CN113015830A

CN113015830A - Balcony system and method

Info

Publication number: CN113015830A
Application number: CN201980075000.9A
Authority: CN
Inventors: A·柯林斯; M·沃尔曼; P·达门托
Original assignee: Innovative Building Technologies LLC
Current assignee: Innovative Building Technologies LLC
Priority date: 2018-11-14
Filing date: 2019-06-21
Publication date: 2021-06-22
Also published as: SG11202104717XA; MX2021004832A; AU2019379504B2; CA3118409C; AU2019379504A1; BR112021009100A2; JP2022507161A; CA3118409A1; TW202022204A; EP3880897A1; EP3880897A4; KR20210072117A; US20210396018A1; WO2020101750A1

Abstract

A balcony system, comprising: a balcony beam comprising a first end and a second end, wherein each of the first end and the second end is configured to be attached to a corresponding structural frame member of a building; a channel balcony frame; an aisle balcony frame attachment member attached to the balcony beams and having one or more holes; one or more reinforcing ribs disposed in an inner space defined by the channel balcony frame; one or more guardrail brackets attached to the access balcony frame via one or more fasteners passing through the one or more guardrail brackets and into the interior space defined by the access balcony frame, wherein the one or more guardrail brackets are secured by a floor formed within the interior space defined by the access balcony frame; one or more post guardrail supports, each post guardrail support attached to a respective one of the one or more guardrail brackets and secured thereto by a corresponding closure plate; a guardrail attached to one or more post guardrail supports; one or more horizontal guardrail members attached to the one or more post guardrail supports; and one or more guardrail plates attached to the one or more horizontal guardrail members.

Description

Balcony system and method

RELATED APPLICATIONS

The present application claims priority from U.S. application entitled "balcony system and method" filed on 2018, 11, 14, and having application number 62/767,355, the entire contents of which are incorporated herein by reference.

Background

The construction industry is increasingly using modular construction technology to improve efficiency. However, certain aspects of building, such as conventional balcony buildings, may still present challenges to improving the efficiency of the building.

Workplace safety regulations, other regulations, or industry conventions may require that all personnel in a building (or area of a building under construction) that is provided with a balcony opening but without balcony rails installed be wearing safety belts, which may increase labor costs and decrease time efficiency. In addition, installation of conventional balcony components can be time consuming and require skilled craftsmanship and specialized equipment.

Disclosure of Invention

Some embodiments may include balcony systems, false balcony (false balconies) systems, and methods of manufacturing and installing such systems. Some embodiments may include a balcony system having a balcony beam including a first end and a second end, wherein each of the first end and the second end is configured to be attached to a corresponding structural frame construction of a building. The balcony system may further include an access balcony frame and an access balcony frame attachment member attached to the balcony beams and having one or more apertures.

The balcony system may further include one or more strengthening ribs disposed in the interior space defined by the access balcony frame, wherein the one or more strengthening ribs extend through one or more holes in the access balcony frame attachment member, and wherein the strengthening ribs and the access balcony frame attachment member are retained within the interior space defined by the access balcony frame by a floor formed within the interior space defined by the access balcony frame, such that after the floor is formed, the balcony beams, the access balcony frame, and the concrete floor form an integral unit;

the balcony system may further include one or more guardrail brackets attached to the access balcony frame via one or more fasteners passing through the one or more guardrail brackets and into the interior space defined by the access balcony frame, wherein the one or more guardrail brackets are secured by a floor formed within the interior space defined by the access balcony frame.

In some embodiments, the balcony system may further comprise a guardrail attached to the one or more post guardrail supports, one or more horizontal guardrail members attached to the one or more post guardrail supports, and one or more guardrail panels attached to the one or more horizontal guardrail members.

In some embodiments, each of the first end and the second end includes a respective plate to couple the balcony beams to corresponding structural frame members of the building. The aisle balcony frame may have a rectangular shape.

In some embodiments, the aisle balcony frame comprises one or more post guardrail support holes, each post guardrail support block configured to enable a respective post guardrail support to pass through a respective post guardrail support hole. The aisle balcony frame may be formed of stainless steel, and the balcony floor may be formed of concrete.

The balcony system may further include a light element coupled to the one or more post guardrail supports. In some embodiments, the one or more balustrade panels comprise one or more of: tempered glass, metal mesh, polycarbonate, photovoltaic panel, or resin panel.

Some embodiments may include a false balcony system having a balcony beam comprising a first end and a second end, wherein each of the first end and the second end is configured to be attached to a corresponding structural frame member of a building, and a balcony beam attachment member attached to the balcony beam such that the balcony beam attachment member and the balcony beam form an integral unit, wherein the balcony beam attachment member comprises one or more apertures. The false balcony system may include one or more guardrail brackets attached to the balcony beam attachment member via one or more fasteners passing through the one or more guardrail brackets and through corresponding holes in the balcony beam attachment member.

The false balcony system may further include one or more post guardrail supports each attached to a respective one of the one or more guardrail brackets and secured by a corresponding closure plate, and a guardrail attached to the one or more post guardrail supports. The false balcony system may further include one or more horizontal guardrail members attached to the one or more post guardrail supports and one or more guardrail plates attached to the one or more horizontal guardrail members.

In some embodiments, each of the first and second ends may include a respective plate to couple the balcony beams to corresponding structural frame members of the building. The false balcony system may further include a light element coupled to the one or more post guardrail supports. The guardrail plate may comprise one or more of the following: tempered glass, metal mesh, polycarbonate, photovoltaic panel, or resin panel.

