Pre-fabricated interchangeable trusses

Abstract

Embodiments of the invention comprise interchangeable pre-fabricated planar trusses, sections, and structures, and methods for efficiently creating the interchangeable pre-fabricated planar trusses, sections and, structures. Embodiments of the method comprise determining the application needs; designing the interchangeable pre-fabricated planar trusses for the application needs; continuously producing the interchangeable pre-fabricated planar trusses through in-line processing; galvanizing the interchangeable pre-fabricated planar trusses; transporting the interchangeable pre-fabricated planar trusses to the assembly site with reduce transportation costs; and assembling the trusses on site with a reduced labor costs.

1 . A method for manufacturing a structure, the method comprising:
 cutting web members and chord members to the requirements of pre-fabricated interchangeable planar trusses for the structure at a cutting station;   staging the chord members, web members, and truss accessories based on the number of the pre-fabricated interchangeable planar trusses for the structure at a staging station;   rigging the chord members, web members, and the truss accessories to form at least one of the pre-fabricated interchangeable planar trusses at a rigging station;   welding the chord members, web members, and truss accessories at a welding station to assemble the at least one of the pre-fabricated interchangeable planar trusses; and   wherein at least one of the pre-fabricated interchangeable planar trusses can be galvanized.   
     
     
         2 . The method of  claim 1 , wherein cutting the web members comprises cutting the web members to the required lengths; wherein cutting the chord members comprises cutting the chord members to the required lengths; and further comprising creating one or more assembly holes at each end of the chord members. 
     
     
         3 . The method of  claim 2 , wherein creating one or more assembly holes comprises using an automated punch machine to punch holes in the chord members 
     
     
         4 . The method of  claim 1 , wherein cutting comprises sawing the members. 
     
     
         5 . The method of  claim 1 , wherein cutting comprises shearing the members. 
     
     
         6 . The method of  claim 1 , wherein the chord members comprise two L-shaped chord support elements. 
     
     
         7 . The method of  claim 1 , wherein the web members comprise two L-shaped web support elements. 
     
     
         8 . The method of  claim 1 , wherein the truss accessories comprise chord spacers, web battens, end brackets, or intermediate brackets. 
     
     
         9 . The method of  claim 1 , wherein staging the web members, the chord members, and truss accessories comprises assembling the chord members, the web members, and truss accessories necessary for manufacturing a single pre-fabricated interchangeable planar truss. 
     
     
         10 . The method of  claim 1 , wherein rigging the chord members, the web members, and truss accessories comprises operatively coupling the chord members to the web members through the use of a clamp or a tack weld. 
     
     
         11 . The method of  claim 1 , wherein welding the chord members and truss accessories comprises welding two L-shaped chord support elements to one or more chord spacers to form a chord gap in the chord members. 
     
     
         12 . The method of  claim 1 , wherein welding the web members and truss accessories comprises welding two L-shaped web support elements together using one or more web battens to form a weld gap in the web members. 
     
     
         13 . The method of  claim 1 , wherein welding the chord members and web members comprises welding toe edges of L-shaped web support elements of the web members to a surface of L-shaped chord support elements of the chord members. 
     
     
         14 . The method of  claim 13 , wherein the at least one pre-fabricated interchangeable planar truss can be galvanized because welding the toe edges of L-shaped web support elements of the web members to the surface of the L-shaped chord support elements of the chord members allows galvanizing fluid to flow in and out of a weld joint between the chord member and web member. 
     
     
         15 . A pre-fabricated interchangeable planar truss comprising:
 a first chord member and a second chord member, wherein the first chord member and second chord member have one or more end assembly holes used to operatively couple more than one pre-fabricated interchangeable planar truss together for use in a structure;   one or more web members, wherein the one or more web members are operatively coupled to the first chord member and the second chord member through a welded joint; and   wherein the pre-fabricated interchangeable planar truss can be galvanized, such that the galvanizing fluid covers the surfaces of the pre-fabricated interchangeable planar truss, including the welded joints.   
     
     
         16 . The pre-fabricated interchangeable planar truss of  claim 15 , wherein the first chord member and second chord member each comprise a first chord support element and a second chord support element operatively coupled through the use of a chord spacer, wherein the chord spacer creates a chord gap between the first chord support element and second chord support element, wherein the surfaces of the chord support elements can be galvanized. 
     
