, the standardized structural components 1910 are mapped to the
grid
coordinates at predetermined distance intervals. For example, the standardized
structural
components 1910 are mapped to the grid at interval of two feet. The selection
of the
predetermined distance interval may be based on a minimum denominator size of
the
standardized structural components 1910.
The mapping solution module 1914 may first map the standardized structural
components 1910 used at part of the floor structure, such as trusses, along
the grid lines.
Example of such trusses used as part of the floor structure include truss 106
disclosed in FIG.
5 and discussed above. Once the mapping solution module 1914 has established
the location
and direction of trusses, the mapping solution module 1914 determines location
and selection
of standardized structural components 1910 that arc used as wall panels.
Examples of such
wall panels include the V-braced horizontal truss panel 20 disclosed in FIG.
3, the open
horizontal truss panel 24 disclosed in FIG. 4, etc. The mapping solutions
module 1914
calculates an efficient layout of such wall panels by analyzing the location
of openings in the
walls, column elements such as the structural column 130, etc. For example,
the mapping
solution module 1914 analyzes the load bearing capacity, the shear capacity,
etc., of the
structural columns together with such performance capacities of various wall
panels to ensure
that the resulting structure accommodates the design for wall openings, etc.,
and also meets
construction code. Specifically, the mapping module 1912 may determine the
selection of
wall panels to maximize efficiency, to minimize cost, etc.
In one implementation, the system 1900 is also configured to change the
selection and
layout of the standardized structural components 1910 based on one or more
changes to the
architectural drawing of the building. For example, if a window opening is
moved from one
wall to another wall or from one location in a wall to another location, the
selection and
placement of the trusses, wall truss panels, etc., are also changed. Yet
alternatively, the
system 1900 also allows an engineer to make localized changes to the structure
and flows the
effect of such changes to the remainder of the building. For example, if the
seismic code in a
particular jurisdiction requires a part'ular configuration of panels along a
wall line of a
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building, an engineer is able to make the required change. In such as case,
the system 130
automatically analyzes the remaining structure to ensure the compliance of the
entire building
with codes, structural soundness, etc.
The system 1900 also includes an output module 1916 that allows a user to
generate
various outputs 1920 based on the results generated by the mapping solutions
module 1914.
While, system 190 illustrates the output module 1916 as a separate module, in
an alternative
implementation, such an output module 1916 may be part of system setup. For
example, a
user may select one or more of the outputs and/or functionalities at the time
of setting up the
system and the output module 1914 generates the necessary output. For the
system 1900
illustrated in FIG. 1, the output module 1916 generates outputs 1922-1934.
Specifically, the output module 1916 is configured to generate a structural
component
list 1922 including unique identification for each of various structural
components for the
each of the various walls in the building. Thus, for example, the structural
component list
1922 may include a listing of fastening screws, bolts, studs, etc., required
for the building
structure. In one implementation, the output module 1916 also generates quick
response (QR)
codes for the various structural components. Such QR codes may be used to
uniquely identify
a particular structural component or a particular type of structural
component. For example, a
QR code is provided for uniquely identifying a particular unification plate
that is used to
attach a structural panel to a horizontal truss panel. Yet alternatively, each
of the QR codes
.. 1924 is associated with other information identifying the structural
component, such as the
location of the structural component in the building structure, the price of
the structural
component, structural characteristics of the structural component, etc.
The output module 1916 may also be configured to generate structural panel
names
1926 for various structural components of the building structure. For example,
each particular
column of the building structure is assigned a structural panel name that
identifies that
particular column and provide various information about the column, such as
the column
thickness, column size, height, column face configuration, etc. Similarly, a
structural panel
name may identify a particular panel, the panel type, panel distance from
comers on various
axes, column offset from an end, etc. Further discussion of structural panel
names is provided
below in FIG. 22.
Furthermore, the output module 1916 may also be configured to generate pages
192
providing information about various structural components of a building
structure. Such
pages 1928 may be configured as web pages with URLs that may be activated via
a QE code.
For example, when a user scans one of the QR codes 1924 using a QR code
scanner, the user
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may be provided the web page containing information about that particular
client. Thus, for
example, if a QR code is provided on a component that is already installed on
a building
structure, scanning that QR code in the field allows a user to get further
information about
that structural component. Additionally, the pages 1928 are also dynamically
updated with
information, such as the location of the structural component, installation
status of the
structural component, etc. In one implementation, one or more applications
provided on a
user device used to scan the QR code can also update the information on the
pages 1928.
