U.S. patent application number 13/432378 was filed with the patent office on 2012-07-19 for method of manufacturing reinforced structures.
Invention is credited to David M. Dooley, Fred J. Gossen, JR..
Application Number | 20120180425 13/432378 |
Document ID | / |
Family ID | 36179279 |
Filed Date | 2012-07-19 |
United States Patent
Application |
20120180425 |
Kind Code |
A1 |
Dooley; David M. ; et
al. |
July 19, 2012 |
Method of Manufacturing Reinforced Structures
Abstract
A method of manufacturing reinforced structures wherein a
hardened steel shell is constructed to desired specifications and
anchored to a structure's foundation. The remainder of the
structure is constructed around the hardened steel shell, thereby
incorporating the steel shell as an integrated room or section of
the structure.
Inventors: |
Dooley; David M.;
(Lafayette, LA) ; Gossen, JR.; Fred J.; (Rayne,
LA) |
Family ID: |
36179279 |
Appl. No.: |
13/432378 |
Filed: |
March 28, 2012 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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12157242 |
Jun 9, 2008 |
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13432378 |
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10967878 |
Oct 18, 2004 |
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12157242 |
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Current U.S.
Class: |
52/745.02 |
Current CPC
Class: |
E04H 9/14 20130101; Y02A
50/14 20180101 |
Class at
Publication: |
52/745.02 |
International
Class: |
E04H 1/00 20060101
E04H001/00 |
Claims
1. A method of manufacturing a reinforced building comprising: a)
manufacturing a steel shell structure having an internal space,
wherein said steel shell structure comprises a plurality of welded
panels; b) anchoring said steel shell structure to a building
foundation using at least one mechanical fastener; c) constructing
a building around said steel shell structure, wherein said steel
shell structure is substantially coincident with at least one room
of said building; and d) wiring an electrical generator to at least
one electrical outlet disposed in said steel shell structure.
2. The method of claim 1, wherein said electrical generator is
disposed within a steel case attached to said steel shell
structure.
3. The method of claim 1, wherein said electrical generator is
fueled by natural gas.
4. The method of claim 1, wherein said steel shell structure
comprises a tubular steel frame.
5. The method of claim 1, wherein said steel shell structure
further comprises a plurality of steel plates attached to said
tubular steel frame.
6. The method of claim 1, further comprising the step of installing
at least one wall covering material on at least one internal
surface of said steel shell structure.
7. The method of claim 6, wherein said at least one wall covering
material is sheet rock.
8. The method of claim 1, further comprising the step of installing
at least one finish material to at least one external surface of
said steel shell structure.
9. The method of claim 8, wherein said at least one finish material
is brick.
10. The method of claim 1, wherein said steel shell structure
further comprises at least one window opening.
11. The method of claim 10, further comprising the step of
installing at least one window having blast resistant glass in said
at least one window opening.
12. The method of claim 1, wherein said steel shell structure
further comprises at least one doorway opening.
13. The method of claim 12, further comprising the step of
installing a reinforced door in each of said at least one doorway
opening.
Description
CROSS REFERENCES TO RELATED APPLICATIONS
[0001] This application is a continuation of non-provisional patent
application Ser. No. 12/157,242 filed Jun. 9, 2008, which is a
continuation of non-provisional patent application Ser. No.
10/967,878, filed Oct. 18, 2004, currently abandoned.
STATEMENTS AS TO RIGHTS TO INVENTIONS MADE UNDER FEDERALLY
SPONSORED RESEARCH AND DEVELOPMENT
[0002] none
BACKGROUND OF THE INVENTION
[0003] 1. Field of the Invention
[0004] The present invention relates to a method of manufacturing
reinforced structures. More particularly, the present invention
relates to a method of manufacturing reinforced components of
dwellings and other buildings. More particularly still, the present
invention relates to a method of manufacturing reinforced rooms
and/or areas of dwellings and other buildings capable of
withstanding hurricanes, tornadoes, earthquakes and other
threats.
[0005] 2. Description of the Prior Art
[0006] Generally, walls of dwellings and other similar buildings
are made from wood, bricks and/or hollow masonry blocks, while
roofs are made from wood. Frequently, wooden trusses, especially
nailed trusses, span the entire interior of such buildings.
