Slab construction system and method for constructing multi-story buildings using pre-manufactured structures
The present invention integrates the use of pre-manufactured structures with minimal on-site installation and lift-slab construction to achieve the construction of multi-story buildings. The pre-manufactured structures are designed to be readily integrated with both horizontal and vertically adjacent building components, including lift-slab components, so that multiple building stories may be readily and securely stacked, one on top of the other. The present invention advantageously permits top-down lift-slab construction for multi-story buildings. The present invention also provides for the development of flexible design plans for institutional, residential, office and other types of buildings. The present invention advantageously provides for easier, more efficient, faster, cheaper, safer, higher quality and more consistent, environmentally advantaged, energy-efficient, easier to maintain, intelligently designed, and customizable multi-story building construction.
1. A method of constructing a multi-story building, the method comprising:
installing a load-bearing structural frame around a perimeter of a foundation;
in response to the installation of the load-bearing structural frame, hoisting and positioning a plurality of slabs to different elevations from a base level of the load-bearing structural frame, wherein each slab of the plurality of slabs is configured to span a complete story of the multi-story building, and wherein hoisting and positioning comprises:
forming and pouring the plurality of slabs, at the base level, to attach to the load-bearing structural frame at each building level, wherein a lower slab between successive slabs of the plurality of slabs is configured to be a formwork for an upper slab;
prior to hoisting each of the lower slabs, loading each of the lower slabs with one or more pre-manufactured non-weight bearing walls, and, optionally, one or more exterior window walls, one or more interior components, or one or more exterior components;
hoisting and positioning the upper slab at a top of the multi-story building, wherein the upper slab positioned at the top of the multi-story building corresponds to a roof slab;
hoisting and positioning other slabs of the plurality of slabs at each successive level of the multi-story building, in a downward sequential manner, wherein hoisting and positioning the other slabs in the downward sequential manner corresponds to hoisting and positioning the other slabs successively beneath the roof slab of the multi-story building, until the construction of the multi-story building is complete; and
attaching the one or more pre-manufactured non-weight bearing walls between hoisted slabs, wherein the one or more pre-manufactured non-weight bearing walls include an interior surface and an exterior surface.
2. The method of claim 1 , wherein attaching the one or more pre-manufactured non-weight bearing walls comprises installing at least one of:
a pre-manufactured non-weight bearing wall with a prefinished exterior,
a pre-manufactured interior component, or
a pre-manufactured exterior component.
3. The method of claim 1 , wherein attaching the one or more pre-manufactured non-weight bearing walls comprises installing one or more of: a utility wall, an end wall, an exterior wall, or an exterior window wall.
4. The method of claim 3 , wherein installing one or more of: the utility wall, the end wall, the exterior wall, and the exterior window wall comprises installing the utility wall, and wherein the utility wall includes features that allow stacking and connection of utilities between one story of the multi-story building and another story of the multi-story building.
5. The method of claim 4 , wherein installing the utility wall that includes features that allow the stacking and the connection of utilities between the one story and the another story of the multi-story building, comprises installing the utility wall that includes electrical wiring that runs vertically from the one story of the multi-story building to the another story of the multi-story building.
6. The method of claim 1 , further comprising:
coupling the roof slab to the load-bearing structural frame; and
coupling a floor slab to the load-bearing structural frame.
7. The method of claim 6 , wherein coupling the floor slab to the load-bearing structural frame comprises coupling a floor slab that includes at least one recess cast into the floor slab.
8. The method of claim 7 , wherein the at least one recess cast is configured to permit controlled passage of water from the floor slab to a utility wall.
9. The method of claim 6 , wherein the floor slab comprises radiant heat coils, attached to the floor slab, to heat the floor slab.
10. The method of claim 6 , wherein the floor slab comprises a covering of acoustical isolation material that comprises pre-fabricated ceiling panels, and wherein the pre-fabricated ceiling panels provide acoustic and impact isolation.
11. The method of claim 1 , wherein installing the load-bearing structural frame around the perimeter of the foundation comprises installing:
a plurality of vertical columns,
a horizontal beam coupled to at least two of the plurality of vertical columns, and
a brace coupled to at least one of the horizontal beam or the at least two of the plurality of vertical columns.
12. The method of claim 11 , wherein installing the brace includes installing a diagonal brace coupled to at least one of the horizontal beam or to the at least two of the plurality of vertical columns.
13. The method of claim 1 , wherein hoisting and positioning of the plurality of slabs to the different elevations from the base level of the load-bearing structural frame comprises one of bolting or pinning each slab of the plurality of slabs to the load-bearing structural frame around an exterior perimeter of each slab of the plurality of slabs.
14. The method of claim 1 , wherein the hoisted and positioned plurality of slabs are supported by at least one of steel reinforcing bars or post tensioned cables, attached to the load-bearing structural frame.
15. The method of claim 1 , wherein each slab of the plurality of slabs is configured to define a finished floor for a unit above a floor slab or a finished ceiling for a unit below a floor slab.
16. The method of claim 5 , further comprising installing at least one of stairs or elevators by attaching the stairs or the elevators to the load-bearing structural frame.
17. The method of claim 5 , further comprising attaching each hoisted slab to the load-bearing structural frame via one or more concrete embedded steel plates configured to align a respective slab using corresponding structural frame steel plates securely attached to the load-bearing structural frame.
18. The method of claim 17 , further comprising, after corresponding plates are aligned, using one of a bolt or pin connection to attach each slab to the load-bearing structural frame.
19. The method of claim 18 , further comprising using exterior walkways or exterior beams of the load-bearing structural frame to provide access to one or more slab connections points, thereby reducing hazards of having workers located under unsecured slabs to access the one or more slab connection points.