Furthermore, the output module 1916 may also be configured to generate three-
dimensional models 1930 of the building structure. In one implementation, such
3-D models
1930 are also dynamically updated such that as the construction of the
building progresses,
the 3-D model 1916 is also updated. Furthermore, the 3-D models 1930 may also
identify
various structural components of the building structure. In one
implementation, the output
module 1916 also generates output files for project engineering review and
approval. For
example, such output files may includes detailed three-dimensional drawings of
the building
structure, various stress analysis reports, data required to be submitted for
compliance
requirements with various building codes, etc. A user may provide a feedback
based on the
review and approval output, in which case, the user input is incorporated in
generating a
different solution for the building structure.
In one implementation, the output module 1916 is also configured to generate a
bill of
material 1932 using information about various structural components of a
building structure.
Such bill if material may be in the form of a spreadsheet that can be further
processed by
users. Alternatively, the bill of material output 1932 may be in the form of a
file that can be
directly imported by an accounting or other financial software for further
processing. Yet
alternatively, the output module 1916 may also generate purchase orders for
the parts that are
outsourced. Again, such purchase order output may be in the form that can be
further
processed by an accounting or financial software.
Yet alternatively, the output module 1916 also generates machine control files
1934
or macro files that can be used to control various machines used to
manufacture structural
components and standardized structural components. For example, the macro
files 1934
generated by the output module 1916 may be used to control various light gauge
roll-forming
machines that produce track and stud elements for the building structure. Such
macro files
may be loaded into the manufacturing machines manually or automatically.
Additionally,
such macro files may also include instructions to the manufacturing machines
to generate
labels for manufactured parts and standardized structural components. Further
discussion of
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the use of the macro files is provided below in FIG. 24. The output module
1916 also
generates shop drawings and specifications 1936 that can be used by the
project design team,
engineers, and building department. For example, a building inspector may use
the shop
drawings generated by the output module 1916 to provide approval for a
building design, etc.
FIG. 20 illustrates an alternative example block diagram of a system for using
the
standardized structural components. Specifically, FIG. 20 illustrates a
software module 2002
that can be used to interact with existing architectural design software and
various
interactions with and inputs/outputs to and from the software module 2002. The
software
module 2002 includes various components or modules 2004 ¨ 2014 that provide
various
functionalities for using standardized structural components. The software
module 2002 may
be installed as a plug-in in any off-the-shelf architectural design software,
computer-aided-
design (CAD) software, etc. Alternatively, the software module 2002 may be
stand-alone
software that communicates with architectural design software using one or
more application
programming interfaces (APIs). For example, the software module 2002 may be
configured
to be installed and operated on a remote server and various CAD software
instances may
make API calls to communicate with the software module 2002.
In the implementation illustrated in FIG. 20, architectural software 2020
communicates with the software module 2002 with a building plan and floor plan
layout. The
building plan and floor plan layout may be in a standard format such as DWG
file, DXF file,
etc. The software module 2002 includes a wall-positioning module 2004 that
assigns floor
levels and heights to each of the walls from the architectural design.
Specifically, the wall-
positioning module 2004 generates a geometric grid based on the architectural
diagram and
maps various walls from the architectural diagram to the geometric grid. For
example, if the
architectural diagram includes a room that is 10' X 9.5', the wall-positioning
module 2004
generates a geometric grid of 10 X 10 or 10 x 8 depending on the architects
final
determination and maps the walls of the room to the grid.
The software module 2002 also includes a floor direction module 2006 that
determines the direction of the floors. Specifically, floor structure in a
building may be
determined by an engineer of record based on loading (live or dead load),
where floor loads
are carried from wall to wall by the trusses. Sometimes it may be clear as to
which direction
to place the floor, for example in the north-south (N-S) direction, in the
east-west (E-W)
direction, etc., for carrying the least load and therefore to use less
(reduced cost) structure.
The system disclosed herein automatically determines the direction of least
loading and
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places the floor in one of the E-W, N-S, or other direction. Where possible
the floor is not
loaded against exterior walls as well, automatically. FIG. 2An opening
analysis module 2008
analyzes the openings in the walls that are fit along the geometric grid. For
example, the
opening analysis module 2008 may analyze doors, windows, pass-throughs, etc.,
in a
particular wall to determine the positioning of various standardized
structural components
that would be included in that particular wall.
