# US 11,078,660 B2 · Prefabricated building system and methods > Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt - Number: US 11,078,660 B2 - Document ID: US11078660B2 - Status: Granted - Kind: B2 - Application number: 16/539,964 - Filed: 2019-08-13 - Published: 2020-02-13 - Granted: 2021-08-03 - Earliest claimed: 2018-08-13 - Assignees: Blach Construction Company; Gregory P. Luth & Associates, Inc.; Quattrocchi Kwok Architects - Applicants: Blach Construction Company; Gregory P. Luth & Associates, Inc.; Quattrocchi Kwok Architects - Inventors: Gino R. Cecchetto, Jr.; Gregory P. Luth; Aaron R. Jobson - Web page: https://patentgrep.com/patent/US11078660B2 ## CPC - E04B 1/35: Extraordinary methods of construction, e.g. lift-slab, jack-block (E04B1/34 takes precedence; falsework, shuttering for shaping walls, floors, ceilings or roofs in situ E04G11/04; conveying or assembling of building materials E04G21/00; working measures on existing buildings E04G23/00) - E02D 27/02: Flat foundations without substantial excavation (E02D27/04, E02D27/08 take precedence) - E02D 27/08: Reinforcements for flat foundations {(E02D27/48 takes precedence)} - E04B 1/08: the elements consisting of metal - E04B 1/2403: {Connection details of the elongated load-supporting parts} - E04B 1/348: Structures composed of units comprising at least considerable parts of two sides of a room, e.g. box-like or cell-like units closed or in skeleton form - E04B 7/026: {consisting of prefabricated modules, e.g. box-like or cell-like units (E04B7/24 takes precedence)} - E04B 7/20: Roofs consisting of self-supporting slabs, e.g. able to be loaded - E02D 2250/0007: using a mold - E02D 2250/0023: Cast, i.e. in situ or in a mold or other formwork - E02D 2300/002: Concrete - E04B 2001/2463: {Connections to foundations} - E04B 2001/2496: {Shear bracing therefor} - E04B 2001/3577: {prefabricating a building and moving it as a whole to the erection site} - E04B: GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS (border constructions of opening in walls, floors or ceilings E06B1/00; {electromagnetic shielding H05K9/0001}) - E02D: FOUNDATIONS; EXCAVATIONS; EMBANKMENTS (specially adapted for hydraulic engineering E02B); UNDERGROUND OR UNDERWATER STRUCTURES {(tunnels, tunnelling, mining E21)} ## 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. ## Claims ### Claim 1 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 slab extending between the grade beam footings, wherein the slab and the grade beam footings have coplanar upper surfaces, and a prefabricated laterally resistive frame including a column component and a brace component, the column component extending into the second layer of concrete in the grade beam footings. ### Claim 2 (depends on 1) The building assembly of claim 1, wherein the grade beam footings and the slab are contiguous. ### Claim 3 (depends on 1) The building assembly of claim 1, wherein the foundation has a constant depth. ### Claim 4 (depends on 1) The building assembly of claim 1, wherein the column component of the braced frame is connected to a plate sandwiched between the first and second layers of concrete in the grade beam footings. ### Claim 5 (depends on 1) The building assembly of claim 1, wherein the column component is vertical, and the brace component is horizontal or diagonal relative to the column component. ### Claim 6 (depends on 1) The building assembly of claim 1, wherein each grade beam footing includes a prefabricated linear rebar cage having a height and a width, the heights of all the prefabricated linear rebar cages are equal, and the widths of all the prefabricated linear rebar cages are equal. ### Claim 7 (depends on 1) The building assembly of claim 1, wherein the grade beam footings include prefabricated rebar cages. ### Claim 8 (depends on 7) The building assembly of claim 7, wherein the rebar cages extend into the second layer of concrete. ### Claim 9 A building assembly, comprising: a foundation including intersecting grade beam footings having a uniform width and depth, a slab extending between the grade beam footings, wherein the slab and the grade beam footings have coplanar upper surfaces, a steel building frame including a pre-welded laterally resistive frame, a column component of the pre-welded laterally resistive frame extending into at least one of the grade beam footings, and a prefabricated wall panel and a prefabricated roof panel, each bolted to the steel building frame. ### Claim 10 (depends on 9) The building assembly of claim 9, wherein the prefabricated wall panel includes a plurality of vertical studs connected to a strongback and a sheathing material. ### Claim 11 (depends on 9) The building assembly of claim 9, wherein the prefabricated roof panel includes a first pair of parallel structural members, a second pair of parallel structural members extending between the first pair of parallel structural members, and a decking material. ### Claim 12 (depends on 9) The building assembly of claim 9, wherein the grade beam footings include a plate between first and second layers of concrete, and the laterally resistive frame is fastened to the plate. ### Claim 13 (depends on 12) The building assembly of claim 12, further comprising a rebar cage including a stirrup that extends into the second layer of concrete. ### Claim 14 A method of constructing a building, comprising: prefabricating a laterally resistive frame including a column component and a brace component, prefabricating a rebar cage, transporting the laterally resistive frame and the rebar cage to a construction site, constructing intersecting grade beam footings at the construction site, the grade beam footings having a uniform width and depth and including the rebar cage, wherein the column component of the laterally resistive frame extends into at least one of the grade beam footings, pouring a concrete slab at a height matching a height of the grade beam footings and extending between the grade beam footings, wherein the slab and the grade beam footings have coplanar upper surfaces. ### Claim 15 (depends on 14) The method of claim 14, wherein the constructing step includes: pouring a first layer of concrete over the rebar cage, installing a plate on top of the first layer, fastening the laterally resistive frame to the plate, and pouring a second layer of concrete over the plate. ### Claim 16 (depends on 14) The method of claim 14, wherein prefabricating the rebar cage includes tying together a plurality of lateral bars and a plurality of stirrups to form a linear rebar cage. ### Claim 17 (depends on 14) The method of claim 14, further comprising placing the rebar cage in a footing excavation and doweling the rebar cage to another rebar cage, using connecting bars temporarily secured inside the rebar cage. ### Claim 18 (depends on 14) The method of claim 14, further comprising: erecting and bolting together pre-welded components, including the laterally resistive frame, to form a steel building frame. ### Claim 19 (depends on 18) The method of claim 18, further comprising: bolting a panelized wall component to the steel building frame.