US3028707A - Method of building construction - Google Patents

Description

April 10, 1962 Filed March 13, 1959 W. SAGALOVITCH METHOD OF BUILDING CONSTRUCTION 6 Sheets-Sheet 1 j i INVENTOR.

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r/mud Mia male Jam I Patented Apr. 10, 1962 3,028,707 METHQD F BUELDXNG 'iIONSTRUCTION Wolfe Sagalovitch, 134 N.'La Selle St., Chicago 2, Ill.

Filed Mar. 13, 1959, Ser. No. 799,199 laims. (Cl. 50-534) This invention relates to improvements in the method of building construction and is particularly concerned with the novel method utilized for forming and thenpositioning concrete floor and roof slabs at selected floor elevations.

Previous known attempts to pre-cast and then locate floor and roof slabs have involved the pouring of all slabs at the ground or first floor level and then successively raising each slab into place and then securing it. This procedure requires the use of costly excessively heavy duty hoisting equipment capable of carrying the full load of a slab and involves intermittent parking and bracing of the slabs and is time-consuming and costly. In one known instance, power-operated units are arranged on the top end of each upright column in the-building structure and complicated and involved electronic control means is utilized in an effort to insure that all units operate at uniform speeds so as to avoid unequal lift and consequent cracking of the slab.

The method disclosed herein avoids all of the known disadvantages present in prior known methods and is such that the slabs are pre-cast in groups of predetermined numbers at various levels above the ground or first floor level and selected slabs then are interconnected by a novel pulley system in a manner that allows a selected slab to be raised into its required position at a higher floor level by the weight of one or more other slabs which move downwardly by gravity for ultimate positioning at the required or lower floor level. Minimum power is applied to some of the pulley systems only and for the sole purpose of regulating the speed at which the slabs move into place to insure uniform operation of the system and for providing braking power without cracking the slabs. The pulley arrangement is such that the slaps are supported in the area surrounding each upright column and only the pulley systems at the corner columns of the structure have applied brakingpower so as to minimize any differential in the motivating power which, if

excessive and present at too many areas of the slabs,

would cause cracking.

The method herein disclosed also embodies a novel method for securely locking the slabs in selected positions of elevation automatically.

It is therefore an object of the invention to provide a novel method for utilizing the weight of one or more pre-cast slabs for raising another one or more pre-cast slabs into desired elevations.

Another object is to provide a novel method of positioning pre-cast concrete slabs at various elevations in a building structure.

Another object is to provide in a method of the character described, the novel step of suspending, in a substantially balanced condition, two or more pre-cast concrete slabs from a multiple of pulley systems which are effective to simultaneously raise and lower said slabs respectively.

Another object is to provide a novel method for braking the movement of slabs in a building structure so as to hold them in place temporarily and to control the rate of their movement while positioning said slabs.

Another object is to provide, as a step in the method described, a novel method for automatically locking and supporting the slabs in their respective positions of elevation.

The structure by means of which the above noted and other advantages and objects of the invention are attained,

will be described in the following specification, taken in conjunction with the accompanying drawings, showing representative building structures wherein the steps of the method are illustrated, and in which:

FIG. 1 is a diagrammatic fragmentary side elevational view of the first four floor levels of a representative building structure illustrating the initial or pouring position of the first four slabs.

FIG. ,2 is a view similar to FIG. 1, showing the'slabs in positions occupied during initial steps of locating same.

FIG. 3 is a view similar to FIGS. 1 and 2, showing the slabs in their final positions at the four floor levels illustrated.

FIG. 4 is a schematic plan view ofa slab audits relation to the upright columns of the building structure.

FIG. 5 is a diagrammatic fragmentary side elevational view of a fifth floor level of another representative building structure, showing one concrete slab positioned at. said level and the broken outline of three additional slabs formed at said elevation.

FIG. 6 is a diagrammatic fragmentary side elevational view of the fourth to tenth floor levels of the building structure illustrated in FIG. 5, and showing the steps of connecting the four slabs to the suspension pulley systems.

