Method and Arrangement for Interconnecting Horizontal Precast Structures

The present disclosure generally relates to construction technology. In particular, the present disclosure relates to connection assembly mechanisms for coupling horizontal structures for use in construction technology.

Existing construction technologies involve one-off (e.g., customized) build-on site approaches in which construction material is brought to the construction site where the actual construction is performed. This has been the traditional methodology and approach for many years but has certain inherent challenges, including non-availability of skilled workers (e.g., manual labor), heavy and expensive on-site machinery, incorrect estimate of completion time of construction projects, delays in delivery of projects, inclement weather, poor quality and wastage of materials, noise and air pollution, and cost involved in disposal of debris. This approach is also “one-off” as it provides no repeatability or scalability leverage. Each building is constructed, and each project is performed differently, and results vary widely, which may be undesirable considering present day demand for symmetrical construction projects with enhanced look and feel. However, constructing or casting each individual component of a building on site incurs significant expenditures in time and resources. It also increases a project's vulnerability to unforeseen factors, such as poor weather, worksite accidents, improper pour, etc.

Such traditional methodologies and approaches use connection methods that typically require shuttering for beam and wall structures. However, such connection methods are time and manpower intensive during installation. Further, on-site rebar binding makes such connection methods quite cumbersome to handle. Furthermore, substantial waiting time may also be observed by using such connection methods for slab and beam elements to gain sufficient strength before starting the next level of work.

In order to address the previously mentioned shortfalls of such build or cast-on site approaches, some construction projects use precast modules. Examples of the precast modules may include walls, beams, slabs, and the like, which are built in factories under factory scaling, repeatability, and in-factory conditions. The precast modules are then delivered to a building site and installed using standard connection mechanisms. Such standard connection mechanisms take less time as compared to the connection methods for the build-on site approaches.

However, even standard connection mechanisms have different challenges for several types of interconnections. In an example for slab-to-beam connections, such standard connection mechanisms increase the depth and width of the beam structure, thereby detracting from the aesthetic look of the interior of the building.

Accordingly, there remains a need in the art for an improved and compact connection assembly mechanism that not only allows for lesser skilled workers on site and saves cost and time in the installation process, but also ensures the structural continuity of the whole structure and transfer of forces between the prefabricated building modules during ultimate load conditions.

Embodiments for a connection assembly mechanism for coupling horizontal precast structures in construction technology are disclosed that address at least some of the above challenges and issues. In an aspect, the present disclosure is directed to a connection assembly mechanism. The connection assembly mechanism includes a first member configured for flush mounting with a lateral surface of a first structure. The first member has opposing first and second surfaces. The connection assembly mechanism further includes a plurality of connectors having opposing first and second ends. Each first end is coupled to the first surface of the first member, and each second end extends from the first surface of the first member. Each second end is configured for embedding within the first structure. The connection assembly mechanism further includes a second member that extends from the second surface of the first member and has opposing top and bottom surfaces. The top surface is configured for supporting a second structure, thereby coupling the first and second structures.

In some embodiments of the present disclosure, each of the plurality of connectors includes an aperture.

In some embodiments of the present disclosure, each of the plurality of connectors comprises at least partially overlapping segments of first and second connector elements.

In some embodiments of the present disclosure, a first segment of each of the plurality of connectors has a rounded corner, a second segment of each of the plurality of connectors is U-shaped, or both.

In some embodiments of the present disclosure, the overlapping segments of the first and the second connector elements are inverted with respect to each other. Each of the plurality of connectors is embedded within the first structure during casting.

In some embodiments of the present disclosure, the connection assembly mechanism further comprises a plurality of support members coupled to the bottom surface of the second member and the second surface of the first member, wherein the plurality of support members is configured for supporting the second member.

In some embodiments of the present disclosure, the bottom surface of the second structure is coupled to the top surface of the second member along the lateral surface of the first structure in accordance with a lateral orientation.

In some embodiments of the present disclosure, the bottom surface of the second structure is coupled to the top surface of the second member along the lateral surface of the first structure in accordance with a transverse orientation.

In some embodiments of the present disclosure, the first structure corresponds to a beam structure.

In some embodiments of the present disclosure, the second structure corresponds to a slab structure.

In some embodiments of the present disclosure, each of the first structure and the second structure corresponds to a precast concrete structure that extends in a horizontal direction.

