Note : Les descriptions sont présentées dans la langue officielle dans laquelle elles ont été soumises.
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APPARARTUS AND METHOD FOR SUPPORTING
A MODULAR BUILDING
Cross Reference to Related Applications
[01] This application claimed the benefit of priority to U.S. Provisional
Application
No. 60/642,548 filed January 11, 2005, the contents are incorporated by
reference.
Field of the Invention
[02] The present invention relates to factory built residential and commercial
structures, and more particularly, to an apparatus and a method of supporting
buildings.
Background
[03] Factory built residential and commercial buildings have become
increasingly
popular. As the cost of new construction rises, the relatively lower cost of
factory
built residential and commercial buildings has attracted many new buyers.
Similarly, the design and use of these buildings has changed over the past
years.
These new designs and uses have made factory built buildings more
aesthetically
attractive to consumers. Factory built buildings are now widely used in place
of
traditionally-styled buildings including residential housing, office
buildings, such
as permanent and portable office buildings, classrooms and transportable
hospitals.
[04] Factory built buildings are traditionally built upon a frame containing
two or more
longitudinal members and/or several transverse beams that support the floors
of
the building. Support systems for these factory built buildings typically
include
concrete blocks or a plurality of support stands placed under the frame for
supporting it and securing it to a type of foundation. Skirting, extending
from the
factory built building's rim joist to a point within the ground, is commonly
used to
secure and hide the foundation support system and provide a more aesthetic
appearance. However, conventional foundation support and skirting systems may
not provide adequate support to the factory built building in response to the
lateral
forces created by heavy winds, seismic activities or heavy snow.
Unfortunately,
those systems that may provide adequate support can be costly to produce and
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install. Additionally, these systems may be aesthetically unattractive.
Further,
when a cement foundation/footing is poured for aesthetic purposes, the poured
concrete must be allowed to set at the job site, thereby delaying the assembly
of
the building at the job site.
[05] There is a need in the art for an apparatus useable with factory built
buildings to
provide ease of assembly and support.
Summary of the Invention
[06] The present invention relates to a method of supporting a building, such
as a
modular home or site built homes.
[07] In one aspect there is provided a method of supporting a building by
securing one
end of a support stand having a telescopic structure to a movable concrete
footer.
The support stand may have another end with a support assembly mounted to the
telescopic structure. The method includes supporting the building with support
assembly of the support stand.
[08] In one aspect, there is provided a method of supporting a building by a
framing
member and a support assembly having an upper plate and lower plate, the upper
plate and the lower plate having a first set of apertures and the framing
member
having a second set of apertures, the method includes a step of positioning
the
frame member between the upper plate and the lower plate and securing a
plurality of fastener members to the framing member and the support assembly
via the first set of apertures and the second set of apertures.
[09] In another aspect of a method of supporting a building, a plurality of
fastening
members have a threaded cylindrical portion which mates with a threaded nut, a
method includes a step of securing the fastening members with the upper plate
keeping the threaded cylindrical portion stationary while advancing the
threaded
nut thereon.
[10] In one aspect, there is provided a method of supporting a building by a
framing
member and a supporting assembly has a support plate, support plate having a
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first set of apertures and the framing member having a second set of
apertures, the
method including a step of positioning the frame ineiuber on the support plate
and
securing the framing member with a plurality of fastener members via the first
set
of apertures and the second set of apertures.
[11] In another aspect of a method of supporting a building, a plurality of
fastening
members have a threaded cylindrical portion which mates with a threaded nut,
the
method including a step of securing the fastening members by the framing
member keeping the threaded cylindrical portion stationary while advancing the
threaded nut thereon.
[12] In another aspect, there is provided a support stand for a supporting a
building.
The stand includes tubular structure including a telescopic adjustment portion
for
adjusting a height of a building. A support assembly mounted to the telescopic
adjustment portion, the support assembly having a support plate with a
plurality
of apertures in a shape configured for retaining a threaded portion of a
fastening
member in a stationary position while a threaded nut is rotated on the
threaded
portion.
[13] The above and other aspects, features and advantages of the present
invention
will be readily apparent and fully understood from the following detailed
description illustrative embodiments in conjunction with the accompanying
drawings, which are included by way of example, and not by way of limitation
with regard to the claimed invention.
Brief Description of the Drawings
[14] Figure 1 is a perspective exploded assembly view of one embodiment of a
support
system;
[15] Figure 2 is a perspective exploded assembly view of an alternative
embodiment of
a support system; and
[16] Figures 3 and 4A-4E illustrate alternative embodiments of a support
system.