Although such buildings can be very economical to construct, they
generally cannot withstand the effects of a hurricane, tornado,
earthquake or other disaster. In many instances, such structures
can be severely damaged, if not completely destroyed, by such a
disaster. Further, buildings in general, and houses in particular,
are typically not of fire resistant construction and are
susceptible to considerable damage due to fires.
[0007] In addition to threats from fires and natural disasters,
buildings and/or dwellings constructed using conventional methods
are also vulnerable to "man-made" threats. Such man-made threats
can include forced entry by intruder(s), as well as chemical,
biological or nuclear attacks.
[0008] Numerous attempts have been made to protect against such
threats. The concept of safe rooms, "panic rooms" and/or fallout
structures within buildings and other dwellings is previously
known. Generally, prior art safe rooms and the like comprise
separate rooms or attachments to buildings or other dwellings which
are made of fire, blast and/or break-in resistant construction.
However, such safe rooms generally are not an integral part of a
building itself, adding to its structural strength and integrity.
Further, such specialized rooms or shelters are rarely, if ever,
used unless a specific need arises.
[0009] In many areas, dwellings and other buildings can be
constructed with storm shelters and/or fallout shelters in cellars
or other underground locations. However, in certain geographic
regions, such as in the vicinity of the Gulf of Mexico, buildings
(including residential dwellings) are often constructed without
cellars because the ground water level is too high. As such,
buildings in these areas typically have only a concrete slab for a
foundation, and safe rooms, "panic rooms" and/or fallout shelters
cannot be constructed in cellars.
[0010] Thus, the need exists for a reinforced room or section of a
building or dwelling which can withstand high winds associated with
tornadoes and/or hurricanes, as well as blasts from other sources.
Similarly, such reinforced room or section should be fire
resistant, and should be able to withstand negative effects of
earthquakes. Such reinforced room or section should be an integral
part of said building or dwelling, and should be able to be capable
of being used and enjoyed even when not being utilized as a
disaster shelter.
SUMMARY OF THE INVENTION
[0011] As opposed to specialized fallout or storm shelters that are
rarely if ever used, a building constructed pursuant to the method
of the present invention integrates the security benefits of such
fallout shelters, storm shelters and/or so-called "panic rooms"
into fully functional room(s) in such building. Buildings
constructed pursuant to the method of the present invention offer
full functionality, even when the reinforced rooms and/or sections
of such buildings are not being specifically used as a shelter.
Dwellings and other buildings constructed pursuant to the method of
the present invention are engineered to withstand tornadoes,
hurricanes, forced entry by intruders and automobile intrusion,
fire, ballistic damage, chemical or toxic releases, and tidal/storm
surges.
[0012] Buildings constructed pursuant to the method of the present
invention can be designed into virtually any new construction
project, or can be added into virtually any existing building or
dwelling. Alternatively, the method of the present invention can be
used to construct stand-alone structures.
[0013] In the case of slab foundation buildings, a proprietary
anchor system is installed within such slab. Once the slab is
poured, steel room (or group of rooms) is constructed, typically at
an off-site location. Thereafter, such room(s) are delivered to the
construction site, set in place and mechanically fastened to such
slab using anchoring devices.
[0014] Room(s) constructed pursuant to the method of the present
invention are equipped with their own electrical, HVAC, plumbing
rough-ins and sheet rock walls/ceilings. In the preferred
embodiment, such room(s) are designed to be totally self-contained,
and are tied to a generator (typically powered by natural gas) that
will automatically actuate when the building's standard source of
power is lost.
[0015] The building or other dwelling is then manufactured around
the room constructed pursuant to the method of the present
invention. Roof joists can be affixed to the steel room or wing,
making such room immensely stronger and capable of withstanding
higher wind loads, fire, ballistic forces and the like.
BRIEF DESCRIPTION OF THE DRAWINGS
[0016] FIG. 1 depicts an exploded perspective view of a steel
structure of the present invention.
[0017] FIG. 2 depicts a perspective view of a steel structure of
the present invention being delivered to a construction site.
[0018] FIG. 3 depicts a perspective view of a steel structure of
the present invention being installed at a construction site.
[0019] FIG. 4 depicts a cross-sectional side view of a slab
foundation for a dwelling or other building.
[0020] FIG. 5 depicts a cross-sectional cut-away view of a dwelling
constructed pursuant to the method of the present invention.