In an aspect, the present disclosure is directed to a connection method that includes flush-mounting a first member with a lateral surface of a first structure, the first member having opposing first and second surfaces. A plurality of connectors has opposing first and second ends, each first end is coupled to the first surface of the first member, each second end extends from the first surface of the first member. Each second end is configured for embedding within the first structure. A second member extends from the second surface of the first member and has opposing top and bottom surfaces, wherein the top surface is configured to support a second structure, thereby coupling the first and second structures. The connection method further includes coupling the first structure and the second structure based on a support provided by the top surface of the second member to the second structure. The connection method further includes applying a screed on top surfaces of the first structure and the second structure together.

In some embodiments of the present disclosure, the method further includes determining a quantity, a type, and a size of a connection assembly mechanism for coupling the first structure with one or more second structures based on a first plurality of parameters associated with the connection assembly mechanism and a second plurality of parameters associated with at least one of the first structure and the second structure.

In some embodiments of the present disclosure, the first plurality of parameters includes material specifications of the connection assembly mechanism.

In some embodiments of the present disclosure, the material specifications of the connection assembly mechanism correspond to at least tensile strength and hardness of the connection assembly mechanism.

In some embodiments of the present disclosure, the second plurality of parameters includes at least one of a location, an orientation, a weight, and an installation level of at least one of the first structure and the second structure.

In some embodiments of the present disclosure, the method further includes coupling a plurality of support members to the bottom surface of the second member and the second surface of the first member, wherein the plurality of support members is configured for supporting the second member.

In some embodiments of the present disclosure, the method further includes coupling the bottom surface of the second structure to the top surface of the second member along the lateral surface of the first structure in accordance with a lateral orientation.

In some embodiments of the present disclosure, the method further includes coupling the bottom surface of the second structure to the top surface of the second member along the lateral surface of the first structure in accordance with a transverse orientation.

In some embodiments of the present disclosure, the bottom surface of the second structure is coupled to the top surface of the second member at a construction site.

The following detailed description is presented to enable any person skilled in the art to make and use the disclosure. For purposes of explanation, specific details are set forth to provide a thorough understanding of the present disclosure. However, it will be apparent to one skilled in the art that these specific details are not required to practice the disclosure. Descriptions of specific applications are provided only as representative examples. Various modifications to the preferred embodiments will be readily apparent to one skilled in the art, and the general principles defined herein may be applied to other embodiments and applications without departing from the scope of the disclosure. The present disclosure is not intended to be limited to the embodiments shown but is to be accorded the widest possible scope consistent with the principles and features disclosed herein.

With modernization in construction-related methodologies and technologies, there has been a rapid shift from normal customized build on-site construction methodologies to construction using modules or blocks that may be built off-site and then assembled on-site to form a construction or a building. However, in the latter case, suitable connection assembly mechanisms for each service, environmental and ultimate load conditions are of utmost importance. The role of a connection assembly mechanism is not only to fix the prefabricated structures together, but also to ensure the structural continuity of the whole structure and to transfer forces between the prefabricated structures when the system is loaded.

Conventional connection methods for build or cast-on site approaches may be too time consuming and labor intensive for execution. Further, on-site rebar binding and shuttering for beam and wall structures makes such connection methods quite cumbersome to handle. Furthermore, substantial waiting time may also be observed by using such connection methods for slab and beam elements to gain sufficient strength before starting the next level of work.

Further, standard connection mechanisms for standard precast modules are also not able to address the previously mentioned shortfalls of conventional connection methods. In an example for slab-to-beam connection, such standard connection mechanisms increase depth and width of the beam structure thereby detracting from the aesthetic look of the interior of the building.

Current connection assemblies and technologies fail to address many concerns, as described hereinbefore. This is especially true for advanced precast structures, which are lightweight due to less material requirements, are more economical (due to less labor, accelerated manufacturing, and reduced cost), and have better performance, factors that together meet today's requirements of enhanced, efficient, and robust connection assembly mechanisms.

The embodiments of the present disclosure address these concerns by providing improved and better-quality connection assembly mechanism allowing for lesser-skilled workers on site and saving cost and time in the installation process. Further, such connection assembly mechanisms also ensure the structural continuity of the whole structure and the transfer of forces between the prefabricated structures during ultimate load conditions.

The disclosed architecture/solution provides several other objects and advantages, some of which are discussed below. The present disclosure supports rapid construction of a structure including precast (prefabricated) modules accommodating erratic site constraints/conditions and/or tight construction schedules. Further, the present disclosure provides for the distribution of at least pre-compression forces across such connection assembly mechanisms for better load distribution, thus improving the durability of enclosure structure. Additionally, an increase in the load resistance of the structure may be obtained by means of embodiments in accordance with the present disclosure. In particular, the disclosed connection assembly mechanisms have very minimal settlement and little or no future challenges, hence, little, or no future maintenance is required. At the least this durability makes the structure economical and also helps reduce the construction times.