Once the wall size, the floor directions, the openings, and other
characteristics of a
wall are determined, a standardized structural panel-fitting module 2010
determines the
standardized structural components that arc to be used for that particular
wall. Thus, for
example, the fitting module 2010 may determine that two V-based horizontal
truss panels,
such as those disclosed in FIG. 3, together with an open horizontal truss
panel, such as those
disclosed in FIGS. 4, 4.1, 4.2 may be used in a given wall. The fitting module
2010 may use a
standardized structural panel database 2012 that stores data structures about
each of various
standardized structural components. For example, each data structure in such
database 2012
may provide information about the dimensions, weight, stress capacities,
adjoining panels,
etc., of a standardized structural panel. The module 2010 selects which
standardized
structural panel fits a particular module based on length of the wall. In one
implementation,
the fitting module 2010 analyzes each of the walls in 2' increments to see
what standardized
structural components are best fits for that particular wall. However, in an
alternative
implementation, other size of increments may also be used.
The fitting module 2010 also determines where to add structural columns along
the
grid lines of the geometric grid. In determining the structural columns, the
fitting module
2010 analyzes the required load bearing capacity and other characteristics of
the building.
Once the fitting module 2010 has fit various standardized structural
components and
structural columns to the grid lines, various output data is generated based
on the solution.
For example, a manufacturing data generation module 2014 generates data about
structural
components that are to be outsourced and the specification thereof, data about
structural
components to be manufactured, macro files for each of the structural
component to be
manufactured, etc. Such macro files may be used by production machines 2030 to
generate
the final manufactured components. For example, a macro file may be generated
for a cold
roll former interface 2032 that instructs a cold roll former machine where to
punch holes,
where to cut the edges for cold rolled panels, etc. Similarly, other macro
files may be used by
a welder interface 2034 that can be used by a robotic welder to determine
where to generate a
welding joint and what kind of welding joint is appropriate. Such macro files
allows
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automation of the process of manufacturing and putting together components
used in a
building construction 2026.
The software module 2002 generates detailed three-dimensional drawings with
specifications, such as stress bearing capacities of each wall (as a
combination of
standardized structural components and structural columns), noise mitigation
specifications,
etc. Such drawings with specifications may be submitted to a review and
approval processor
2022, such as a local building approval board, an engineer, etc., for further
review, the
processor may approve the drawings or recommend changes via the architectural
software
2020, in which case, the software module 2002 generates a new set of drawings
with
specifications for revised approval.
Once the designs are approved by the review and approval processor 2022, the
architectural software uses the input from the software module 2002 to
generate plans and
specifications 2024 for the building construction engineers. Such plans and
specifications
2024 may include, for example, the schedule specifying the order in which the
building
construction is to proceed, instructions about how specific components are to
be installed,
etc., for the actual building construction 2026.
FIG. 21 illustrates an example flowchart 2100 of a method of using the
standardized
structural components. An operation 2102 receives architectural drawings. For
example, a
software module plugged in design software may receive such architectural
drawings from
.. the design software. After determining the floor dimensions, an operation
2104 generates a
geometric grid based on the architectural design. In one implementation, the
geometric grid
has granularity of 2' X 2'. However, in an alternative implementation,
geometric grid with
other granularity may also be used. Specifically, the geometric grid includes
various grid
lines and their intersections. Subsequently, an operation 2106 determines the
floor
dimensions and directions from the received architectural design. In one
implementation, if
the architectural design has multiple rooms, the operation 2106 may analyze
each room at a
time and determine the floor dimensions and directions of each room
separately.
Alternatively, the operation 2106 may determine the floor dimensions and
directions of all
the rooms in a combined manner.
An operation 2108 positions various walls from the architectural design onto
the grid
lines. Specifically, only those walls that fit the geometric grid lines to
their intersections are
positioned along the grid lines. Thus, for example, if a wall was curved wall
or its dimension
was less than 2', such a wall may not be positioned along a grid line. In such
an example, if
the architect wants to use a curved or an angled wall, or other walls that arc
not in 2'
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increments, such curved walls, etc., ale determined to be non-standardized
walls. In this case,
such walls do not map or reside on the grid lines. Specifically, non-load
bearing walls also
may not map to the grid lines. An example, of such fitting the architectural
walls to the grid
lines is provided in further detail below in FIG. 25.
Subsequently, an operation 2110 positions standardized components along the
walls
that are positioned along the grid lines. Specifically, given that grid lines
have a granularity
of 2' X 2', standardized components fit this walls without requiring any
custom
manufactured components. Thus, for example, if a 6' wall was positioned along
a grid line, a
horizontal panel of 4' and anothcr horizontal panel of 2' may be used to
create the 6' wall.