FIG. 7 is a view similar to FIG. '6, but showing in full lines the positions of the slabs during performance of the next and a following step of the method.

FIG. 8 is a view similar 0t FIG. 7, but illustrating the locations assumed by the slabs during performance of further steps of the method, and showing a new series of slabs poured at another higher elevation.

FIG. 9 is a fragmentary enlarged elevational view of a vertical column and showing in section, the adjacent surrounding areas of a plurality of slabs and the lock mechanism carried by said column.

'FIG. 10 is a view of the power controlled braking mechanism mounted on each of the corner columns 'of the. building structure.

The steps of the method of building'construction herein disclosed can best be described by reference tothe accompanying drawing in which two representative structures are illustrated and in each of which there is disclosed the steps of forming a multiplicity of slabs at a predetermined level orlevels and then moving said slabs, when cured, to desired floor levels, without the aid of applied 'mechanical lifting force. This is accomplished through the use of a system of conventional pulleys and cables connected -to two or more slabs so as to enable-one or more of said connected slabs to substantially counterbalance the remaining connected slab or slabs and overcome frictional resistance and permit movement of said connected slabs by gravity into positions at desired floor levels upon release of power controlled braking mechanism. The method .also includes the step'of controlling the rate of speed at which the slabs are allowed to move and the step of locking said slabs in place automatically.

More particularly, the method comprisesthe pouring of a plurality of physically separated slabs at a predetermined floor level above the lowest level at which oneof said slabs is to be positioned, and wherein at least one of said slabs may have a greater weight than the-others; connecting selected slabs to pulleysysterns so as to allow a bottom slab, or .in some instances, two slabs, to move downwardly by gravity and carry another of the slabs upwardly; controlling the rate of movement of the slabs, and finally locking said slabs automatically in place, after which the final step of cementing, grouting or otherwise securing the slabs to the vertical columns is accomplished. At predetermined times during the positioning of the slabs and before all slabs are secured permanently in place, an additional slab or slabsis poured over, but maintained physically separated from, a selected slab or slabs,

which newly poured slabs are successively positioned at respective fioor levels by the steps of the method of positioning herein disclosed.

Referring now to the building representation illustrated in FIGS. 1 to 4, the method comprises initially erecting requisite vertical columns 21 which may be of steel, concrete encased steel, stanchions or reinforced concrete, having formed therein, at each floor level, suitable means for automatically positioning and locking pre-formed slabs in place after they are carried into engagement therewith. One such means is illustrated in FIG. 9, and is described in detail hereinafter insofar as its structure, operation and function relates to practice of the herein disclosed method.

The usual basement slab (not shown) is poured and, in the instant disclosure, the vertical columns 21 are of a height substantially equal to, but not lower than, the level of the fourth floor of the building structure. These floor levels are indicated in the drawings by horizontal dot-dash lines identified as 1st, 2nd, 3rd and 4th.

Following the erection of vertical columns 21, a suitable pouring form is arranged, in this disclosure, at a level slightly below the 2nd floor level which in this instance is spaced above the 1st floor level at a height greater than the spacing between the 2nd and 3rd, or 3rd and 4th floor levels.

A slab 1 (FIG. 1) then is poured into the form. This slab, as well as all other slabs hereinafter referred to are of considerable size such, for example, of a size to constitute the entire or a substantial portion of the floor area of the structure. As is perhaps best shown in FIG. 4, substantially square frames 22 are arranged around each column and each is of a size to slide freely upwardly and downwardly over the embraced column so as to enable the slab in which it is embedded integrally to be raised and/or lowered.

After the slab 1 is poured and set, a membrane of separating medium S is placed over said slab and a second slab 2 is poured thereover. Similarly, slabs 3 and 4 are poured, each over a membrane of such separating material. The slabs 2, 3 and 4 are preferably of uniform weight whereas the bottom slab 1 may be of the same or of greater weight. Increased weight in slab 1 may be obtained by using standard concrete for slab 1 and light weight concrete for slabs 2, 3 and 4, or by increasing the thickness of slab 1.