Some embodiments may include a method comprising: forming a balcony beam having a first end and a second end and forming a channel balcony frame. The method may further include forming a balcony beam attachment member and attaching the balcony beam attachment member to the balcony beam. The method may further include attaching the guardrail brackets to the access balcony frame and forming a balcony floor within the space defined by the access balcony frame to form an integral balcony unit including the balcony beams, the access balcony frame, and the balcony floor.

The method may further include providing an integral balcony unit and a guardrail portion to a construction site of the building, wherein the guardrail portion includes a guardrail and one or more post guardrail supports, and attaching the integral balcony unit to a structural frame of the building. The method may further comprise attaching the guardrail sections to the integral balcony unit and attaching one or more guardrail panels to the guardrail.

The method may further include attaching a respective plate to each of the first and second ends to couple the balcony beams to a structural frame of the building. Forming the aisle balcony frame includes forming the aisle balcony frame in a rectangular shape.

The access balcony frame includes one or more post guardrail support holes, each post guardrail support hole configured to enable a respective post guardrail support to pass through the respective post guardrail support hole. Forming the aisle balcony frame may include forming the aisle balcony frame with stainless steel. The guardrail plate may comprise one or more of the following: tempered glass, metal mesh, polycarbonate, photovoltaic panel, or resin panel.

Some embodiments may include a method comprising: a balcony beam having a first end and a second end is formed, and a balcony beam attachment member is formed. The method may further include attaching a balcony beam attachment member to the balcony beam to form an integral balcony unit, and providing the integral balcony unit and a guardrail portion to a construction site of the building, wherein the guardrail portion comprises a guardrail and one or more post guardrail supports. The method may further include attaching the integrated balcony unit to a structural frame of the building and attaching the guardrail portion to the integrated balcony unit. The method may further include attaching one or more guardrail plates to the guardrail.

The method may further include attaching a respective plate to each of the first and second ends to couple the balcony beams to a structural frame of the building. The guardrail plate may comprise one or more of the following: tempered glass, metal mesh, polycarbonate, photovoltaic panel, or resin panel.

Drawings

FIG. 1 illustrates a perspective view of an example balcony system from a lower vantage point, according to some embodiments.

Fig. 2 illustrates a side perspective view of an example balcony system according to some embodiments.

Fig. 3 illustrates a rear perspective view of an example balcony system according to some embodiments.

FIG. 4 illustrates a side cross-sectional view of a guardrail connection according to some embodiments.

Figure 5 illustrates a top plan view of a guardrail connection according to some embodiments.

Figure 6 illustrates a front view of a guardrail connection according to some embodiments.

Figure 7 illustrates a false balcony system according to some embodiments.

Figure 8 illustrates a balcony according to some embodiments.

Figure 9 illustrates an example building with a false balcony and a balcony, according to some embodiments.

Fig. 10A, 10B, and 10C illustrate an elevation view, a plan view, and a frame view, respectively, of a metal-filled example studio unit balcony, according to some embodiments.

Fig. 11A, 11B, and 11C illustrate an elevation, plan, and frame view, respectively, of a metal-filled example studio-unit balcony, according to some embodiments.

Fig. 12A, 12B, and 12C illustrate an elevation view, a plan view, and a frame view, respectively, of a metal-filled example studio unit balcony, according to some embodiments.

Figures 13A, 13B, and 13C illustrate an elevation view, a plan view, and a frame view, respectively, of a metal-filled example single bedroom unit balcony, according to some embodiments.

Fig. 14A, 14B, and 14C illustrate an elevation view, a plan view, and a frame view, respectively, of a metal-filled example single bedroom unit balcony, according to some embodiments.

Fig. 15A, 15B, and 15C illustrate an elevation view, a plan view, and a frame view, respectively, of a metal-filled example single bedroom unit balcony, according to some embodiments.

Figures 16A, 16B, and 16C illustrate an elevation, plan, and frame view, respectively, of a metal-filled example single bedroom unit balcony, according to some embodiments.

Figures 17A, 17B, and 17C illustrate an elevation view, a plan view, and a frame view, respectively, of a metal-filled example two bedroom unit balcony, according to some embodiments.

Fig. 18A, 18B, and 18C illustrate an elevation view, a plan view, and a frame view, respectively, of a metal-filled example two bedroom unit balcony, according to some embodiments.

Figure 19 is a cross-sectional view of an example balcony filled with metal according to some embodiments.

Figure 20 is a cross-sectional view of an example balcony filled with metal according to some embodiments.

Figure 21 is a cross-sectional view of an example balcony filled with metal according to some embodiments.

Figure 22 illustrates a cross-sectional detail of an example metal-filled balcony, according to some embodiments.

Fig. 23 is a flow diagram of an example method of manufacturing and installing a balcony system according to some embodiments.

Fig. 24 is a flow chart of an example method of manufacturing and installing a false balcony system according to some embodiments.

Detailed Description

In the following detailed description, reference is made to the accompanying drawings, which form a part hereof. In the drawings, like numerals generally identify like components, unless context dictates otherwise. The illustrative embodiments described in the detailed description, drawings, and claims are not meant to be limiting. Other embodiments may be utilized, and other changes may be made, without departing from the spirit or scope of the subject matter presented here. As generally described herein, and illustrated in the figures, the various aspects of the present disclosure may be arranged, substituted, combined, separated, and designed in a wide variety of different configurations, all of which are contemplated herein.

The present disclosure is particularly directed to methods, systems, products, equipment and/or devices generally associated with balconies including full balconies (balconies) and false balconies (also known as balconies or French balconies). As used herein, unless the context indicates otherwise, a "balcony" may refer to a balcony and/or a false balcony as disclosed herein.

