Precast Structure and Construction Method Thereof

The subject disclosure relates to a construction structure and the method thereof, in particular, a precast structure and the construction method thereof.

Traditional methods of building reinforced concrete (RC) structures involve constructing floor by floor from the bottom up, which can be time-consuming. This approach also requires numerous processes such as tying reinforced steel, molding, grouting, and more, which necessitates a large workforce on the construction site. The quality of the construction is heavily reliant on the skill and experience of the workers and is also susceptible to weather conditions, making it difficult to control. In contrast, using steel reinforced concrete (SRC) for load-bearing beams and columns can speed up the construction process, but it also requires a significant amount of steel, leading to higher construction costs. To address these challenges, the precast construction method was developed.

The precast construction method involves producing concrete structures in a factory by pouring concrete into reusable molds, allowing it to harden in a controlled environment, and then transporting it to the construction site for installation. This method offers several advantages, including environmental stability, immunity to weather conditions, reduced reliance on skilled labor, and standardized operating procedures. On the construction site, mechanical equipment can be used to assemble and lift the precast structures without the need for external scaffolding. This allows for simultaneous installation of exterior walls and interior decorations, effectively shortening construction time. Additionally, precast construction methods help preserve forest resources, are environmentally friendly, and keep construction sites neat and clean. These methods are particularly suitable for building structures that need to bear heavy loads, such as precast columns or beams.

In traditional building construction, the process typically involves constructing one story at a time, starting from the lowest level and working upwards to complete the entire building. This method can be complex and time-consuming, especially when it comes to coordinating the various tasks involved in the construction process, such as hoisting structures, transporting materials, and providing access for workers. As the building gets taller, these logistical challenges only become more difficult to manage. As a result, traditional construction methods may not be the most efficient way to complete a building project.

Given the significant investment in the high-tech industry and the rapid pace of change in the market for high-tech goods, there is a need for quick construction of high-tech plants in order to expedite the construction of interior clean rooms and the arrangement of manufacturing machines. This is necessary to meet or exceed production timelines for the fabrication of high-tech products such as chips. For instance, on precast construction sites, precast columns and beams are placed in predetermined locations by tower cranes or mobile cranes. However, these cranes have their own limitations in terms of loading capacity and distance, making it more costly and challenging to lift heavier precast columns and beams. As a result, the conventional construction method is unable to meet the requirements for rapid construction and shortened construction periods.

Based on the information provided, we are seeking a solution to expedite the construction process for high-tech plants.

An embodiment of the present disclosure provides a construction method. The method comprises: providing a first precast column, a second precast column and a third column arranged at sequential intervals; providing a first precast beam, the first precast beam comprises a first section, a second section spaced apart from the first section, and a first rebar penetrating through the first section and the second section; lifting the first precast beam, so that the first precast beam bridges the first precast column and the second precast column, wherein two end portions of the first section are respectively arranged on a first end of the first precast column and a second end of the second precast column, the first end of the first precast column facing the second end of the second precast column, the second section is arranged on a third end, opposite to the second end, of the second precast column; providing a second precast beam, the second precast beam comprises a first end portion and a second end portion opposite to the first end portion; lifting the second precast beam, so that the first end portion of the second precast beam is arranged on a temporary supporting frame, and the second end portion of the second precast beam is arranged on a fourth end of the third precast column; and moving the second precast beam, and coupling the first end portion of the second precast to a connecting end of the first rebar in the first precast beam, the connecting end extending beyond an end of the second section of the first precast beam.

An embodiment of the present disclosure provides a precast structure precast structure, comprising: a first precast beam and a second precast beam. The first precast beam comprises a first section, a second section and a first rebar. The second section is spaced part from the first section and a gap is formed therebetween. The first rebar connects and penetrates through the first section and the second section along a length direction of the precast beam structure. The second precast beam is substantially aligned with the first precast beam along the length direction thereof and is adjacent to the second section of the first precast beam. The second precast beam is coupled to the first bar of the first precast beam.

The following disclosure provides many different embodiments, or examples, for implementing different features of the provided subject matter. Specific examples of components and arrangements are described below to simplify the present disclosure. These are, of course, merely examples and are not intended to be limiting. For example, the formation of a first feature over or on a second feature in the description that follows may include embodiments in which the first and second features are formed in direct contact, and may also include embodiments in which additional features may be formed between the first and second features, such that the first and second features may not be in direct contact. In addition, the present disclosure may repeat reference numerals and/or letters in the various examples. This repetition is for the purpose of simplicity and clarity and does not in itself dictate a relationship between the various embodiments and/or configurations discussed.

