Systems and methods for modular construction of large structures

Abstract

Systems and methods wherein large superstructures are simplified and then constructed using prefabricated, modular components. The components include a combined prefabricated primary support and roof system and shop-fabricated floor panels.

1 . A method of erecting a structure for generating power with a boiler, the method comprising: 
 erecting a primary framing system comprising prefabricated, modular components including a combined prefabricated primary support and roof system and composite columns; and    constructing a plurality of intermittent floor bays comprising prefabricated floor panels made up of at least one of grating panels, checkered plates, and composite decks.    
   
   
       2 . A method in accordance with  claim 1  wherein a majority of floor panel connections are with bearing connections  
   
   
       3 . A method in accordance with  claim 1  wherein no diagonal horizontal bracing is used and no vertical bracing is used in two of four planes defined by the structure.  
   
   
       4 . A method in accordance with  claim 1  wherein the first two steps are performed substantially simultaneously.  
   
   
       5 . A method in accordance with  claim 1  wherein components are sized to fit on vehicles for shipment.  
   
   
       6 . A method in accordance with  claim 6  wherein the vehicle is a standard truck-trailer combination and the components are sized to fit on the trailer.  
   
   
       7 . A method in accordance with  claim 1  wherein the type of prefabricated panels may further comprise composite decking.  
   
   
       8 . A structure comprising: 
 a primary framing and roof support system comprising prefabricated roof truss sections, the roof truss sections being formed with horizontal panels consisting of interconnected beams and vertical trusses interconnected with the beams of the panels;    a plurality of intermittent floor bays within the primary framing and roof support system, the bays comprising floor support structures comprising prefabricated panels of at least one of grating and decking coupled to beams, the panels being coupled to beams of the primary framing and roof system; and    a primary support structure comprising prefabricated panels of checker plate panels coupled to the primary framing and roof support system.    
   
   
       9 . A structure in accordance with  claim 8  wherein a majority of connections between components are with bearing connections.  
   
   
       10 . A structure in accordance with  claim 8  wherein the primary support is for a boiler for generating power and the support comprises columns comprising composite material.  
   
   
       11 . A structure in accordance with  claim 8  wherein no diagonal horizontal bracing is used and no vertical bracing is used in two of four planes defined by the structure.  
   
   
       12 . A structure in accordance with  claim 8  wherein components are sized to fit on vehicles for shipment.  
   
   
       13 . A structure in accordance with  claim 12  wherein the vehicle is a standard truck-trailer combination and the components are sized to fit on the trailer.  
   
   
       14 . A structure in accordance with  claim 8  wherein the types of prefabricated panels may further comprise composite decking.  
   
   
       15 . A method of erecting a structure for generating power with a boiler, the method comprising: 
 erecting a primary framing and roof support system comprising prefabricated roof truss sections, the roof truss sections being formed with horizontal panels consisting of interconnected beams and vertical trusses interconnected with the beams of the panels;    creating a plurality of intermittent floor bays within the primary framing and roof support system, the bays comprising floor support structures comprising prefabricated panels of at least one of one of grating and decking coupled to beams, the panels being coupled to beams of the primary framing and roof support system;    creating a plurality of intermittent support bays within the primary framing and roof support system, the support bays comprising prefabricated panels of at least one of grating and decking coupled to trusses, the modules being coupled to beams of the stair modules; and    erecting a primary support structure comprising prefabricated panels of checker plate panels coupled to the primary framing and roof support system.    
   
   
       16 . A method in accordance with  claim 15  wherein a majority of floor panel connections are with bearing connections  
   
   
       17 . A method in accordance with  claim 15  wherein no diagonal horizontal bracing is used and no vertical bracing is used in two of four planes defined by the structure.  
   
   
       18 . A method in accordance with  claim 15  wherein the first two steps are performed substantially simultaneously.  
   
   
       19 . A method in accordance with  claim 15  wherein components are sized to fit on vehicles for shipment.  
   
   
       20 . A method in accordance with  claim 19  wherein the vehicle is a standard truck-trailer combination and the components are sized to fit on the trailer.  
   
   
       21 . A method in accordance with  claim 15  wherein the type of prefabricated panels may further comprise composite decking.