While the concrete in the slabs is curing, a series of pulley systems 23 is installed. Each system comprises one or more (preferably two) pulleys 24 supported on the top of each vertical column. These pulley systems are identical with the exception that the pulley system 23M on each corner column has associated with it a motor controlled braking gear mechanism, best shown in FIG. and to be described presently, each connected in a common electrical circuit and operable for controlling the speed at which said pulleys 24 operate and for braking the load. The remaining pulley systems 23 are free wheeling.

Referring now particularly to FIG. 1, cables 25 are trained one over each pulley 24. One end of each cable is connected, as at 26, to the slab 1 (or to frames 22 thereof) whereas the other end is connected to a sheave 27 which has trained thereover a second cable 28. One end of cable 28 is connected, as at 29, to the related column 21 and its other end, at 29a, is connected to slab 4. Slab 2, with slab 3 seated thereon, is locked to the columns by means of lock mechanisms shown in FIG. 9 and to be described later. The form or other support means for the bottom slab 1 is removed and power is fed to the braking motors on pulley systems 23M to release the braking effect thereof whereupon the load of slab 1 causes it to move downwardly and at a speed controlled by said braking mechanism so as to carry slab 4 upwardly. Such movement continues until slab 4 reaches and is temporarily locked at the 3rd floor level, as illustrated in FIG. 2. At this time, owing to the presence of sheaves 27, the

bottom slab has moved one-third of the distance required to locate it at the 1st floor level.

End extensions 31 of cables 25 are now connected, as at 32, 33, to slabs 3 and 4 respectively, and the cables 28 and sheaves 27 are then disconnected and/or removed. The motors or pulley systems 23M are restarted to again release the braking mechanism and thereby allow slab 1 to descend by gravity, assisted by operation of the braking motors, to the 1st floor level and to elevate slabs '3 and 4 simultaneously to the 3rd and 4th floor levels respectively, all as shown in FIG. 3.

The next step in the method is the automatic locking of the slabs in their respective floor level positions. Suitable automatic locks for temporarily holding slab 4- at the 3rd floor level, as shown in FIG. 2, and for holding all of the slabs in their final set positions (FIG. 3) may comprise mechanism of the character best illustrated in FIG. 9 and now to be described.

When the four slabs are poured at the 2nd floor level, as shown in FIG. 1, frames 22 are secured together as by bolts 34 (FIG. 9) extending through the frames and through sleeves 35 embedded in the concrete. Frame 22 of slab 2 is engaged by plate latches 36 mounted in perimeter recesses 37 formed by mounting flanged collars 33 on each column. These plate latches 36 are loose and normally are held in an engageable position by a break wire 39 but when engaged, have their upper edges bearing against the bottom face of a ledge 41, as shown. There is a like perimeter recess and like latch plates at each floor level. When slabs are to be moved from the FIG. 1 position to the FIG. 2 position, bolts 34 are removed after cables 25 are attached. As each slab reaches a floor level during each step of placement thereof, the respective latch plates 36 at said floor level are initially displaced and then will fall into locking position (FIG. 9) beneath a related ledge 41 to support the slab in such position. More specifically, when slab 4, for example moves upwardly, the washer 42 forming ledge 41 will strike the related latch plate and move it out of its path. As the washer 42 clears the latch plate, said plate returns to its initial position and engages beneath ledge 41 (underside of washer 42) so as to support the slab in its elevated position. As for the downwardly moving slab 1, the inclined ledge 41a thereof comes to rest on the latch plate 36, at its respective floor level, breaking the break wire 39 and causing it to rock outwardly into snug engagement with said ledge.

After the slabs are in place and each temporarily held by engaged latch plates 36, said latch plates then are welded to the abutting face of frames 22 and to flanges 43 of collars 38. The ledges then are removed by removing their holding bolts 44 whereupon concrete or other filler is poured into the spaces between frames 22 and column recesses 37.