In some embodiments, a building may have one or more balconies. In some embodiments, a prefabricated balcony may be installed while the building is being constructed. A prefabricated balcony may provide a portion of the exterior surface of the building. In some embodiments, a prefabricated balcony may be coupled to one or more structural frame members of a building. In some embodiments, balconies may be attached to the structural frame members to help align the structural frame members prior to installation of the exterior or interior wall panels. In some embodiments, the balcony is coupled to a load-bearing structure of the building. For example, the load bearing structure may be an external structural steel frame.

In some embodiments, one or more of the balconies may have pre-installed lights or other equipment. The equipment may include electrical equipment, plumbing equipment, heating and air conditioning equipment, telecommunications equipment, and/or other equipment. Installing the lights or equipment during the manufacture of the balcony prior to delivery to the building site may allow for faster assembly of the building and may, in some embodiments, reduce the number of skilled technicians required to install the balcony in the building.

In some embodiments, the balconies may include two types of balconies — full balconies and false balconies. In some implementations, one or more balconies may be configured to provide at least a portion of an exterior surface of a building.

In some embodiments, the material composition of the balcony may include steel. In some embodiments, the material composition may include aluminum. In other embodiments, the components of the balcony system may be made of a variety of different suitable building materials, ranging from metals and/or metal alloys, wood and Wood Polymer Composites (WPC), wood products (lignin), other organic building materials (bamboo), organic polymers (plastics), hybrid materials, earthen materials such as ceramics, and the like. In some embodiments, cement or other castable or moldable building materials may also be used. In other embodiments, any combination of suitable building materials may be combined by using one building material for some components of the balcony and another building material for other components of the balcony. The selection of any material may be made by reference to material options (e.g., options provided in the International Building Code) in determining the load bearing requirements of the structure to be constructed, or based on the knowledge of one skilled in the art. Larger and/or taller structures may have greater physical strength requirements than smaller and/or shorter buildings. Adjustment of the building material to accommodate the magnitude of structural and/or load and environmental stresses (environmental stress) may determine the best economic choice of building material for all components in the balcony described herein. The availability of various building materials in different parts of the world may also affect the choice of materials used to build the systems described herein. The choice of material may also be influenced by the adoption of international building codes or the like.

Any reference herein to "metal" includes any construction grade metal or metal alloy that may be suitable for use in the manufacture and/or construction of the balconies and components described herein. Any reference herein to "wood" includes wood, wood laminate products, wood press products, Wood Polymer Composites (WPC), bamboo or bamboo related products, wood products, and any plant derived products, whether chemically treated, refined, processed, or simply harvested from a plant. Any reference herein to "concrete" includes any construction grade settable composite material including cement, water, and granular aggregate. The particulate agglomerates may include sand, gravel, polymer, ash, and/or other minerals.

In general, in some embodiments, balcony systems or false balcony systems may be manufactured and installed according to a method comprising manufacturing and assembling portions of a balcony or false balcony outside a construction site, and transporting the partially built balcony and kit of parts to the construction site for completion of the installation and assembly at the construction site. For example, a steel manufacturer may manufacture balcony beams and weld channel members to the beams. The channel member may comprise a lightweight "c" section with holes perforated at given intervals (e.g., 12 inches), wherein the perforations are made for inserting steel reinforcement bars (reinforcing bars) during the fabrication of the balcony floor. The balcony frame may be made of rolled stainless steel.

The balcony beams and the frames may be transported to a concrete precast shop (concrete precast shop). In the prefabrication yard, steel reinforcement bars (or reinforcing bars) are inserted into holes welded into the channels of the balcony beams. The balcony beams and the balcony frames may be placed in formworks (form) that support the beams and frames and allow the insertion of steel bars into the holes of the channel members. In addition, the guard rail support member may be installed and fixed to the balcony frame. The form may then be cast with concrete (or other material suitable for casting). Once the concrete cures, it secures the balcony beams to the balcony frame and establishes the integral balcony assembly. Likewise, the guardrail support members are secured by cured concrete.

Some embodiments may include a guardrail with horizontal members to which glass (glazing) for balcony guardrails may be attached. By providing horizontal members for glass attachment, the balcony systems and false balcony systems described herein allow for standardization of glass pieces and are not limited to their attachment to guardrail post supports (e.g., posts). This provides the advantage of allowing the guard rail post support spacing to be standardised, as the glass is not directly fixed to the post support.

DETAILED DESCRIPTION OF THE DRAWINGS DETAILED DESCRIPTION FIGS. 1-3 are diagrams of an example balcony system 100, according to some embodiments. The balcony system 100 is attached to two structural frame members (e.g., wide-flange posts) 102 and 104.

The balcony system 100 comprises two sets of components. The first set of components may be manufactured and assembled off-site (e.g., not at the construction site where the balcony system 100 is installed). The second set of components (including the guardrail components) may be mounted to the balcony system 100 at the construction site.

The first set of components includes balcony beams 112, channel balcony frames 114, one or more reinforcing ribs 116, precast concrete balcony floors 118, balcony beam attachment members 120, and one or more guardrail brackets 122. In an example embodiment, the metal components (e.g., 112, 114, 116, 120, 122) may be manufactured and assembled (or partially assembled) in a metal manufacturing facility. The assembled or partially assembled metal parts may then be sent to a concrete casting facility that pours and casts a concrete balcony floor 118. Once cured, the concrete balcony floor 118 secures the metal and concrete components together into an integral balcony unit that may be transported to a construction site for use in construction.