Furthermore, another operation 2110 analyzes the location of windows and other
openings in
the walls to determine if open horizontal panels, such as those disclosed in
FIGS. 4, 4.1, and
4.2 are required. The selection of the standardized structural components also
takes into
account the fact that various structural columns arc to be added to the
structure. Specifically,
an operation 2114 adds selects and adds such structural components to the
structure. An
example of such as structural panel is one disclosed in FIG. 6 above.
Once all the structural components, such as standardized panels, trusses, and
columns,
are mapped to the architectural design walls, an operation 2116 analyzes the
mapped
solution. In one implementation, the solution is analyzed with respect to
compliance of the
resulting structure with various codes, its load bearing capacity, etc. The
analyzing operation
2116 may generate output reports including warnings, violations, etc., that
will be used by
inspectors, engineers, etc., to recommend change to the resulting structure,
if necessary.
Furthermore, an operation 2118 generates various outputs that can be used in
automating the
manufacturing and construction of the building structure. If there are any
changes necessary,
one or more operations of the flowchart 2100 may be repeated as necessary.
FIG. 22 illustrates example of structural panel names generated by the system
disclosed herein. Specifically, FIG. 22 illustrates an example of a structural
panel name 2210
using panel name abbreviations and a structural column name 2240 using various
column
name abbreviations. In the example structural panel name 2210, PA represents
the type of
panel, 312 represents the system size (3.5" or 5.5") of the panel and length
of the panel. For
.. example, 3 in 312 denotes that 3.5" system size and 12 represents the
length of the panel
being 12' (the panel length is in increments of 2'). The number 4032
represents the height of
the panel in 1/32" increments, Sxxx represents the offset of a first stud on
the panel from a
center line (CL) of a column or from a grid line, Xxxx represents the distance
of the panel to
a corner on an x-axis, Yxxx represents the distance of the panel to a comer on
a y-axis, Wxxx
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represents a width of an opening, Hxxx represents a height of an opening, and
Exxx
represents an offset from CL at the end.
In the example structural column name 2240, CB represents column thickness,
3XX
represents column size, 4032 represents height of the column in 1/32"
increments, AOJO
represents the face configuration of the column, 3033 represents a size of a
connected panel
to the column, the first A3030 represents the type of an end plate attached to
the top of the
column, and the second A3030 represents the type of an end plate attached to
the bottom of
the column.
FIG. 23 illustrates example flowchart 2300 of a method for using specialized
code to
track building construction progress. Specifically, the flowchart 2300
discloses one or more
operations that arc taken by the system for using quick response (QR) codes to
track building
construction. An operation 2302 generates the QR codes. The QR codes are
generated such
that various standardized structural components, such as panels, columns,
trusses, etc., can be
uniquely identified by a given QR code. Alternatively, a QR code may be used
to identify a
plurality of components that are similar to each other. Thus, for example, all
unification
plates 154 may be identified by a similar QR code. As another example, the QR
code for a
panel may be attached with a field containing the structural panel name 2210
that provides
information about that particular panel.
Subsequently, an operation 2304 attaches information related to a structural
.. component to the QR code. Thus, for example, in a database each of the QR
code may be
attached to one or more fields that provide information about the structural
component that is
related to that QR code. Such structural component information may include the
dimensions
of the structural component, the location of the structural component in a
building structure,
cost information of that structural component, etc. Subsequently, the QR code
is physically
attached to the structural component. Thus, for example, a QR code for a truss
is printed and
attached to that particular truss after it is manufactured.
Once a structural component is provided with a QR code, a determining
operation
2308 determines if that QR code has been scanned. For example, a specialized
QR code-
scanning device, a generic QR code-scanning device such as a smartphone, etc.,
may be used
to scan the QR code. If the QR code has been scanned, control is transferred
to another
determining operation 2310 that determines if there are any changes to the
information
related to the structural component. For example, a QR code-scanning device
may be
provided with a capability to update the status of the structural component in
the building
construction process, to update the location of the structural component in
the building, etc. If
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the determining operation 2310 determines that such update of information is
received, an
updating operation 2312 updates the structural component information. Such
updating may
involve, for example, updating of various fields in a database that are
related to the particular
structural component. As an example, a scanning device may scan a QR code on a
truss that
is already installed on the building structure and update the status of that
truss to "installed."
In this manner, the system disclosed herein provides automatic tracking and
updating of
deployment of various structural components, including the standardized
structural
components used in a building construction.