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Detailed Description
[17] The following embodiments and aspects thereof are described and
illustrated in
conjunction with systems and methods which are meant to be illustrative and
non-
limiting in scope. In a brief overview, an aspect of the present invention
relates to
a method of supporting a modular building, such as a modular home. Modular
buildings according to the present invention include modular "factory built"
buildings and "site built" (stick built) buildings. Modular factory built
buildings
used with this method include those buildings built in a factory in modules.
The
modules are then transported to the erection site on temporary "carrier"
chassis
that are removed before the building is completed. After arriving at the
erection
site, the modules are connected together to form a complete building. Site
built
buildings include those buildings that are constructed using raw materials on
the
site in which they are intended to remain permanently.
[18] Both modular factory built buildings and site built buildings include
outer, lower
fraining members that form the outer framing support structure of the building
and part of the flooring system. These framing members are substantially
planar
and located along the outer sides of the buildings. These lower framing
members
are also positioned proximate the lowest points of the building. As a result,
vertical and horizontal support stands can be located under the building and
secured to the appropriate framing members in order to hold the building in
place.
These framing members are typically planar members aligned with the lower
surface of the building or vertically spaced from the lower surface of the
building.
Examples of these planar members include wooden boards, such as 2x8's or
2x10's. Other known framing boards can also be used. Alternatively, the
framing
members can be formed of metal or other materials that can include holes,
including threaded holes.
[19] Figure 1 illustrates a support system 10 for a modular building that can
be used in
a method of the present invention. The modular building is generally
constructed
and assembled with framing members 80 (Figure 2) that form the outer lower
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framework of the modular building and a support structure for the flooring
system
of the modular building, as discussed above. The support system 10 includes
support stands 30 that are spaced about the perimeter of the building.
Preferably,
the support stands 30 are spaced approximately 10 and 12 feet apart, depending
on the under structure of the building. However, the number and placement of
the
stands 30 are typically dictated by local building codes.
[20] As illustrated in Figures 1-4A, an embodiment of the support stand 30
includes a
clainping assembly 40, a head unit 45 and base 70. The base 70 includes base
plate 72 and a plurality of fasteners 74 which secure the plate 72 to light-
weight
concrete footers 20. The fasteners 74 can include nuts and bolts, masonry
screws
or other similar fasteners. The footers 20 support the support stands 30 above
leveled ground or a poured slab, such as a poured concrete pad.
[21] In one embodiment, the plate 72 is 8" x 8" and 1/4 inch thick. For this
embodiment, the footer 20 can be 24" wide x 48" long and is 4" thick in the
center. This footer 20 is produced using a concrete mold in a factory under
controlled conditions so that the size and shape are controlled. The footer 20
has
an 8" x 8" flat square top surface that includes two plastic inserts poured
into the
footer 20. These plastic inserts receive the fasteners 74.
[22] In an embodiment, the clamping assembly 40 positively locks the support
stand
30 to the framing members 80 of the modular building. In an embodiment
illustrated in Figure 1, the clamping assembly 40 includes a support plate 42
for
receiving and supporting the lower surface of at least one framing member 80
and
a second plate 43 that can be positioned on an upper surface 82 of the
supported
framing member 80. This clamping assembly is similar to that disclosed in U.S.
Patent No. 5,862,635 to Linse that is herein incorporated by reference.
Fasteners
41 extend through the framing member 80 and the first and second plates 42, 43
to secure the framing member 80 to the support stand 30. In a preferred
embodiment, the fasteners 41 include nuts and bolts; however, any conventional
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fastener for securing two plates together may be used. If desired, circular
rods 44
maybe added to the plate 42. (FIG. 1)
123] In an embodiment illustrated in Figure 2, the second plate 43 is not
utilized.
Instead, the fastener 41 is directly in contact with the top side of the
framing
member 80. In this embodiment, the bolt or nut head would engage the framing
member 80 in place of the second plate 43.
[24] In a third embodiment illustrated in Figures 3 and 4A-4E, the clamping
assembly
40 includes the support plate 42 for at least one framing member 80 and a
plurality of fasteners 41, such as lag bolts, that can extend through the
support
plate 42 and be secured directly into the framing member(s) 80. In the
illustrated
embodiment, the first plate 42 is 8" x 10" x 1/4" thick. The top plate has a
series of
holes or apertures 59 (see Figures 4A-4E) formed in a predetermined pattern
that,
with the fasteners 41, provides a secure connection between the first plate 42
and
the framing member 80. Different hole 59 patterns can be provided for plates
42
used at different locations along the framing member 80. Each hole 59 in the
plate 42 receives an elongated threaded fastener 41, such as a screw. An
exainple
of such a screw is a lag screw, also known in the industry as a lag bolt.