The second set of components may be transported to the building site along with the above-described integral balcony unit for final assembly of the balcony. The second set of components may include a guardrail 106, which guardrail 106 may be a one-piece or may be a multi-piece guardrail. The second set of components may also include one or more post guardrail supports 108, one or more guardrail plates 110, and one or more sets of hardware including one or more closure plates 124 to attach the one or more post guardrail supports 108 to corresponding guardrail brackets 122.

At the construction site, the integrated balcony unit may be mounted to the building structure. For example, the balcony system 100 includes a balcony beam 112, the balcony beam 112 including a first end and a second end. The first ends of the balcony beams 112 are attached to the corresponding first structural frame members 102 and the second ends of the balcony beams are attached to the corresponding second structural frame members 104. Attachment may be accomplished at each of the first and second ends of the balcony beams 112 via panels that can be bolted or otherwise attached to the

structural frame members

102 and 104.

Once the integrated balcony unit is installed, a second set of balcony components may be installed for final assembly of the balcony system. Once the balcony guardrail 106 is in place, the risk of falling out of the balcony opening is substantially reduced. Accordingly, the need or demand for using a safety belt in a space or area of a building having a balcony system can be removed, and a worker can work in the space or area with greater safety and efficiency by performing works such as interior wall construction, electrical connection, mechanical connection, and finishing without wearing a mounting belt.

As shown in fig. 3, the second set of components (e.g., guardrail components) may include horizontal members 302 attached to the post guardrail support 108. The guardrail plate 110 may be attached to the horizontal member 302.

In one embodiment, the balcony beams 112 and the aisle balcony frames 114 may be formed of stainless steel. The guardrail brackets 122 may include angle brackets that are attached to the access balcony frame 114 via a bolt system (e.g., 5 inch bolts) that extends into the interior space defined by the access balcony frame 114 and is retained by the concrete balcony floor.

Figures 4-6 illustrate a side cross-sectional view, a top plan view, and a front view, respectively, of a guardrail connection according to some embodiments. The connection includes bolts 402 and 404 (e.g., 5 inch bolts) that attach the guardrail brackets 122 (which may be corner guardrail brackets) to the aisle balcony frame 114 and are secured by hardware (e.g., nuts, shims, etc.) and the cured concrete balcony floor 118. Corner guardrail brackets 122 are used to support the post guardrail supports 108 and to attach the post guardrail supports 108 to the aisle balcony frame 114.

Fig. 7 illustrates a false balcony system 700 according to some embodiments. The false balcony system 700 includes a guardrail 702, one or more post guardrail supports 704, one or more guardrail panels 706, horizontal guardrail members 708, optional lights 710 (e.g., a continuous LED light strip), "Z" -section-shaped balcony beam attachment members 712, one or more guardrail brackets 714, and balcony beams 716.

The "Z" -section shaped balcony beam attachment member 712 is attached (e.g., welded or otherwise secured or coupled) to the balcony beam 716. Guardrail brackets 714 are attached to the "Z" -section shaped balcony beam attachment members 712.

Figure 8 illustrates a balcony system 800 according to some embodiments. The balcony system 800 includes a guardrail 802, one or more post guardrail supports 804, one or more guardrail panels 806, horizontal guardrail members 808, optional lights 810 (e.g., continuous LED light strips), an access balcony frame 812, one or more guardrail brackets 814, one or more bolts 816 (attaching the guardrail brackets 814 to the access balcony frame 812), a poured concrete balcony floor 818, balcony beam attachment members 820 (connected to the reinforcement members and poured into the concrete balcony floor), balcony beams 822 (attached to the balcony beam attachment members 820), and one or more access balcony frame attachment bolts 824 (securing the access balcony frame 812 into the concrete balcony floor 818). A thermal break (thermal break) is provided between the poured concrete balcony floor 818 and the building.

Figure 9 is a schematic diagram illustrating an example building having a false balcony 700 and a balcony 800 according to some embodiments. The building may include zero or more false balconies 700 and zero or more balconies 800.

Figures 10A, 10B, 10C illustrate an elevation, plan, and frame view, respectively, of a metal-filled example studio-unit balcony, according to some embodiments. In particular, fig. 10A shows structural columns 1002 coupled to balcony support members 1004 (e.g., 6 "x 10" steel tube members), the balcony support members 1004 supporting the balcony and aligning and spacing the balcony and structural columns apart. The balcony includes a sway brace top 1016 (e.g., 1/2 "x 3-1/2"), the sway brace top 1016 being connected to a vertical post 1012 by factory welding, the vertical post 1012 fitting into a through hole 1014 (e.g., a 3' hole drilled in the center) in the balcony frame and being bolted to the balcony frame (e.g., 2204). The balcony also includes horizontal members 13 (e.g., 1-1/2 "x 1-1/2" x2-1/2 "t-channel extrusions factory welded to the vertical posts) to which fence panels 1020 are attached. The guardrail panel of fig. 10A or other figures herein may include one or more of the following: tempered glass, 3Form, metal mesh, polycarbonate, and/or photovoltaic panels. The balcony may also include factory installed decking 1026. The deck 1026 may comprise any suitable deck material, such as synthetic material, tile, wood, and the like. Details of the cross section indicated by S1 in fig. 10A are shown in fig. 19.

As shown in fig. 10B, the balcony frame may be covered and welded on the steel pipe support 1006. As also shown in FIG. 10B, the continuous Z-section members (e.g., 2 "x 2-1/8" x2 "x 2") have platform retaining clips and are bolted to the balcony frame at the factory.