It is primarily because of the size and resultant heavy load of the slabs and the tendency of slabs to flex or tilt while being raised or lowered, that the system disclosed includes the novel method of supporting each slab in the area of each vertical column by cables and a breaking or control pulley system 23M in association with the cables at each corner thereof. Exemplary power braking mechanism is shown in FIG. 10. As illustrated, the pulley system 23M comprises a pair of pulleys 24 mounted firmly on a common shaft 25a having a gear 46 mounted firmly thereon which meshes at all times with a worm 47 on a shaft 48 carrying spur gear 49. A worm gear 51 on shaft 52 of motor 53 is meshed with gear 49. When motor 53 is idle the gear train is locked, thus preventing rotation of the pulleys and operation of cables 25 and braking the load. However, when power is supplied to operate the slow speed motor, the pulleys 24 are permitted to respond to the gravitational force of the slabs connected to their cables and rotate at a rate of speed controlled by the gear train and the operating motor. At any time braking is required of any of speaker the controlled pulley systems, the related motors are momentarily stopped, thus locking the gear trains.

By providing visual means for observing the rate of movement of each motor, the rate of slab movement can be carefully regulated and the intermediate areas of the slabs will at all times be adequately supported by free wheeling pulleys Z -l-and cables trained thereover. Further, it is proposed that each slab be adequately reinforced by interlaced rods 54, or the like, secured wherever possible, as by welding, to frames 22.

Summarized, the steps of the hereinabove disclosed method consist of first erecting vertical columns; pouring a plurality of individual floor slabs, one of which may be heavier than the others, at a predetermined floor level; allowing said slabs to cure; removing the form therefrom and attaching cables to selected slabs; moving said selected slabs vertically in opposed directions to preselected positions, by gravity; attaching cables to other of said slabs and moving the attached slabs to preselected positions by gravity; utilizing a positioned slab as a form for pouring additional slabs; moving said slabs into preselected positions by gravity; locking each slab in its preselected position to each vertical column; and finally filling all gaps between the slabs and columns with concrete or other filler before or after removing the cables.

It should be understood that me step sequence hereinabove recited may be altered to suit specific problems of construction.

The steps of the method illustrated in FIGS. to 8 inclusive, are substantially like that previously discussed except as to the sequence of operation and the precise location of slabs following successive steps of the method.

In this disclosure, the multiplicity of slabs comprising any one group of slabs are located at the 5th and every fourth floor level thereafter. By permanently attaching one of the slabs of each group of slabs to the columns as work progresses, a solid wind bracing is prowided at every fourth floor, successively. The slabs are moved into place at their respective fioor levels by means of pulley systems operating substantially as in the method described hereinabove.

Specifically, this method of building structure comprises the initial erection of the vertical columns 21 of a height exceeding the 9th floor level and then mounting the pulley systems 2 3 and 23M thereon. A plurality of slabs, in this instance four, are provided at the 5th floor level, as best illustrated in FIG. 5, by initially raising bottom slab 55 upwardly from a lower level and then pouring the additional slabs 5'6, 57 and 58- thereon. After said slabs have cured, the slab 55 is connected to cable 25, as at 59, and said cable carries sheave 27 at its other end over which is trained cable 28. One end of cable 28 is connected to the column as at 61, and its other end is secured to the top slab 58, as at 61a. The connection is such that slab 55 and slab 56 seated thereon are permitted to drop by gravity a distance substantially equal to one-half the slab thickness (FIG. 6) before securing cable 28 to slab 58. When so arranged, the intermediate slab 57 is at the 5th floor level and is locked to the columns in the manner described hereinabove.