These
screws (lag bolts) can be 2-1/2" long x%2" in diameter.
[25] As shown in Figures 1-4A, and 4C, the head unit 45 is positioned below
the
clamp assembly 40 and attached thereto. The unit 45 includes a U-shaped
channel member 46 secured to the underside of the first plate 42. In a
preferred
embodiment, the channel member 46 is welded to the first plate 42, however,
other well known securing techniques may be used. The channel member 46
defines a space 47 between its inner bottom floor 48 and the underside of the
first
plate 42 which contains a support member 49, an end 52 of a threaded rod 51
and
a bushing 57. The support member 49 is secured to the end 52 of the rod 51 and
rotates with the rod on bushing 57 for ease of turning. Preferably, support
member 49 is a threaded nut that is welded to the end of the threaded rod 51.
As
shown in Figure 2, tolerance exists between support member 49 and the
underside
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of first plate 42 before the framing member 80 is fully loaded on the first
plate 42
so that clamping assembly 40 can tilt slightly relative to support member 49,
thereby facilitating the contact between the first plate 42 and the framing
member
80. When the framing member 80 is properly positioned on first plate 42,
support
member 49 contacts first plate 42 and distributes the load of the building
over the
entire head unit 45 so the forces experienced by any one portion of the
support
stand 30 are lower when compared to conventional support stands. This
distribution of the load extends the life of the support stand 30 and reduces
its
chance of failure.
[26] A fine height adjusting mechanism 50 and a stepwise height adjusting
mechanism
60 are provided between the clamping assembly 40 and the base 70 for leveling
the building. These mechanisms 50, 60 vary the distance between the building
and the foundation to compensate for uneven terrain or the movement of the
foundation over time. The stepwise height adjustment mechanism 60 varies the
height of the building in predetermined increments. Increments of
approximately
two to five inches are preferred, with the most preferred increment being
approximately three inches. The fine height adjustment mechanism 50 varies the
height of the building within the increments of the stepwise adjustment
mechanism 60.
[27] Fine height adjusting mechanism 50 includes the threaded rod 51, a tool
engaging
member 53 secured to rod 51 and a rod receiving member 54 operatively attached
to base 70. The tool engaging member 53 supports the underside of the U-shaped
channel member 46 and initially receives the load of the building frame when
it is
placed on the first plate 42, to prevent failure of the rod 51 and allow for
the
clearance discussed above between the underside of the first plate 42 and the
support member 49. In a preferred embodiment, the tool engaging member 53 is
a nut secured to the threaded rod 51 by welding or other known techniques.
Gradual and fine adjustment of the building height relative to the foundation
is
accomplished by rotating rod 51 within a receiving member 54 using tool
engaging member 53. The tool engaging member 53 receives a wrench or other
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such tool for rotating the rod 51. Receiving member 54 is preferably a
threaded
nut which fixed to an upper end 61 an inner tube 62 of the stepwise adjustment
mechanism 60. The receiving member 54 could also be positioned within the
inner tubular member 62.
[28] The stepwise height adjusting mechanism 60 includes the inner telescopic
tubular
member 62 carrying the receiving member 54 and an outer tubular member 64
which telescopically receives inner tubular member 62. A plurality of
apertures
63 are vertically spaced along opposite sides of the inner tubular member 62
at
intervals which achieve the predeterrnined, incremental height adjustment
discussed above. As shown, apertures 65 are also located on opposite sides of
the outer tubular member 64. A bayonet pin or bolt 67 is placed through the
apertures 65 when they are properly aligned for a given height with a pair of
the
apertures 63 in the first tubular member 62. The outer tubular member 64 also
includes an anti-rattle aperture 68. A bolt 69 is inserted through aperture 68
and
frictionally engages the inner tubular member 62 to prevent it from rattling
within
the outer tubular member 64. It is also contemplated that the telescopic
relationship between the tubular members 62, 64 could be reversed.
[29] The method according to the present invention includes a step of
supporting a
modular building at a predetermined erection site. The building can be a
factory
built or site built building as discussed above. The method includes the steps
of
securing the support stand 30 to the light-weight concrete footer 20 as shown
in
the figures. The footer 20 and support stand 30 are then positioned at
appropriate
locations on a properly graded site for supporting the building. When secured
on
top of the support stand 30, the building is supported against applied
vertical and
lateral loads. The position of these footers 20 and support stands 30 is
determined
by the building manufacturer's instructions or engineer instructions.
[30] After the position of the footer 20 and support stand 30 have been
approximately
set, the course height adjustment of the support stand 30 is set for a given
height.