Further, spatially relative terms, such as “beneath,” “below,” “lower,” “above,” “upper” and the like, may be used herein for ease of description to describe one element or feature's relationship to another element(s) or feature(s) as illustrated in the figures. The spatially relative terms are intended to encompass different orientations of the device in use or operation in addition to the orientation depicted in the figures. The apparatus may be otherwise oriented (rotated 90 degrees or at other orientations) and the spatially relative descriptors used herein may likewise be interpreted accordingly.

It should be understood that, although the terms first, second, etc., may be used herein to describe various elements, these elements should not be limited by these terms. Unless indicated otherwise, these terms are only used to distinguish one element from another element.

As used herein, the terms “approximately,” “substantially,” “substantial” and “about” are used to describe and account for small variations. When used in conjunction with an event or circumstance, the terms can refer to instances in which the event or circumstance occurs precisely as well as instances in which the event or circumstance occurs to a close approximation. For example, when used in conjunction with a numerical value, the terms can refer to a range of variation less than or equal to ±10% of that numerical value, such as less than or equal to ±5%, less than or equal to ±4%, less than or equal to ±3%, less than or equal to ±2%, less than or equal to ±1% less than or equal to ±0.5%, less than or equal to ±0.1%, or less than or equal to ±0.05%. For example, two numerical values can be deemed to be “substantially” the same as or equal if a difference between the values is less than or equal to ±10% of an average of the values, such as less than or equal to ±5%, less than or equal to ±4%, less than or equal to ±3%, less than or equal to ±2%, less than or equal to ±1%, less than or equal to ±0.5%, less than or equal to ±0.1%, or less than or equal to ±0.05%

As shown in the figures of the instant application, and in the following description of the embodiments, to facilitate explanation of the disclosure, xyz-coordinates will be used. The xyz-coordinates include an X-axis and a Y-axis and a Z-axis.is a schematic view showing a construction process in accordance with one embodiment of the present disclosure. A first precast column, a second precast columnand a third precast columnare arranged at sequential intervals along the direction of the X-axis.

As shown in, the first precast columnincludes a first bodyand a first rebar set. The first bodycontains concrete encased stirrups (not shown). The first rebar setincludes a set of vertical column rebars, in which the rebars are spaced apart within the first bodyin the direction of the X-axis, and extend upwardly (along the direction of the Y-axis) from the inside of the first bodyand to beyond a top surfaceof the first body. In the present embodiment, the first rebar setis exemplified by only two rebars, while in some embodiments of the present disclosure, the first rebar setmay comprise a plurality of rebars, such as twelve or more rebars. In addition, the first precast columnhas a first endthat faces the second precast column.

The second precast columnincludes a second bodyand a second rebar set. The second bodycontains concrete encased stirrups (not shown). The second rebar setincludes a set of rebars, in which the rebars are spaced apart within the second bodyin the direction of the X-axis, and extend upwardly (along the direction of the Y-axis) from the inside of the second bodyand to beyond a top surfaceof the second body. In the present embodiment, the second rebar sethas structures similar to those of the first body. The second precast columnhas a second endand a third endopposite to the second endalong the direction of the X-axis. The second endof the second precast columnfaces the first endof the first precast column, and the third endof the second precast columnfaces the third precast column. The method of constructing the present embodiment comprises the step of providing a corner bracketat an outer side of the third endof the second precast column, wherein the corner bracketfaces the third precast column, and a top surfaceof the corner bracketis substantially flush with the top surfaceof the second bodyof the second precast column. In the present embodiment, a plurality of triangular corner bracketsare disposed on the side of the third endof the second precast columnand are arranged in parallel along the direction of the Z-axis.