     
         17 . The pre-fabricated interchangeable planar truss of  claim 15 , wherein the one or more web members comprise a rod. 
     
     
         18 . The pre-fabricated interchangeable planar truss of  claim 15 , wherein the one or more web members comprise a first web support element and a second web support element operatively coupled through the use of a web batten, wherein the web batten creates a web gap between the first web support element and the second web support element, wherein the surfaces of the web support elements can be galvanized. 
     
     
         19 . The pre-fabricated interchangeable planar truss of  claim 15 , wherein more than one pre-fabricated interchangeable planar trusses may be operatively coupled through an end bracket using the one or more end assembly holes. 
     
     
         20 . The pre-fabricated interchangeable planar truss of  claim 19 , wherein the end bracket is operatively coupled to cross-bracing members used for operatively supporting more than one pre-fabricated interchangeable planar trusses. 
     
     
         21 . The pre-fabricated interchangeable planar truss of  claim 15 , further comprising:
 one or more intermediate assembly holes in the first chord member or the second chord member;   an intermediate bracket operatively coupled to the first chord member or the second chord member, through the one or more intermediate assembly holes; and   wherein the intermediate bracket is operatively coupled to cross-bracing members used for operatively supporting more than one pre-fabricated interchangeable planar trusses.   
     
     
         22 . The pre-fabricated interchangeable planar truss of  claim 15 , wherein the web members comprise of web support elements that are L-shaped. 
     
     
         23 . The pre-fabricated interchangeable planar truss of  claim 22 , wherein the L-shaped web support elements are welded to the surface of the chord members along a surface of the L-shaped web support elements. 
     
     
         24 . The pre-fabricated interchangeable planar truss of  claim 22 , wherein the L-shaped web support elements are welded to the surface of the chord members along a portion of a first toe edge and a second toe edge of the L-shaped web support elements, such that heals of the L-shaped web support elements are pointed outward from the weld. 
     
     
         25 . The pre-fabricated interchangeable planar truss of  claim 15 , wherein the chord members comprise of two L-shaped chord support elements. 
     
     
         26 . The pre-fabricated interchangeable planar truss of  claim 15 , wherein the first chord member and the second chord member are parallel. 
     
     
         27 . The pre-fabricated interchangeable planar truss of  claim 15 , wherein the first chord member and the second chord member comprise of diverging ends and converging ends. 
     
     
         28 . A method comprising:
 creating a plurality of first chord members and a plurality of first web members;   creating a plurality of first pre-fabricated interchangeable planar trusses by operatively coupling one or more first web members to a near first chord member and a far first chord member; wherein the near first chord member is operatively coupled to a first end of one or more first web members and the far first chord member is operatively coupled to a second end of the one or more first web members;   wherein the plurality of first pre-fabricated interchangeable planar trusses can be shipped to the assembly site; and   wherein the plurality of the first pre-fabricated interchangeable planar trusses can be assembled into a structure by operatively coupling three or more first pre-fabricated interchangeable planar trusses together through the use of one or more first end brackets to form a first section with three or more corners, each corner being formed from the operative coupling of the near first chord member of the first pre-fabricated interchangeable planar trusses to the far first chord member of other first pre-fabricated interchangeable planar trusses to form corners with two operatively coupled first chord members.   
     
     
         29 . The method of  claim 28 , wherein the structure can be formed by assembling the plurality of first pre-fabricated interchangeable planar trusses into two or more interchangeable first sections by operatively coupling three or more first pre-fabricated interchangeable planar trusses to each other through the use of one or more of the plurality of first end brackets to form each first section; and wherein the two or more interchangeable first sections are operatively coupled to each other through the use of the one or more of the plurality of first end brackets. 
     
     
         30 . The method of  claim 28 , wherein creating the plurality of first chord members comprises creating two first chord support elements; and operatively coupling the two first chord support elements together to form the plurality of first chord members. 
     
     
         31 . The method of  claim 28 , wherein creating the plurality of first web members comprises creating two first web support elements; and operatively coupling the two first web support elements together to form the plurality of first web members. 
     