DETAILED DESCRIPTION OF A PREFERRED EMBODIMENT
[0021] Referring to the drawings, FIG. 1 depicts an exploded
perspective view of a shell having an internal space formed by
steel structure 1 of the present invention. Steel structure 1 can
be fabricated in any number of different configurations. In the
preferred embodiment, steel structure 1 is designed to fit the
design parameters of a dwelling or other building into which such
steel structure 1 is to be incorporated.
[0022] Although steel structure 1 can be configured any number of
different ways, in the preferred embodiment of the present
invention, said steel structure 1 has substantially horizontal
planar floor 2, a plurality of side walls 3 and substantially
horizontal planar ceiling 4. Said substantially horizontal planar
floor 2, side walls 3 and substantially horizontal planar ceiling 4
together form an enclosure defining interior space within steel
structure 1. It is to be observed that substantially horizontal
planar ceiling 4 is anchored to the upper portion of side walls 3;
however, said horizontal planar ceiling 4 is shown in exploded FIG.
1 to illustrate the interior space within steel structure 1.
[0023] In the preferred embodiment, steel structure 1 is initially
fabricated from a tubular steel frame. Thereafter, steel plates
having desired strength characteristics are welded to said frame in
order to form substantially horizontal planar floor 2, vertical
side walls 3 and substantially horizontal planar ceiling 4. Of
course, while the preferred embodiment of the present invention
describes use of steel, other materials such as composites having
desired characteristics could be employed in place of steel in
certain applications.
[0024] Still referring to FIG. 1, external doorway 5 is provided in
at least one vertical side wall 3. Depending upon the configuration
of steel structure 1, it may be desirable to incorporate more than
one doorway into the design of steel structure 1, but this will
typically depend on the desired layout of said steel structure 1.
Doorway 5 permits access to the internal space of steel structure 1
defined by substantially planar floor 2, vertical side walls 3 and
substantially horizontal planar ceiling 4. Similarly, optional
window openings 6 can be fabricated into vertical side walls 3.
[0025] At least one optional internal wall 7 having internal
doorway 3 can be constructed within the interior space of steel
structure 1. Although such internal wall(s) are not required, said
walls may be desirable to divide or configure the internal space
within steel structure 1. By way of example, but not limitation,
when steel structure 1 of the present invention is utilized as the
master suite of a dwelling, it is typically desirable to
incorporate one or more internal walls to define a master bath
area, closet space and the like. Although such internal walls can
be constructed of steel or other reinforcing material, in most
applications this is not necessary because vertical side walls 3 of
steel structure 1 provide desired strength characteristics for the
entire internal space defined within steel structure 1.
[0026] In the preferred embodiment, reinforced case 9 is provided.
Although reinforced case 9 can be situated in any number of
different locations, in most applications said reinforced case is
located on the upper surface of substantially planar horizontal
ceiling 4. Said reinforced case 9 can be used to house hot water
heater(s), HVAC equipment and/or other life support components.
[0027] FIG. 2 depicts a perspective view of steel structure 1 of
the present invention being delivered to an installation site.
Although it is possible that such steel structure 1 can be
manufactured at such installation site, in the preferred embodiment
said steel structure) is manufactured at another site, such as a
remote fabrication facility, and then transported to an
installation site via truck 20.
[0028] Referring to FIG. 3, steel structure 1 is off-loaded from
truck 20 using crane 21. Said steel structure 1 is positioned on to
building foundation slab 30 using crane 21. Specifically, steel
structure 1 is positioned on a predetermined portion of building
foundation slab 30 which has been designed to receive said steel
structure 1. In the preferred embodiment, said building foundation
slab 30 includes a plurality of anchor bolts 31 which are implanted
or otherwise installed within said slab 30 and protrude vertically
upward out of building foundation slab 30. Similarly,
plumbing/utility stubs 32 extend upward from said building
foundation slab 30.
[0029] FIG. 4 depicts a detailed cross-sectional view of building
foundation slab 30. Said building foundation slab 30 has footers 33
which extend into ground 34. Said building foundation slab has
upper surface 35 and recessed area 36 partially defined by upper
surface 36a. Recessed area 36 is sized and configured to receive
steel structure 1, which rests upon recessed upper surface 36a of
building foundation slab 30. Anchor bolts 31 and plumbing/utility
stubs 32 extend upward from building foundation slab 30 within
recessed area 36. Said anchor bolts 31 and plumbing/utility stubs
32 are spaced to be received within mating apertures within
substantially horizontal planar floor 2 of steel structure 1.