FIG. 24 illustrates an example flowchart 2400 of a method for using machine
control
filed or macro files to control the manufacturing of the standardized
structural components.
An operation 2402 generates the macro files. In one implementation, such macro
files is
generated based on the dimensions of the component that is to be manufactured.
For
example, for manufacturing a chord of a truss, the length of the chord, the
width of the chord,
the location of pilot holes and weld slots in the chord, etc., is included in
the macro file. An
operation 2404 loads the macro file in a machine used to generate the
structural component.
For example, if the macro file is for generating a chord of a truss, the macro
file is loaded in
the controlling module of a light gauge roll machine.
In this example, at operation 2406 the light gauge roll machine generates the
cold
rolled truss chord and cuts it at appropriate length, angle, etc. In one
implementation, the
macro file is also provided information about the QR code that is to be
assigned to the
manufactured part. In such an implementation, an operation 2408 generates a QR
code that is
to be used to label the manufactured truss chord. Furthermore, an operation
2410 also
communicates the specification for component to a welding machine that is used
to generate
the assembled component, such as a truss that uses the cold rolled truss to be
combined with
various cold rolled braces, etc. The welding machine may use the component
specification to
automatically generate the welding joints between the various truss
components.
Additionally, an operation 2412 generates a list of parts for which the
manufacturing
in outsourced. Specifically, operation 2412 may also generate a purchase order
with the
detailed specification about the part. As an example, specification for the
unification plates
154 maybe generated by the operation 2412 and sent to an outside manufacturer
in the form
of a purchase order. In one implementation of the system disclosed herein, an
operation 2414
assembles standardized structural components such as columns, trusses, panels,
etc., using
one or more components that are manufactured and/or outsourced. For example,
an automatic
assembly machine may be provided a macro file with instructions for assembling
the
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component parts to generate the standardized structural component.
Additionally, once the
standardized structural component is assembled, a labeling operation 2416
labels it with a QR
code or other identification code. For example, each of the trusses may be
labeled with a QR
code that uniquely identifies that truss. Alternatively, all trusses of the
same type are labeled
with the same QR code. Subsequently, at an operation 2418 the standardized
structural
components are used to erect the building structure.
FIG. 25 illustrates an example geometric grid 2500 used by the method and
system
disclosed herein. Specifically, the geometric grid 2500 is an active grid
where various
standardized structural components can be mapped (or "snapped") to the precise
grid
coordinates of the geometric grid 250. For example, the geometric the grid
2500 includes
horizontal and vertical grid lines 2502. In one implementation, the grid lines
are provided in
increments of two feet. However, in alternative implementation, other
incremental dimension
may be provided. An architect using the system disclosed herein can draw one
or more
structural walls of a building structure to the grid lines 2502. Thus, for
example, structural
walls 2504 that are mapped or snapped to one of the geometric grid lines 2502.
If there are
any walls or other elements of the building that do not fit to the geometric
grid lines 2502,
they are not mapped to the grid lines. For example, in the illustrated
implementation, divider
walls 2506, doors, etc., are not snapped or mapped to the geometric grid lines
2502.
FIG. 26 illustrates an example plan view 2600 of a geometric grid with various
standardized structural components along the grid lines. Specifically, the
plan view 2600
illustrates a number of grid lines 2602 and various standardized structural
components 2604,
2606, etc., along the grid lines 2602. As discussed above, each of the
standardized structural
components 2604, 2606 may be associated with a QR code and saved in a database
that
includes other information about such standardized structural components 2604,
2606.
FIG. 27 illustrates an example elevation view 2700 of a building structure
using
various standardized structural components. For example, the elevation view
2700 illustrates
various standardized structural components including standardized trusses
2702, standardized
panels 2704, standardized columns 2706, etc. FIG. 28 illustrates a three-
dimensional view
2800 of a structure generated using various standardized structural
components. For example,
the three-dimensional view 2800 illustrates various standardized trusses 2802,
standardized
panels 2804, standardized columns 2806, etc.