The control pulley systems 23M are then operated permitting controlled movement of slabs 55, 56 downwardly by gravity to carry slab 58 upwardly. The pulley-sheavecable system connecting and supporting the slabs is such that when slabs 55, 56 reach the 3rd floor level and slab 56 is locked to columns 21 (FIG. 7) slab 53 has been carried to the 9th floor level and is temporarily secured in place. The next step in the method is to then pour an additional slab dzover slabs 55, 56 at the 3rd floor level and to pour three more slabs 63, 64 and 65 over slab 5d at the 9th floor level. The cable 28 and sheave 27 if not already removed, are now disconnected and/ or removed and one end of cable 25 is now connected, as at 62a, to the newly poured slab 62 as shown in PEG. 7. The fram s 22 of slabs 55, 56 are unbolted so that when the pulley systems are again operated, the load of slab carries said slab into the 2nd floor level by gravity and elevates slab 62 to the fourth floor level, as shown in FIG. 8, where saidslabs are locked by the previously described plate latches 36. The second, third, fourth and fifth floor levels have now each been provided with a slab which is secured firmly in place, and a plurality of slabs 53, 63, 64 and 6:? are now present at the 9th floor level for distribution into their proper floor levels. Before this distribution can take place, the columns 21 are extended upwardly and the pulley systems 23, 23M are re-.

mounted at the tops'thereof. The steps of the method as subsequently practiced in placing slabs 58, d3, 64 and 65 at their respective floor levels as like those described with reference to slabs 55, 58 and, when the operating cycle is completed, slabs 58, 63, '64 and 65 will be located at the 6th, 7th, 9th and 13th fioor levels respectively, whereupon the entire cycle is repeated for each additional group of floor levels added to the height of the building.

Although I have described preferred embodiments of my invention in considerable detail, it will be understood that the descriptions thereof are intended to be illustrative of the steps of the method herein disclosed and that various modifications and variations may be made in the method without departing from the spirit or scope of the invention. Accordingly, I do not desire to be restricted to the exact Steps of the method disclosed or to the exact constructions illustrated.

I claim:

1. The steps in the method of positioning pre-cast slabs at selected floor elevations of a building structure which comprises erecting vertical columns, mounting a lock engaging device on each column one at each floor level, forming up a floor slab mold at an elevation above the lowermost floor level of saidstructure, pouring a first floor slab on said mold, applying a non-adhering membrane over the top surface of said slab, pouring second,

third and fourth slabs in succession one over the other 7 level to which any one of said slabs is to be elevated,

applying power operated brake means to at least some of the pulleys, connecting one end of each cable to the said first slab and its other end to a sheave, training second cables one around each sheave and connecting them at one end to the column and at their other end to the said fourth slab, releasing said brake means to allow the said first and second slabs to move downwardly by gravity into a lower floor level position and carry the said fourth slab upwardly into an upper floor level position, locking said first, second and fourth slabs in such positions, pouring a fifth slab of less weight than the first slab over said second slab, disconnecting the first cables from said sheaves and connecting said cables to the said fifth slab, unlocking the first slab and allowing it to move downwardly by gravity into a lower floor level position while carrying the said fifth slab into a higher floor level position, locking said first and fifth slabs in place on the columns, and finally removing the cables.

2. The steps in the method of positioning precast slabs at selected floor elevations of a building structure which comprises erecting vertical columns, placing lock devices at each floor level and on each column, forming up a floor slab mold at an elevation above the lowermost level of said construction, pouring a floor slab in said mold, applying a non-adhering substance to the top surface of said slab, pouring additional slabs over the said slab and providing a non-adhering substance between each of said slabs, connecting the two bottom slabs and the top slab t of the two bottom slabs in said group of slabs to carry such slabs by gravity into a preselected position at a lower floor level and to raise the top slab in said group of slabs into a preselected position at a higher floor level, locking said slabs in place, placing a non-adhering substance on the top surface of the upper one of said two lowered slabs, disconnecting the cables from the elevated slab, pouring another slab over the said last named substance, said last named slab being of less weight than the bottom slab, connecting the disconnected ends of said cables to said last named slab, releasing the locking means of the bottom slab and allowing it to move downwardly by gravity while elevating the last named slab to locate them at floor levels above and below the remaining slab in this group of slabs, locking all of said slabs in place and disconnecting the cables therefrom, then pouring additional separable slabs one over the other and on the highest located slab, and finally relocating said last named group of slabs by use of said cables and in a manner corresponding substantially to the relocation of the initial group of slabs.