The third precast columnincludes a third bodyand a third rebar set. Similarly, the third bodycontains concrete encased stirrups (not shown). The third precast columnhas a fourth endand a fifth endopposite to the fourth endalong the direction of the X-axis. The fourth endfaces the third endof the second precast column. The third rebar setincludes a set of rebars, in which the rebars are spaced apart within the third bodyin the direction of the X-axis. The third rebar setcomprises a first main barand a second main bar. In the present embodiment, the first main barof the third precast columnis adjacent to the fifth endof the third precast columnand extends from the inside of the third precast columnand beyond a top surfaceof the third bodyof the third precast column. The second main barof the third precast columnis adjacent to the fourth endof the third precast column, and a top end of the second main baris entirely embedded in the third precast columnin the direction of the Y-axis. In the present embodiment, the top end of the second main baradjacent to the fourth endis further provided therein with a second couplerexposed to the surfaceof the third precast column. In the figures of the present embodiment, the first main barand the second main barare exemplified by a single bar respectively, while in some other embodiments of the present disclosure, the first main barand the second main barmay be plural, such as six or more for each.

is a schematic view showing another construction process in accordance with the above embodiment of the present disclosure. As shown in, a first precast beamincludes a first section, a second sectionand a first rebar. The first sectionand the second sectionare spaced apart by a gap G. The first rebarpenetrates through and connects the first sectionand the second sectionalong a length direction of the first precast beam(i.e., the direction of the X-axis shown in). A free endof the first rebardistant from the second precast columnextends beyond an end surface of the first sectionand further extends upwardly from a side of the first precast columnin an upward direction (i.e., the direction of Y-axis). A connecting endof the first rebaropposite to the free endextends beyond an end surface of the second sectionof the first precast beamby a predetermined distance. The figures of the present embodiment are illustrated with a single first rebaras examples, while in practice, the first rebarsgenerally include a plurality of rebars spaced apart along the direction of the Z-axis.

In the present embodiment, a crane (not shown) lifts the first precast beamwith a hook, so that the first precast beambridges the first precast columnand the second precast columnwith its two end portions (i.e., the first end portionand the second end portion). In the present embodiment, cablesof the crane are bundled with stirrup hooksextending from the inside of and to beyond a top surface of the first sectionof the first precast beam, so as to lift the first precast beam. In other embodiments, cablesof the crane are wrapped around and secured to the first sectionfor lifting the first precast beam. The two opposite end portions (i.e., the first end portionand the second end portion) are arranged respectively on the first endof the first precast columnand the second endof the second precast column, wherein the first endof the first precast columnfaces the second endof the second precast column. The second sectionis arranged on the third endof the second precast columnopposite to the second end. In such a case, the gap G is formed on top of the second bodyof the second precast columnand is configured to receive the second rebar setprotruding from a top surfaceof the second precast column, and the rebars in gap G do not interfere with each other. In the present embodiment, the step of lifting the first precast beamfurther comprises causing at least a portion of the second sectionof the first precast beamto be placed on a top surfaceof the corner bracketsecured to the side surface of the second precast column. In other words, a portion of the second sectionof the first precast beamis arranged on the top of the second body, and another portion thereof is arranged on the corner bracket. With the corner bracket, the landing area of the second sectionof the first precast beamis increased, enhancing the stability of the first precast beam. In other embodiments, other corner brackets (not shown) are arranged both on the first endof the first columnand the second endof the second precast column.

is a schematic view showing another construction process in accordance with the above embodiment of the present disclosure. In the present embodiment, a temporary supporting frameis provided on the ground between the second precast columnand the third precast column, and a top surfaceof the temporary supporting frameis substantially aligned with the top surfaceof the second precast columnand the top surfaceof the corner bracket.

is a schematic view showing another construction process in accordance with the above embodiment of the present disclosure. As shown in, a second precast beamcomprises a body, a second rebarand a first coupler. The bodyof the second precast beamhas a channelextending along a length direction of the second precast beam(i.e., the direction of the X-axis shown in) therein, and comprises a first end portionand a second end portionopposite to the first end portion. The first coupleris embedded in the channelof the first end portion. The second rebaris inserted from the second end portioninto the channelof the body, so that the first endof the second rebaris placed in the first end portionof the body. In addition, the first endof the second rebaris fixed to the first couplerin the body. The opposing second endof the second rebarextends beyond an end surface of the second end portionby a distance and is then bent upward in the direction of the Y-axis.