FIG. 29 illustrates an example computing system that can be used to implement
one
or more components of the method and system described herein. A general-
purpose computer
system 1000 is capable of executing a computer program product to execute a
computer
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process. Data and program files may be input to the computer system 1000,
which reads the
files and executes the programs therein. Some of the elements of a general-
purpose computer
system 1000 are shown in FIG. 10, wherein a processor 1002 is shown having an
input/output
(I/O) section 1004, a Central Processing Unit (CPU) 1006, and a memory section
1008. There
may be one or more processors 1002, such that the processor 1002 of the
computer system
1000 comprises a single central-processing unit 1006, or a plurality of
processing units,
commonly referred to as a parallel processing environment. The computer system
1000 may
be a conventional computer, a distributed computer, or any other type of
computer such as
one or more external computers made available via a cloud computing
architecture. The
described technology is optionally implemented in software devices loaded in
memory 1008,
stored on a configured DVD/CD-ROM 1010 or storage unit 1012, and/or
communicated via a
wired or wireless network link 1014 on a carrier signal, thereby transforming
the computer
system 1000 in FIG. 10 to a special purpose machine for implementing the
described
operations.
[0086] The 1/0 section 1004 is connected to one or more user-interface devices
(e.g.,
a keyboard 1016 and a display unit 1018), a disk storage unit 1012, and a disk
drive unit
1020. Generally, in contemporary systems, the disk drive unit 1020 is a DVD/CD-
ROM drive
unit capable of reading the DVD/CD-ROM medium 1010, which typically contains
programs
and data 1022. Computer program products containing mechanisms to effectuate
the systems
and methods in accordance with the described technology may reside in the
memory section
1004, on a disk storage unit 1012, or on the DVD/CD-ROM medium 1010 of such a
system
1000, or external storage devices made available via a cloud computing
architecture with
such computer program products including one or more database management
products, web
server products, application server products and/or other additional software
components.
Alternatively, a disk drive unit 1020 may be replaced or supplemented by a
floppy drive unit,
a tape drive unit, or other storage medium drive unit. The network adapter
1024 is capable of
connecting the computer system to a network via the network link 1014, through
which the
computer system can receive instructions and data embodied in a carrier wave.
Examples of
such systems include Intel and PowerPC systems offered by Apple Computer,
Inc., personal
computers offered by Dell Corporation and by other manufacturers of Intel-
compatible
personal computers, AMD-based computing systems and other systems running a
Windows-
based, UNIX-based, or other operating system. It should be understood that
computing
systems may also embody devices such as Personal Digital Assistants (PDAs),
mobile
phones, smart-phones, gaming consoles, set top boxes, tablets or slates (e.g.,
iPads), etc.
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When used in a LAN-networking environment, the computer system 1000 is
connected (by wired connection or wirelessly) to a local nctwork through the
network
interface or adapter 1024, which is one type of communications device. When
used in a
WAN-networking environment, the computer system 1000 typically includes a
modem, a
.. network adapter, or any other type of communications device for
establishing
communications over the wide area network. In a networked environment, program
modules
depicted relative to the computer system 1000 or portions thereof, may be
stored in a remote
memory storage device. It is appreciated that the network connections shown
are exemplary
and other means of and communications devices for establishing a
communications link
between the computers may be used.
Further, the plurality of internal and external databases, data stores, source
database,
and/or data cache on the cloud server are stored as memory 1008 or other
storage systems,
such as disk storage unit 1012 or DVD/CD-ROM medium 1010 and/or other external
storage
device made available and accessed via a cloud computing architecture. Still
further, some or
all of the operations for the system disclosed herein may be performed by the
processor 1002.
In addition, one or more functionalities of the system disclosed herein may be
generated by
the processor 1002 and a user may interact with these GUIs using one or more
user-interface
devices (e.g., a keyboard 1016 and a display unit 1018) with some of the data
in use directly
coming from third party websites and other online sources and data stores via
methods
including but not limited to web services calls and interfaces without
explicit user input.
A server hosts the system for using the standardized structural components
disclosed
herein. In an alternate implementation, the server also hosts a website or an
application that
users visit to access the system for using the standardized structural
components. Server may
be one single server, or a plurality of servers with each such server being a
physical server or
a virtual machine or a collection of both physical servers and virtual
machines. Alternatively,
a cloud hosts one or more components of the system for using the standardized
structural
components. The user devices, the server, the cloud, as well as other
resources connected to
the communications network access one or more of servers for getting access to
one or more
websitcs, applications, web service interfaces, etc., that are used in the
system for using the
standardized structural components. In one implementation, the server also
hosts a search
engine that is used by the system for accessing the system for using the
standardized
structural components and to select one or more services used in the system
for using the
standardized structural components.
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Accordingly, the description of the present invention is to be construed as
illustrative
only and is for the purpose of teaching those skilled in the art the best mode
of carrying out
the invention. The details may be varied substantially without departing from
the spirit of the
invention, and the exclusive use of all modifications, which are within the
scope of the
appended claims, is reserved.
28