[0030] FIG. 5 depicts a cross-sectional view of a reinforced room
constructed in accordance with the method of the present invention
within standard dwelling 50. Steel structure 1 of the present
invention is incorporated within such dwelling 50. Steel structure
1 can be fabricated in any number of different configurations and
typically comprises substantially horizontal planar floor 2,
plurality of vertical side walls 3 and substantially horizontal
planar ceiling 4. In the preferred embodiment, steel structure 1 is
configured to fit the design parameters of dwelling 50. In many
cases, the steel structure 1 will comprise and be coincident with
the master suite of dwelling 50, but it is to be observed that said
steel structure can be incorporated into in any number or other
areas within dwelling 50.
[0031] Building foundation slab 30 has footers 33 which extend into
ground 34. Said building foundation slab has upper surface 35 and
recessed area 36 partially defined by upper surface 36a. Recessed
area 36 is sized and configured to receive steel structure 1, which
rests upon recessed upper surface 36a of building foundation slab
30. Anchor bolts 31 extend upward from building foundation slab 30
within recessed area 36. Said anchor bolts 31 are spaced to be
received within mating apertures within substantially horizontal
planar floor 2 of steel structure 1. Steel structure 1 is
mechanically anchored to building foundation slab 30 using anchor
bolts 31. Although not shown in FIG. 5, plumbing and/or utility
fixtures (such as plumbing/utility stubs 32 in FIG. 4) are used to
bring plumbing and/or electricity into the area(s) within steel
structure 1.
[0032] Still referring to FIG. 5, external doorway 5 is provided in
at least one vertical side wall 3 of steel structure 1. In FIG. 5,
although said doorway 5 is situated along an external wall of steel
structure 1, said doorway is located internally within dwelling 50.
Depending upon the configuration of steel structure 1, it may be
desirable to incorporate more than one such doorway into the design
of steel structure 1, but this will typically depend on the desired
layout of said steel structure 1 and dwelling 50. Doorway 5 permits
access to the internal space of steel structure 1 defined by
substantially planar floor 2, vertical side walls 3 and
substantially horizontal planar ceiling 4 from other areas of
dwelling 50. Reinforced, heat resistant door 51 is mounted within
doorway 5. Similarly, windows manufactured from blast resistant
glass or other similar material(s) can be installed within the
window openings 6 in side walls 3 of steel structure 1.
[0033] At least one optional internal wall having an internal
doorway can be constructed within the interior space of steel
structure 1. Although such internal wall(s) are not required, said
walls may be desirable to divide or configure the internal space
within steel structure 1. By way of example, but not limitation,
when steel structure 1 of the present invention is utilized as the
master suite of a dwelling, it is typically desirable to
incorporate one or more internal walls to define a master bath
area, closet space and the like. Although such internal walls can
be constructed of steel or other reinforcing material, in most
applications this is not necessary because vertical side walls 3 of
steel structure 1 provide desired strength characteristics for the
entire internal space defined within steel structure 1.
[0034] Reinforced case 9 is provided on the upper surface of
substantially planar horizontal ceiling 4 of steel structure 1.
Said reinforced case 9 can be used to house generator 52, HVAC
equipment 53 and/or other life support components, such as a hot
water heater. Gas line 54 supplies fuel to generator 52.
[0035] After said steel structure 1 is installed on building
foundation slab 30, other portions of dwelling 50 can be
constructed. For example, joists 55 and truss members 56 can be
used to support roof 57. Where desired, external surfaces of
dwelling 50 can be equipped with desired finishes, such as brick
surfaces 58. Internal surfaces of steel structure can be equipped
with sheet rock 59 and flooring 60. In the preferred embodiment,
steel structure 1 blends seamlessly into dwelling 50 and is not
visible from the outside or inside living area of dwelling 50.
[0036] In certain applications, a room or other section of building
installed pursuant to the method of the present invention can
include a positive pressure system. Such positive pressure system
prevents chemical, biological or other agents from entering the
living space defined by steel structure 1.
[0037] Whereas the invention is herein described with respect to a
preferred embodiment, it should be realized that various changes
may be made without departing from essential contributions to the
art made by the teachings hereof.
* * * * *