Prefabricated building system and methods

Abstract

A method of constructing a building is disclosed, including selecting a standard dimension less than a wide-load trucking permit limit and designing a building on a grid defined by the selected standard dimension. The building includes a plurality of prefabricated elements, wherein each prefabricated element has a width correspond to the selected standard dimension. The plurality of prefabricated elements includes a wall panel, a roof panel, a laterally resistive frame, and a rebar cage. The method includes fabricating each of the plurality of prefabricated elements at a manufacturing plant and transporting the elements by truck to a building site. The method includes constructing intersecting grade beam footings at the building site and pouring a slab between the intersecting grade beam footings. The grade beam footings include the rebar cage and have a uniform width and depth, the grade beam footings and the slab having contiguous upper surfaces.

1 . A method of constructing a building, including:
 selecting a standard dimension,   designing a building on a grid defined by the selected standard dimension, the building including a plurality of prefabricated elements, wherein each prefabricated element has a width corresponding to the selected standard dimension, and the plurality of prefabricated elements includes rebar cages   fabricating each of the plurality of prefabricated elements at a manufacturing plant;   transporting the plurality of prefabricated elements by truck from the manufacturing plant to a building site,   constructing intersecting grade beam footings at the building site, the grade beam footings having a uniform width and depth and including the rebar cages, and,   pouring a slab between the intersecting grade beam footings, wherein the grade beam footings and slab have contiguous coplanar upper surfaces, and the rebar cages extend into the slab.   
     
     
         2 . The method of  claim 1 , wherein the constructing step includes:
 pouring a first layer of concrete over one of the rebar cages,   installing a plate on top of the first layer,   fastening a laterally resistive frame to the plate, and   pouring a second layer of concrete over the plate.   
     
     
         3 . The method of  claim 2 , wherein the rebar cage includes a stirrup that extends into the second layer of concrete. 
     
     
         4 . The method of  claim 2 , further comprising:
 erecting and bolting together pre-welded components, including the laterally resistive frame, to form a steel building frame.   
     
     
         5 . The method of  claim 4 , further comprising:
 bolting a wall panel to the steel building frame.   
     
     
         6 . The method of  claim 4 , further comprising:
 bolting a roof panel to the steel building frame.   
     
     
         7 . The method of  claim 1 , wherein the standard dimension is less than 11 feet. 
     
     
         8 . A building assembly, comprising:
 a foundation including intersecting grade beam footings having a uniform width and depth, wherein the grade beam footings include a first layer of concrete and a second layer of concrete,   a steel building frame including columns and laterally resistive frames,   wherein each column is located at an intersection of the grade beam footings, and each laterally resistive frame extends between two grid intersections.   
     
     
         9 . A building assembly, comprising:
 a foundation including intersecting grade beam footings having a uniform width and depth, wherein the grade beam footings include an upper layer of concrete and a lower layer of concrete,   a base plate sandwiched between the upper and lower layers of concrete,   anchor bolts extending from below the foundation, up through the lower layer of concrete, to connect to the base plate,   a laterally resistive frame extending into the upper layer of concrete, and bolted to the base plate.