FIG. 10C shows a metal filler comprising one or more C-channel members 1008 (e.g., 4 "x 1.76" steel C-channel), profile channel 2204, steel plate 1010 (e.g., 1/4 "steel plate), factory-welded to steel tubular member 1004, and metal spikes 1022 (e.g., 2-1/2" and 4 ") factory-attached to C-channel members 1008.

Fig. 11A, 11B, 11C and 12A, 12B, 12C show an elevation, plan and frame view, respectively, of a metal-filled example studio unit balcony, with features similar to those shown in fig. 10A-10C. The example balconies shown in fig. 11A-11C and 12A-12C differ in size and/or number of parts.

Fig. 13A, 13B, 13C, 14A, 14B, 14C and 15A, 15B, 15C show an elevation, plan and frame view, respectively, of a metal-filled example single bedroom unit balcony, with features similar to those shown in fig. 10A-10C. The example balconies shown in fig. 13A-13C, 14A-14C, and 15A-15C differ in size and/or number of parts.

Fig. 16A, 16B, 16C show an elevation, plan, and frame view, respectively, of a metal-filled example single bedroom unit balcony, which features are similar to those shown in fig. 10A-10C. In addition to the features shown in fig. 10A-10C, fig. 16A and 16B also show a trim panel 1602 (e.g., a PVC panel) attached to the balcony.

Fig. 17A, 17B, 17C show an elevation, plan, and frame view, respectively, of a metal-filled example two bedroom unit balcony, which features are similar to those shown in fig. 10A-10C. In addition to the features shown in fig. 10A-10C, fig. 17A and 17B also show a trim panel 1702 (e.g., PVC panel) attached to the balcony.

Fig. 18A, 18B, 18C show an elevation, plan, and frame view, respectively, of a metal-filled example two bedroom unit balcony, which features are similar to those shown in fig. 10A-10C. In addition to the features shown in fig. 10A-10C, fig. 18A and 18B also show a trim panel 1802 (e.g., a PVC panel) attached to the balcony.

Fig. 19 is a cross-sectional view of an example metal filled balcony (denoted as S1 in previous figures) according to some embodiments. In particular, fig. 19 shows a steel tube balcony support member 1902 (e.g., a 6 "x 10" steel tube member similar to 1004 in fig. 10A), a vertical post 1904, a horizontal member 1908 having an angle steel welded to the vertical post and a T-slot extruded member 1906 attached to the angle steel, a balustrade panel 1910, an optional continuous light strip 1912 (e.g., a continuous LED light strip). The balcony further comprises a platform (deck) comprising cement panels 1914, a waterproofing membrane 1916, and a decking (decking)1920 (e.g. composite decking material) mounted on top of the metal-filled balcony frame, the cladding panels 1918 being applied to the underside of the metal-filled balcony frame. Fig. 19 also shows the balcony to corbel beam 1922, including a gap between the balcony and corbel beam 1922.

Figure 20 is a cross-sectional view of an example balcony filled with metal according to some embodiments. In particular, fig. 20 shows a steel tube balcony support member 2002 (e.g., a 6 "x 10" steel tube member similar to 1004 in fig. 10A), a diagonal steel member 2004 factory welded to a vertical post, a horizontal member 2008 having an angle steel welded to a vertical post and a T-slot extruded member 2006 attached to the angle steel, a balustrade panel 2010, an optional continuous light strip 2012 (e.g., a continuous LED light strip). The balcony also includes a platform that includes a cement panel 2014, a waterproofing membrane 2016, and a decking 2020 (e.g., composite decking material) mounted on top of the metal-filled balcony frame, with a skin panel 2018 applied to the underside of the metal-filled balcony frame. Fig. 20 also shows the relationship of the balcony to the corbel bars 2022, including a gap between the balcony and the corbel bars 2022. Fig. 20 also shows a trim panel 2024 (e.g., PVC panel) attached to the inclined member 2004.

Fig. 21 is a cross-sectional view of an example dummy balcony filled with metal according to some embodiments. Figure 21 shows diagonal steel strip headers 2106 factory welded to vertical columns 2104. Guardrail plate 2108 is attached to vertical post 2104, vertical post 2104 is attached to balcony frame member 2106, balcony frame member 2106 is factory welded to balcony support beam 2102.

Fig. 22 shows an interface detail of an example metal-filled balcony (D1-D4) according to some embodiments. As shown in fig. 22, the balcony frame 2204 is attached to the balcony beams 2202. The balcony comprises metal filler members, such as c-channel members 2206, factory welded to balcony beams 2202 and balcony frame 2204.

The balcony comprises a plurality of flat steel vertical struts 2214 bolted to guardrail support members 2208, and the guardrail support members 2208 are factory welded to the balcony frame 2204. The connection of the stanchion 2214 to the guardrail support member 2208 is reinforced by a closure plate 2210. If desired, a backing plate 2212 can be used in the post 2214 to protect the guardrail support member 2208 connections.

As described above, the metal-filled balcony may include the metal stub 2216 attached (e.g., factory welded) to the c-channel member 2206.

The balcony platform shown in fig. 22 comprises a waterproof membrane 2218, composite decking rails 2226 (e.g., 1 "x 3" fire rating class a), composite decking 2224 (e.g., 1 "x 6" fire rating class a), steel sheet 2220 (e.g., 1/4 "steel sheet factory welded to c-channel member 2206), and steel sheet 2228 (e.g., 1/4" steel sheet factory welded to the balcony frame and c-channel member with water tight welds). The interior of the balcony may include a factory installed fire insulation layer 2230, one or more skin panels 2222 (e.g., two layers of Densglass skin panels), and fire bars and sealant 2232.