     
         32 . The method of  claim 28 , further comprising:
 creating a plurality of second chord members and a plurality of second web members;   creating a plurality of second pre-fabricated interchangeable planar trusses by operatively coupling one or more second web members to a near second chord member and a far second chord member; wherein the near second chord member is operatively coupled to a first end of one or more second web members and the far second chord member is operatively coupled to a second end of the one or more second web members;   wherein the plurality of second pre-fabricated interchangeable planar trusses can be shipped to the assembly site;   wherein the plurality of the second pre-fabricated interchangeable planar trusses can be assembled into the structure by operatively coupling three or more second pre-fabricated interchangeable planar trusses together through the use of one or more of second end brackets to form a second section with three or more corners, each corner being formed from the operative coupling of the near second chord member of the second pre-fabricated interchangeable planar trusses to the far second chord members of other second pre-fabricated interchangeable planar trusses to form corners with two operatively coupled second chord members; and   wherein the second section is operatively coupled to the first section to form the structure.   
     
     
         33 . The method of  claim 32 , wherein the near second chord members and the far second chord members have diverging ends and converging ends; wherein the diverging ends can be operatively coupled to the ground and the converging ends can be operatively coupled to the first section. 
     
     
         34 . The method of  claim 32 , wherein a first section footprint is smaller than a second section footprint. 
     
     
         35 . The method of  claim 28 , further comprising:
 creating a plurality of third chord members and a plurality of third web members;   creating a plurality of third pre-fabricated interchangeable planar trusses by operatively coupling one or more third web members to a near third chord member and far third chord member; wherein the near third chord member is operatively coupled to a first end of one or more third web members and the far third chord member is operatively coupled to a second end of the one or more third web members;   wherein the plurality of third pre-fabricated interchangeable planar trusses can be shipped to the assembly site;   wherein the plurality of the third pre-fabricated interchangeable planar trusses can be assembled into the structure by operatively coupling three or more third pre-fabricated interchangeable planar trusses together through the use of one or more third end brackets to form a third section with three or more corners, each corner being formed from the operative coupling of the near third chord members of the third pre-fabricated interchangeable planar trusses to the far third chord members of other third pre-fabricated interchangeable planar trusses to form corners with two operatively coupled third chord members; and   wherein the third section is operatively coupled between the first section and a second section to form the structure.   
     
     
         36 . The method of  claim 35 , wherein the third section footprint is smaller than the second section footprint but larger than the first section footprint. 
     
     
         37 . An apparatus comprising:
 a plurality of first pre-fabricated interchangeable planar trusses each comprising a near first chord member, a far first chord member, and a plurality of first web members that operatively couple the first near member to the first far member;   a plurality of truss accessories, wherein the truss accessories comprise a plurality of first end brackets;   wherein three or more first pre-fabricated interchangeable planar trusses are operatively coupled though the use of one or more of the plurality of the first end brackets to form a first interchangeable truss section with three or more corners;   wherein each corner of the first interchangeable truss section comprises the near first chord member of one of the plurality of the first pre-fabricated interchangeable planar trusses operatively coupled to the far first chord member of another one of the plurality of the first interchangeable planar trusses to form corners with two operatively coupled first chord members; and   wherein two of the first interchangeable truss sections are operatively coupled through the use of the one or more of the plurality of the first end brackets to form a structure.   
     
     
         38 . The apparatus of  claim 37 ; wherein the plurality of the first end brackets are brackets that are used to operatively couple three or more first pre-fabricated interchangeable planar trusses for the first interchangeable truss section and two or more of the plurality of first interchangeable truss sections. 
     
     
         39 . The apparatus of  claim 37 , wherein the near first member and the far first member are substantially parallel. 
     
     
         40 . The apparatus of  claim 37 ; wherein the structure further comprises a second truss section; wherein the second truss section is operatively coupled to the ground; and wherein the second truss section is operatively coupled to the first interchangeable truss section through the use of one or more of a plurality of second end brackets. 
     
     
         41 . The apparatus of  claim 40 ; wherein the second truss section comprises three or more second pre-fabricated interchangeable planar trusses operatively coupled though the use of one or more of the plurality of the second end brackets; wherein the three or more second pre-fabricated interchangeable planar trusses have a near second chord member and a far second chord member operatively coupled by one or more second web members; wherein a first end of the second truss section is operatively coupled to the ground and a second end of the second truss section is operatively coupled to the first interchangeable truss section. 
     