Connection assembly mechanisms, in accordance with the disclosure, provide advantages in their compactness and simplicity of manufacture and system performance. By leveraging a controlled environment production, these connection assembly mechanisms ensure quality, cost reduction, and speedy installation.

Further, connection assembly mechanisms in accordance with the present disclosure exhibit substantial fire resistance owing to metallic body, which in turn reduces insurance costs due to increased safety, security, reliability, and structural soundness.

Structurally, connection assembly mechanisms in accordance with the present disclosure provide substantial loading capacity and further offer the enclosure structure a remarkably high resistance to wind, hurricanes, floods, and other damaging environmental occurrences.

Certain terms and phrases have been used throughout the disclosure and will have the following meanings in the context of the ongoing disclosure.

“Cast-in-place concrete” or “Cast-in-situ concrete” is a building-construction technology where elements of an enclosure structure are cast at the site in formwork.

“Pre-cast structure” refers to a construction product produced by casting concrete in a reusable mold or form which is then cured in a controlled environment at an offsite location, transported to a construction site, and maneuvered into a targeted place. Examples may include pre-cast beams, slabs, wall panels, and the like.

“Wall panel” refers to a prefabricated multi-layered wall fabricated at an offsite location and installed on-site, wherein “on-site” denotes a construction site and “offsite” denotes a location away from the construction site. The wall panel may be with or without door or window openings based on the design of the enclosure structure.

“Slab” refers to a prefabricated structure formed at an offsite location and installed on-site. A slab includes a concrete base and a structural topping. The structural toppings, also referred to as topping screeds, are specialized materials applied to an existing concrete base of the slab to enhance performance, durability, and aesthetics.

“Beam” refers to a construction element that is made by casting concrete into a mold and then curing it in a controlled environment at the offsite location. Beams may be used for both load-bearing and non-load bearing applications and may be made in a variety of shapes and sizes.

“Sealant” refers to substances used to seal, block, or close gaps between enclosure structures to prevent fluids, air, and pests from passing through. These materials seal joints where dissimilar materials meet and fill any irregularities that may exist between the two surfaces.

“Modular” refers to individual and independent blocks or any mechanism or procedure for arranging them.

“Lattice girders” refer to three-dimensional, industrially prefabricated reinforcing elements. They consist of an upper chord, two lower chords, and continuous truss wires (e.g., diagonal chords). Typically, the continuous truss wires are connected to the chords by means of electric resistance welding.

is a perspective view of an enclosure structure, in accordance with some embodiments. Referring to, there are shown at least a foundation structureand multiple precast structures, including a first wall structure, a second wall structure, a slab structure, a beam structure, a staircase slab, and a connection assembly mechanism. The precast structures may be prefabricated at an offsite location away from a construction site and installed on-site at the construction site.

The foundation structuremay correspond to a monolithic cast-in-place foundation structure. The foundation structureis the lowest part of the enclosure structurethat is in direct contact with the soil and transfers loads from the enclosure structureto the soil safely. To construct the foundation structure, trenches are dug deeper into the soil till a hard stratum is reached. Reinforcement cages are incorporated, and concrete is poured. Because the foundation structureis a cast-in-place module and is poured all at once, it is erected much faster, thereby keeping labor costs low. The foundation structureis designed to account for the characteristics of the underlying soil and local environment (e.g., slope of underlying soil, soil type, compactness, local weather conditions, etc.) such that the underlying soil below the foundation structuredoes not undergo shear failure.

The first wall structuremay correspond to a level-1 wall which is installed directly on the foundation structure. The first wall structuremay be a multi-layered precast structure that can withstand load, climate changes, and daily wear and tear as may be subjected to the enclosure structure. It will be appreciated that the first wall structureobtained due to the construction technology is high quality, forming repeatable and scalable building structures.

It will be appreciated that the enclosure structureis merely illustrative of some embodiments. For example, in some embodiments, the first wall structuremay be installed indirectly on the foundation structure, such as by intermediate elements, another wall structure may be installed indirectly on the first wall structure, or both.

The first wall structuremay form an IECC energy compliant high-performance envelope. In an exemplary scenario, the first wall structuremay be, for example, an 8-inch precast insulated wall. The second wall structuremay be similar to the first wall structureand may be installed vertically above the first wall structureat level 2 of the enclosure structure. It will be appreciated that in other embodiments, the first wall structuremay have other thicknesses and dimensions.