3. The steps in the method of positioning pre-cast slabs at selected floor elevations of a building structure which comprises erecting vertical columns, placing lock engaging devices at each floor level, forming up a floor slab mold at an elevation above the lowermost level of said construction, pouring a first slab in said mold, applying a nomadhering substance on said slab, pouring second, third and fourth slabs of less weight over said first slab with a non-adhering substance between each, locking the said second slab in place on the columns, connecting cables of a pulley system supported at an upper level to the first and fourth slab, controlling the operation of said pulley system by power operated means, removing the mold form, then using the weight of the first slab to carry said first slab into a predetermined lower position and to elevate the fourth slab into a predetermined higher floor level, locking said first and fourth slabs to the columns, disconnecting the cables of the pulley system from said elevated fourth slab and reconnecting them to the third slab, unlocking the first slab and permitting it to settle by gravity to a preselected lower floor level and simultaneously carrying the third slab into a preselected higher floor level, locking all of said slabs in place, and then removing the pulley system.

4. The steps in the method of building construction which comprises, erecting vertical columns, pouring a first slab between and around all of said columns, coating the top surface of said slab with a non-adhering substance, pouring second and third lightweight slabs each coated with non-adhering substance over said first slab, pouring a heavier fourth slab over said third slab, all of said slabs being located and temporarily locked at a floor level above the lowermost fioor of the building structure, arranging a pulley system including cables on the upper end of each vertical column, connecting said cables with the first heavier slab and with the heavy fourth slab, controlling the operation of some of said pulley systems by power operated means, unlocking the cable connected first and fourth slabs and the second slab from the columns so as to permit the first and second slabs to move downwardly as a unit by gravity to a lower floor level and to carry the upper slab to a higher floor level, locking said slabs in place, pouring a lightweight fifth slab over the surface of the second slab, reconnecting the cables of the pulley system to the first and fifth slabs, unlocking said first slab and permitting it to settle by gravity to a lower floor level and simultaneously raise the fifth slab to an intermediate higher floor level, locking said first and fifth slabs in place and then disconnecting the pulley system, and then pouring additional slabs over the uppermost of the slabs of said aforesaid group of slabs and repeating the raising and lowering steps to locate said slabs at desired floor levels by means of the pulley systems in the same manner as the first groups of slabs vere positioned.

5. The steps in the method of building construction which comprises, erecting vertical columns, pouring a slab between and around all of said columns, pouring additional lightweight slabs over said slab, coating said slabs to maintain them physically separated, said slabs being located and temporarily locked to the columns at a floor level above the lowermost floor level of the building structurc, arranging a pulley system including cables on each vertical column and above said slabs, connecting said cables with the bottom one of said slabs and with the uppermost one of the remaining slabs, controlling the operation of some of said pulley systems by power operated means, unlocking the cable connected slabs and the slab immediately above the said bottom slab from the columns so as to permit the two lower slabs to move downwardly as a unit to a lower level by gravity and carry the uppermost slab to a higher fioor level, securing the uppermost and lower slabs in place, pouring another iigbtweight slab over the two lower slabs, disconnecting the pulley system from the uppermost slab and connecting it to the newly poured slab, unlocking said lower slab and permitting it to settle by gravity to a lower floor level and raise the newly poured slab to an intermediate higher floor level, and finally disconnecting the pulley system and locking said slabs in a place on the columns.

References Cited in the file of this patent UNITED STATES PATENTS 1,066,436 Peltzer July 1, 1913 2,300,630 Norton et al. Nov. 3, 1942 2,715,0l3 Slick Aug. 9, 1955 2,732,177 Ludowici Jan. 24, 1956 2,846,851 Pelham Aug. 12, 1958

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