Fig. 23 is a flow diagram of an example method of manufacturing and installing a balcony system according to some embodiments. The various operations of the methods described herein do not have to be performed in the exact order shown. Moreover, some operations may be added, removed, modified, and/or combined together. The method may begin at 2302, where a balcony beam is formed. In some embodiments, the balcony beams may be formed of tubular steel and pre-finished (e.g., finished at the time of manufacture and prior to installation in a building). In some embodiments, the balcony beams may be prefabricated elements that are formed with the concrete platform (deck) and cast as a single piece, which would eliminate the need for tubular steel balcony beams. The method continues at 2304.

At 2304, a channel balcony frame is formed. For example, the channel balcony frame may be formed from rolled stainless steel. The method continues at 2306.

At 2306, an aisle balcony frame is attached to the balcony beams. For example, a balcony beam attachment member (e.g., 820) is attached to the balcony beam (e.g., by welding or other attachment means), and one or more strengthening ribs or members may be connected to the balcony beam attachment member. The method continues at 2308.

At 2308, one or more guardrail brackets are attached to the aisle balcony frame. For example, bolts (e.g., 816) are used to attach the guardrail brackets to the aisle balcony frame, wherein the bolts extend into the interior space defined by the aisle balcony frame. The method continues at 2310.

At 2310, a concrete balcony floor is poured into the interior space defined by the balcony channel frame. Once cured, the concrete balcony floor helps to secure the access balcony frame, the guardrail brackets, the reinforcement members, the balcony beam attachment members, and the balcony beams as an integral unit (or balcony platform). The method continues at 2312.

At 2312, balcony platforms and rail portions are provided to the construction site. The method continues at 2314.

At 2314, a balcony platform or integral balcony unit is attached to the building. For example, balcony beams are attached at each end to respective structural frame members (e.g., wide-edged metal posts). Attaching the integral balcony unit may be used to attach the integral balcony unit to the structure and may also help align structural members (e.g., wide-flange posts). The method continues at 2316.

At 2316, a guardrail is attached to the integral balcony unit. For example, a post guardrail support may be attached to a guardrail housing. The guardrail may be attached to a post guardrail support. The horizontal guardrail member may be attached to the post guardrail support. The method continues at 2318.

At 2318, a guardrail panel is attached to the horizontal guardrail member.

Fig. 24 is a flow chart of an example method of manufacturing and installing a false balcony system according to some embodiments. The method begins 2402 in which a balcony beam is formed. In some embodiments, the balcony beams may be formed of tubular steel and finished (e.g., finished prior to installation in a building).

At 2404, a "Z" -section shaped member (or balcony beam attachment member) is formed. For example, the "Z" section member may be formed from rolled stainless steel. The method continues at 2406.

At 2406, a "Z" -section shaped member is attached to the balcony frame. For example, a balcony beam attachment member (e.g., 712) is attached to the balcony beam (e.g., by welding or other attachment means), and one or more strengthening ribs or members may be connected to the balcony beam attachment member. The method continues at 2408.

At 2408, one or more guardrail brackets are attached to the balcony beam attachment member. The method continues at 2410.

At 2410, the balcony beam and rail portions are provided to a construction site. The method continues at 2412.

At 2412, attaching the balcony beams to the building. For example, balcony beams are attached at each end to respective structural frame members (e.g., wide-edged metal posts). Attaching the integral balcony unit may be used to attach a dummy balcony unit to the structure and may also help align structural members (e.g., wide-edged posts). The method continues at 2414.

At 2414, attaching the guardrail to the integral balcony unit. For example, a post guardrail support may be attached to a guardrail housing. The guardrail may be attached to a post guardrail support. The horizontal guardrail member may be attached to the post guardrail support. The method continues at 2416.

At 2416, a guardrail plate can be attached to the horizontal guardrail member.

The balcony may be attached to a frame of the building, such as an external structural frame, via one or more panels bolted to the wide-flange posts. For example, the balconies may be attached to an external steel frame, which may provide structural support and/or alignment for the building. In general, any mechanism may be used to attach the balcony to the frame of the building, such as an exterior steel frame. Generally any type of fastener may be used. In some embodiments, the balcony may be coupled to a vertical beam or a horizontal beam included in the frame of the building.

Concrete may be poured on the floor and ceiling. The poured concrete may form the floor of the balcony. In some embodiments, the balcony may transfer a horizontal load (longitudinal load) to the horizontal load system of the building. In this way, after the floor and ceiling have been positioned at the desired floor, concrete can be poured at the finished height of the floor of the building, thereby forming the floor of the unit in that floor. In some embodiments, the balcony is installed after the concrete has cured on the floor and ceiling.

Embodiments of the balcony and false balcony system may provide a floor and ceiling system that may be used for mid-and high-rise residential projects, and the like. Panels with or without installed closures and tracks may be configured to conform to one or more of the following building codes: fire protection, energy, handicap (handicap), life safety, and acoustics (impact and ambient noise transfer). In some embodiments, the pre-assembled floor and ceiling, with or without closures and tracks, may be considered a fully integrated subassembly that complies with fire, sound impact, energy, and life/safety regulations. In some embodiments, floors and ceilings may be fully integrated with electrical, fire-resistant, energy-insulating, and sound-insulating capabilities. The floor and ceiling may be designed to achieve a fire rating, for example, a 2 hour fire rating, set by applicable building codes.