     
         42 . The apparatus of  claim 41 , wherein the structure further comprises a third truss section comprising three or more third pre-fabricated interchangeable planar trusses operatively coupled though the use of one or more of a plurality of third end brackets, wherein the three or more third pre-fabricated interchangeable planar trusses have a near third chord member and a far third chord member operatively coupled by one or more third web members; and wherein the third truss section is operatively coupled between the first interchangeable truss section and the second truss section. 
     
     
         43 . The apparatus of  claim 37 , wherein the truss accessories comprise a chord spacer; wherein the first chord members comprise two L-shaped chord support elements operatively coupled together with the chord spacer to form the first chord member with a chord gap between the two L-shaped chord support elements. 
     
     
         44 . The apparatus of  claim 37 , wherein the truss accessories comprise a web batten; wherein the first web members comprise two L-shaped web support elements operatively coupled together with the web batten to form the first web member with a web gap between the two L-shaped web support elements. 
     
     
         45 . An apparatus comprising:
 a plurality of pre-fabricated interchangeable planar trusses each comprising a first chord member, a second chord member, and a plurality of web members that operatively couple the first chord member to the second chord member;   one or more couplings;   wherein three or more pre-fabricated interchangeable planar trusses are operatively coupled though the use of the one or more couplings to form a first interchangeable truss section with three or more corners;   wherein three or more pre-fabricated interchangeable planar trusses are operatively coupled though the use of the one or more couplings to form a second interchangeable truss section with three or more corners;   wherein each corner comprises the first chord member of the first interchangeable planar truss operatively coupled to the second chord member of the second interchangeable planar truss to form corners with two operatively coupled chord members; and   wherein the first interchangeable truss section is operatively coupled to the second interchangeable truss section through the use of the one or more couplings to form a structure.   
     
     
         46 . The apparatus of  claim 45 ; wherein the one or more couplings are three or more end brackets that are used to operatively couple three or more pre-fabricated interchangeable planar trusses of the first interchangeable truss section with three or more pre-fabricated interchangeable planar trusses of the second interchangeable truss section. 
     
     
         47 . The apparatus of  claim 45 , wherein the first chord member and the second chord member of the plurality of pre-fabricated interchangeable trusses are substantially parallel. 
     
     
         48 . The apparatus of  claim 45 , wherein the structure further comprises a third interchangeable truss section that is a base section; wherein the first interchangeable truss section and the second interchangeable truss section form a top section of the structure; and wherein the base section is operatively coupled to the top section through the use of the one or more couplings. 
     
     
         49 . The apparatus of  claim 48 , wherein the base section comprises three or more pre-fabricated interchangeable planar base trusses operatively coupled though the use of the one or more plurality of couplings, wherein the three or more pre-fabricated interchangeable planar base trusses comprise a first leg truss operatively coupled to a second leg truss each comprising two or more leg chord members operatively coupled by leg web members. 
     
     
         50 . The apparatus of  claim 48 , wherein the truss structure further comprises a fourth interchangeable section that is a mid-section; wherein the mid-section comprises three or more pre-fabricated interchangeable planar mid-section trusses operatively coupled though the use of the one or more couplings; wherein the three or more pre-fabricated interchangeable planar mid-section trusses comprises a first mid-section chord member and a second mid-section chord member operatively coupled by mid-section web members; and wherein the mid-section operatively couples the base section to the top section. 
     
     
         51 . The apparatus of  claim 45 , wherein the first chord member and the second chord member comprise two L-shaped support elements operatively coupled together through the use of one or more chord spacers to form a chord gap between the two L-shaped support elements. 
     
     
         52 . The apparatus of  claim 45 , wherein the plurality of web members are operatively coupled to the first chord member and the second chord member though the use of welded joints. 
     
     
         53 . The apparatus of  claim 45 , wherein the plurality of web members comprise two L-shaped web support elements operatively coupled to the first chord member and the second chord member by welding toe edges of the web support elements to a surface of the first chord member and the second chord member. 
     
     
         54 . The apparatus of  claim 53 , wherein the L-shaped web support elements are operatively coupled together through the use of one or more web battens to form a web gap between the two L-shaped support elements. 
     
     
         55 . The apparatus of  claim 45 , further comprising a support arm section comprising one or more support arm planar trusses operatively coupled to the first interchangeable truss section or the second interchangeable truss section through the use of one or more arm brackets. 
     
     
         56 . The apparatus of  claim 45 , wherein the plurality of couplings are substantially L-shaped brackets.