As shown in. the second precast beamis lifted so that the first end portionof the second precast beamis arranged on the top surfaceof the temporary supporting frame, and the second end portionof the second precast beamis arranged on the fourth endof the third precast columnand covers the top end of the second main barin the third precast column. In such a case, the second precast beamis substantially aligned with the first precast beamin the length direction thereof (i.e., in the direction of the X-axis), and the first end portionof the second precast beamis adjacent to the second sectionof the first precast beam. As shown in, cablesof the crane (not shown) are bundled with stirrup hooksextending from inside of and to beyond a top surface of the bodyof the second precast beamfor lifting the second precast beam. It should be noted that although the second end portionof the second precast beamis arranged on the fourth endof the third precast columnand above the top end of the second main barin the third precast column, the lifting of the second beamwould not interfere with the third precast columnbecause the second main barand the second couplerare embedded in the third body.

is a schematic view showing another construction process in accordance with the above embodiment of the present disclosure. As shown in, an operator by operating the crane (not shown) moves the second precast beamto the left side along the X-axis after the above steps, so that the first couplerwithin the first end portionof the second precast beamis coupled to the connecting endof the first rebar, wherein the connecting endextends beyond the second sectionof the first precast beam. As such, the second rebarof the second precast beamis coupled to the first rebarof the first precast beamthrough the first coupler. Meanwhile, since the second precast beamhas been moved, the second coupleris exposed to the top surfaceof the third precast column. Specifically, the present embodiment further comprises: aligning the second precast beamand the first precast beamalong their respective length directions (i.e., the direction of the X-axis shown in); laterally moving the second precast beamto the left side shown in, causing the first end portionof the second precast beamto be arranged on the top surfaceof the corner bracket, with the second portionof the second precast beamstill on the top surfaceof the third bodyof the third precast column; and coupling the first couplerin the second precast beamto the connecting endof the first rebarof the first precast beam. As shown in, a gap Gbetween the first precast beamand the second precast beamis provided, so that concrete or mortar can be poured into the gap Gfor connecting the first precast beamto the second precast beam.

is a schematic view showing another construction process in accordance with the above embodiment of the present disclosure. As shown in, the operator fixes an end of a column rebarto the second couplerin the top of third precast columnafter the above steps, so that the column rebaris erected on the third precast columnalong the Y-axis. It should be noted that the column rebarand the first main barare staggered with the second rebarin the Z-axis direction, so as to avoid any interference with each other.

is a schematic view showing another construction process in accordance with the above embodiment of the present disclosure.is a cross sectional view along line-shown in. Referring toand, a third precast beamis provided. The operator further lifts the third precast beamso that an endof the third precast beamis arranged in the gap G between the first sectionand the second sectionof the first precast beam, wherein the length direction of the third precast beamis along the direction of the Z-axis and is substantially perpendicular to the length direction of the first precast beamor the second precast beam(i.e., the direction of the X-axis). The gap G between the first sectionand the second sectionis configured to receive the endof the third precast beamwherein the third precast beamis substantially perpendicular to the first precast beamand the second precast beam. Specifically, the endof the third precast beamis arranged on the top surfaceof the second precast column, and on a sixth endof the second precast column, which is between the second endand the third endof the second precast column(as shown in). On the other hand, as shown in, the second precast beamcan be arranged on another corner bracketand a temporary supporting frame, so as to carry the other part of the third precast beam. Afterward, concrete can be poured between the first section, the second sectionof the first precast beamand the endof the third precast beamto form a joint among them.

In some embodiments, the third precast beammay include two spaced sections (not shown) connected by at least one rebar. The above two sections of the third precast beamcan be arranged respectively on the sixth endand a opposite seventh endof the top surfaceof the second precast column

In sum, the present disclosure provides a precast structure and a construction method thereof, wherein a first precast beam has first and second sections spaced apart by a gap. The first precast beam has a first rebar therein and is connected to a second rebar in the second precast beam. With this structure, the beams are lighter in weight and can be quickly assembled on the precast columns. Such precast structure and construction method can greatly enhance the efficiency of assembling the precast beams and shorten the construction period. As described above, the precast structure and the construction method are able to spare space for lifting precast beams. Consequently, the beams at different levels need not to be lifted in a stair-type lifting procedure as shown in(the precast beams “a” and “b” of the upper and lower stories should be lifted in a stair-like sequence). In contrast, the present disclosure enables vertical lifting procedure as shown in(the precast beams “a” and “b” of the upper and lower stories can be lifted in a manner wherein one is on top of another). Hence, the lifting space is saved and the construction efficiency is increased.

The above embodiments merely describe the principle and effects of the present disclosure, instead of being used to limit the present disclosure. Therefore, persons skilled in the art can make modifications to and variations of the above embodiments without departing from the spirit of the present disclosure. The scope of the present disclosure should be defined by the appended claims.