The balconies described herein may be manufactured in a factory or store off-site and transported to a construction site (construction site) for attachment to a structural frame of a building, for example, a structural exoskeleton (exoskeleton). Balcony systems or false balcony systems or parts thereof can be manufactured in various sizes, for example, 8 feet to 10 feet in width, up to 22 feet in width. At the construction site, balconies may be attached to structural frame members, floors and ceilings, headwalls, abduction walls, function boards, construction facilities, or any combination thereof. The structural frame members may provide support to a balcony, which may comprise concrete panels, which are cast off-site in a casting facility, or cast on-site. In some embodiments, the balcony transfers the load to the structural frame members. In some embodiments, the balcony transfers the load directly to the steel structure of the building, and the balcony does not transfer the load from the floor and ceiling to the structure. In some embodiments, the balcony may be non-load bearing (e.g., in the case of a false balcony).

The examples provided herein are for illustrative purposes only and should not be taken as limiting the scope of the present disclosure. Each example embodiment may be practical for a particular environment (e.g., urban mixed-use development, low-rise dwelling units, and/or remote cells). The materials and dimensions of the various elements may be selected to conform to one or more of the following building codes without departing from the scope of the principles of the present specification: fire protection, energy, obstacles, life safety, and acoustics (impact and ambient noise transfer). The elements and/or systems can also be configured to comply with social and/or religious specifications, as desired. For example, the materials, systems, methods, and/or devices may be configured to comply with international building codes that have been adopted in jurisdictions.

The present disclosure is not limited to the particular embodiments described in this application, which are intended as illustrations of various aspects. Many modifications and embodiments can be made without departing from the spirit and scope thereof. In addition to the functions and methods recited herein, functionally equivalent methods and apparatuses are possible within the scope of the present disclosure in light of the foregoing description. Such modifications and embodiments are intended to fall within the scope of the appended claims. The disclosure is to be limited only by the terms of the appended claims, along with the full scope of equivalents to which such claims are entitled. The present disclosure is not limited to a particular method, which can, of course, vary. The terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting.

With respect to the use of substantially any plural and/or singular terms herein, the terms "a", "an", and "the" can be used interchangeably and/or refer to the plural as they are used in the context and/or application. Various singular/plural permutations may be expressly set forth herein for the sake of clarity.

In general, the terms used herein, and especially in the appended claims (e.g., bodies of the appended claims), are generally intended as "open" terms (e.g., the term "including" should be interpreted as "including but not limited to," the term "having" should be interpreted as "having at least," the term "includes" should be interpreted as "includes but is not limited to," etc.).

If a specific number is intended to be introduced in the recitation of a claim, that intent will be explicitly recited in the claim, and in the absence of such recitation no such intent is present. For example, as an aid to understanding, the following appended claims may contain usage of the introductory phrases "at least one" and "one or more" to introduce claim recitations. However, the use of such phrases should not be construed to imply that the introduction of a claim recitation by the indefinite articles "a" or "an" limits any particular claim containing such introduced claim recitation to embodiments containing only one such recitation, even when the same claim includes the introductory phrases "one or more" or "at least one" and indefinite articles such as "a" or "an" (e.g., "a" and/or "an" should be interpreted to mean "at least one" or "one or more"); the same holds true for the use of definite articles used to introduce claim recitations. In addition, even if a specific number of an introduced claim recitation is explicitly recited, such recitation should be interpreted to mean at least the recited recitation (e.g., the bare recitation of "two recitations," without other modifiers, means at least two recitations, or two or more recitations).

Further, in these examples using conventions similar to "at least one of A, B, and C, etc." in general, such configurations are in a sense one of ordinary skill in the art would understand (e.g., "a system having at least one of A, B, and C" would include, but not be limited to, systems having a alone, B alone, C alone, a and B together, a and C together, B and C together, and/or A, B, and C together, etc.). In these examples using conventions similar to "A, B, or at least one of C, etc." in general, such configurations are in a sense a convention understood by those of skill in the art (e.g., "a system having at least one of A, B, or C" would include but not be limited to systems having a alone, B alone, C alone, both a and B, both a and C, both B and C, and/or A, B, and C, etc.). Any disjunctive word and/or phrase presenting two or more alternative terms, whether in the description, claims, or drawings, should be understood to contemplate the possibilities of including one of the terms, either of the terms, or both of the terms. For example, the phrase "a or B" will be understood to include the possibility of "a" or "B" or "a and B".

In addition, where features or aspects of the disclosure are described in terms of Markush groups (Markush groups), the disclosure is thus also described in terms of any single member or subgroup of members of the Markush group.

For any and all purposes, such as in terms of providing a written description, all ranges disclosed herein also encompass any and all possible subranges and combinations of subranges thereof. Any listed range can be easily identified as fully descriptive and the same range can be broken down into at least equal halves, thirds, quarters, fifths, tenths, etc. As a non-limiting example, each range discussed herein may be readily divided into a lower third, a middle third, and an upper third, etc. Language such as "at most," "at least," "greater than," "less than," and the like includes the recited number and refers to ranges that may be subsequently subdivided into subranges in the manner described above. A range includes each individual member. Thus, for example, a group having 1-3 items refers to groups having 1, 2, or 3 items. Similarly, a group having 1-5 items refers to groups having 1, 2, 3, 4, or 5 items, and so on.