When each support stand 30 has been set to an appropriate height, the building
is
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either lowered onto the support stands 30 (for a factory built building) or
the
assembly of the building begins on the support stands 30 (for a site built
building). Regardless of which type of building is supported, the clamp
assembly
embodiments 40 discussed above can be used to secure the building to the
support
stand 30.
[31] For a factory built building, the ground level portions are either craned
or in some
other way lowered onto the support stands 30. Typically if the modules are
crane
set, one corner of the module is set on a support stand 30 and the module is
lowered slowly in order to manipulate the module into the correct position in
which it will remain permanently. The module is then lowered into its final
resting position. Additional modules are set in the same fashion and attached
permanently to the modules that are already set. The support stands 30 can be
moved in any direction as needed before the building modules are completely at
rest in order to obtain the proper positioning. Second-story modules of the
building can then be added if applicable on top of the ground level modules.
Once the building is in its permanent resting position, the head assemblies
are
fully secured to the framing member 80.
[32] The clamping assembly 40 illustrated in Figures 1-4A secures the framing
member 80 of either the factory built building or the site built building to
the
support stand 30. In this part of the method, the plate 42 is positioned under
the
framing member 80 of either the factory built or site built building so that
it
supports the framing member(s) 80. The fasteners 41, such as lag bolts, are
advanced through the openings 59 in the plate 42 and into the framing member
80
(See Figure 3). This is performed for each of the support stands 30.
[33] In an alternative embodiment of the method, the fasteners 41 extended
through
the plate 42 are bolts that cooperate with nuts to secure the framing member
80 to
the support stand 30. In this embodiment (Figure 2), the support stand 30 and
framing member 80 are positioned so that the framing member 80 is supported by
the plate 42. Then, the bolts are advanced through the openings 59 in the
plate
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42. Threaded fastening nuts are secured to the ends of the bolts on the
opposite
side of the framing member 80 from the plate 42. In an embodiment, the framing
member can include a recess that matches the shape of the nut and bolt head so
that a wrench is not needed to hold the nut or bolt head as the nut and bolt
are
being tightened.
[34] In another embodiment, the clamping assembly 40 illustrated in Figure 1
is used
to secure the framing member 80 to the support stand 30. In this embodiment,
the
plate(s) 43 is positioned on the opposite side of the framing member from the
plate 42. As a result, after the support stand and framing member are in the
proper vertical and horizontal position, the plate 43 is positioned on the top
surface of the framing member 80 and bolts are advanced through the plates 42,
43 and the framing member 80. In this embodiment, it may be necessary to have
access to the upper surface of the framing member 80 at the time that the nut
and
bolt are tightened. Alternatively, the plate 43 can include a recess that
matches
the shape of the nut and bolt head so that a wrench is not needed to hold the
nut or
bolt head as the nut and bolt are being tightened.
[35] After the clamping assemblies 40 have secured the framing member(s) 80 to
their
respective support stands 20, the final height of the building can be
adjusted,
where needed, by manipulating the height adjustment mechanisms 50, 60. Also,
for the site built buildings, the remainder of the building can be constructed
on top
of the framing members 80. For example, if just the floor of the building was
constructed above the framing members 80 prior to securing the framing members
80 to the support stands 30, the remainder of the building would be framed and
completed.
[36] After the height of the building is set and the building is level,
skirting panels can
be positioned against the supports and/or the building to hide the support
stands
30 and increase the aesthetic appearance of the building. Slcirting panels
that can
be used in the method are disclosed in U.S. Patent Application Nos.
10/821,837;
10/821,873 and 10/821,874. All of these applications were filed on April 12,
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2004 and are hereby incorporated in this application by reference. After the
skirting panels are in place, the area around the panels can be backfilled for
support.
[37] In another embodiment, the support plates 42 positioned at the corners of
the
buildings could include vertical sidewalls on both their outer and inner
edges. In
such an embodiment, the framing member 80 could be secured to the support
stand 30 using both vertically and horizontally positioned fasteners.
[38] Different sized building frames can be accommodated by the present
invention
merely by changing the size of the clamping assembly 40.
[39] Numerous characteristics, advantages and embodiments of the invention
have
been described in detail in the foregoing description with reference to the
accompanying drawings. However, the disclosure is illustrative only and the
invention is not limited to the illustrated embodiments. It will be apparent
to
persons ordinarily skilled in the art that modifications may be made thereof
within
the scope of the invention, which scope is to be accorded the broadest
interpretation of the claims such as to encompass all equivalents, devices,
and
methods. Therefore, various changes and modifications may be effected therein
by one skilled in the art without departing from the scope or spirit of the
invention.
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