The subject matter described herein sometimes illustrates different components contained within, or connected with, different other components. The architecture described is merely an embodiment and, in fact, many other architectures can be implemented which achieve the same functionality. In a conceptual sense, any arrangement of components to achieve the same functionality is effectively "associated" such that the desired functionality is achieved. Hence, any two components herein combined to achieve a particular functionality can be seen as "associated with" each other such that the desired functionality is achieved, irrespective of architectures or intermedial components. Likewise, any two components so associated can also be viewed as being "operably connected," or "operably coupled," to each other to achieve the desired functionality, and any two components capable of being so associated can also be viewed as being "operably couplable," to each other to achieve the desired functionality. Particular embodiments that can be operatively coupled include, but are not limited to, components that are physically matable and/or physically interacting.

Although various aspects and embodiments have been disclosed herein, other aspects and embodiments are possible. The various aspects and embodiments disclosed herein are for purposes of illustration and are not intended to be limiting.

Claims

1. A balcony system, comprising:

a balcony beam comprising a first end and a second end, wherein each of the first end and the second end is configured to be attached to a corresponding structural frame member of a building;

a channel balcony frame;

an aisle balcony frame attachment member attached to the balcony beams and having one or more holes;

one or more reinforcing ribs disposed in an interior space defined by the channel balcony frame, wherein the one or more reinforcing ribs extend through the one or more holes in the channel balcony frame attachment member, and wherein the reinforcing ribs and the channel balcony frame attachment member are retained within the interior space defined by the channel balcony frame by a floor formed within the interior space defined by the channel balcony frame, such that the balcony beams, the channel balcony frame, and the concrete floor form an integral unit after the floor is formed;

one or more guardrail brackets attached to the channel balcony frame via one or more fasteners passing through the one or more guardrail brackets and into the interior space defined by the channel balcony frame, wherein the one or more guardrail brackets are secured by the floor formed within the interior space defined by the channel balcony frame;

one or more post guardrail supports, each post guardrail support attached to a respective one of the one or more guardrail brackets and secured thereto by a corresponding closure plate;

a guardrail attached to the one or more post guardrail supports;

one or more horizontal guardrail members attached to the one or more post guardrail supports; and

one or more guardrail plates attached to the one or more horizontal guardrail members.

2. The balcony system according to claim 1, wherein each of the first and second ends includes a respective panel to couple the balcony beams to the corresponding structural frame members of the building.

3. The balcony system according to claim 1, wherein the aisle balcony frame has a rectangular shape.

4. The balcony system according to claim 1, wherein the access balcony frame includes one or more post guardrail support holes, each post guardrail support hole being configured to enable a respective post guardrail support to pass therethrough.

5. The balcony system according to claim 1, wherein the aisle balcony frame is formed of stainless steel and the balcony floor is formed of concrete.

6. The balcony system according to claim 1, further comprising a light element coupled to the one or more post guardrail supports.

7. The balcony system according to claim 1, wherein the one or more balustrade panels comprise one or more of: tempered glass, metal mesh, polycarbonate, photovoltaic panel, or resin panel.

8. A false balcony system, comprising:

a balcony beam attachment member attached to the balcony beam such that the balcony beam attachment member and the balcony beam form an integral unit, wherein the balcony beam attachment member comprises one or more holes;

one or more guardrail brackets attached to the balcony beam attachment member via one or more fasteners passing through the one or more guardrail brackets and through corresponding holes in the balcony beam attachment member;

a guardrail attached to the one or more post guardrail supports;

9. The false balcony system according to claim 8, wherein each of the first and second ends includes a respective panel to couple the balcony beams to the corresponding structural frame member of the building.

10. The false balcony system according to claim 8, further comprising a light element coupled to the one or more post guardrail supports.

11. The false balcony system according to claim 8, wherein the guardrail panel comprises one or more of: tempered glass, metal mesh, polycarbonate, photovoltaic panel, or resin panel.

12. A method, comprising:

forming a balcony beam having a first end and a second end;

forming a channel balcony frame;

forming a balcony beam attachment member;

attaching the balcony beam attachment member to the balcony beam;

attaching a guardrail bracket to the aisle balcony frame;

forming a balcony floor in a space defined by the channel balcony frame to form an integral balcony unit including the balcony beams, the channel balcony frame, and the balcony floor;

providing the integrated balcony unit and the guardrail section to a construction site of a building, wherein the guardrail section comprises a guardrail and one or more post guardrail supports;

attaching the integral balcony unit to a structural frame of the building;

attaching the guardrail section to the integral balcony unit; and

attaching one or more guardrail plates to the guardrail.

13. The method of claim 12, further comprising attaching a respective plate to each of the first and second ends to couple the balcony beams to the structural frame of the building.

14. The method of claim 12, wherein forming the aisle balcony frame comprises forming the aisle balcony frame in a rectangular shape.

15. The method of claim 12, wherein the aisle balcony frame includes one or more post guardrail support holes, each post guardrail support hole configured to enable a respective post guardrail support to pass therethrough.

16. The method of claim 12, wherein forming the aisle balcony frame comprises forming the aisle balcony frame from stainless steel.

17. The method of claim 12, wherein the guardrail panel comprises one or more of: tempered glass, metal mesh, polycarbonate, photovoltaic panel, or resin panel.

18. A method, comprising:

forming a balcony beam having a first end and a second end;

forming a balcony beam attachment member;

attaching the balcony beam attachment member to the balcony beam to form an integral balcony unit;

attaching the integral balcony unit to a structural frame of the building;

attaching the guardrail section to the integral balcony unit; and

attaching one or more guardrail plates to the guardrail.

19. The method of claim 18, further comprising attaching a respective plate to each of the first and second ends to couple the balcony beams to the structural frame of the building.

20. The method of claim 18, wherein the guardrail panel comprises one or more of: tempered glass, metal mesh, polycarbonate, photovoltaic panel, or resin panel.