Method and Arrangement for Coupling Horizontal Vertical Precast Structures

The present disclosure generally relates to construction technology. In particular, the present disclosure relates to a connection assembly mechanism for coupling horizontal and vertical precast 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 include placing rebars and lapping them together with adjacent bars during formwork. However, such connection methods may consume a substantial time and require more workers for execution. 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 aforesaid 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 lesser 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-wall connection or beam-to-wall connection, such standard connection mechanisms require pull out bar connection. Waiting time is to be allowed till connection strength is achieved. Overall, such standard connection mechanisms hamper the aesthetic look of the interior of the building.

Embodiments for a connection assembly mechanism for coupling precast structure, such as a horizontal precast structure and a vertical precast structure, 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 flat bracket having a first surface and a second surface. The second surface is configured for flush mounting with a horizontal precast structure. A first set of shear connectors extending from the first surface is configured for embedding within the horizontal precast structure. The connection assembly mechanism further includes a wall bracket having a horizontal flange and a vertical flange orthogonal to each other. An outer surface of the horizontal flange is configured for flush-mounting with a base portion of a pocket member of a vertical precast structure. A second set of shear connectors extending from inner surfaces of the horizontal flange and the vertical flange is configured for embedding within the vertical precast structure. The connection assembly mechanism further includes a connection mechanism configured for coupling the outer surface of the horizontal flange of the wall bracket and the second surface of the flat bracket, thereby coupling the horizontal precast structure and the vertical precast structure at a construction site.

In an embodiment of the present disclosure, the connection assembly mechanism further comprises an elastic pad configured for slab bearing between the second surface of the flat bracket and the outer surface of the horizontal flange of the wall bracket.

In an embodiment of the present disclosure, the wall bracket further comprises an angular elongated connector configured for embedding within the vertical precast structure.

In an embodiment of the present disclosure, the horizontal flange and the vertical flange of the wall bracket conform with an edge portion of the base portion of the pocket member provided at a top portion of the vertical precast structure.

In an embodiment of the present disclosure, the connection assembly mechanism further comprises an outer surface of the vertical flange of the wall bracket configured for chamfer-mounting at a vertical portion orthogonal to the base portion of the pocket member of the vertical precast structure.

In an embodiment of the present disclosure, the connection assembly mechanism further comprises a flat bar configured for mechanically coupling the outer surface of the horizontal flange of the wall bracket with the second surface of the flat bracket at a first side with respect to the first set of shear connectors.

In an embodiment of the present disclosure, the connection assembly mechanism further comprises a flat bar configured for mechanically coupling the outer surface of the horizontal flange of the wall bracket with the second surface of the flat bracket at a second side with respect to the first set of shear connectors.

In an embodiment of the present disclosure, the first set of shear connectors is further configured for embedding within a concrete portion of the horizontal precast structure. Top portions of the first set of shear connectors are further configured for embedding in a base of a structural topping of the horizontal precast structure.

In an embodiment of the present disclosure, the vertical precast structure is a precast wall.

In an aspect, the present disclosure is directed to a connection method that includes flush-mounting a second surface of a flat bracket with a horizontal precast structure. A first set of shear connectors extend from a first surface of the flat bracket and is embedded within the horizontal precast structure. The connection method further includes flush-mounting an outer surface of a horizontal flange of a wall bracket with a base portion of a pocket member of a vertical precast structure. A second set of shear connectors extend from a set of inner surfaces of the wall bracket and is embedded within the vertical precast structure. The connection method further includes coupling the outer surface of the horizontal flange of the wall bracket and the second surface of the flat bracket using a connection mechanism at a construction site.

In an embodiment of the present disclosure, the connection method further includes determining a type, a quantity, and a size of a connection assembly mechanism for coupling the horizontal precast structure and the vertical precast structure based on a first set of parameters associated with the connection assembly mechanism and a second set of parameters associated with at least one of the horizontal precast structure and the vertical precast structure.

In an embodiment of the present disclosure, the first set of parameters includes material specifications of the connection assembly mechanism. In an embodiment 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 an embodiment of the present disclosure, the second set of parameters includes environmental conditions and at least one of a location, an orientation, and a weight of at least one of the horizontal precast structure and the vertical precast structure.

In an embodiment of the present disclosure, the connection method further includes placing an elastic pad for slab bearing between the second surface of the flat bracket and the outer surface of the horizontal flange of the wall bracket.

In an embodiment of the present disclosure, the second surface of the flat bracket is flush-mounted along an edge of a bottom surface of the horizontal precast structure. The horizontal flange and a vertical flange of the wall bracket conform with an edge portion of the base portion of the pocket member provided at a top portion of the vertical precast structure. The horizontal flange and the vertical flange are arranged orthogonally with respect to each other.

In an embodiment of the present disclosure, the connection method further includes chamfer-mounting an outer surface of the vertical flange of the wall bracket at a vertical portion orthogonal to the base portion of the pocket member of the vertical precast structure.

In an embodiment of the present disclosure, the method further comprises coupling the outer surface of the horizontal flange of the wall bracket with the second surface of the flat bracket at a first side with respect to the first set of shear connectors using a flat bar.

In an embodiment of the present disclosure, the method further comprises coupling the outer surface of the horizontal flange of the wall bracket with the second surface of the flat bracket at a second side with respect to the first set of shear connectors using a flat bar.

In an embodiment of the present disclosure, the method further comprises embedding top portions of the first set of shear connectors in a base of a structural topping of the horizontal precast structure.

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 assemblies 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 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 aforesaid shortfalls of conventional connection methods. By ways of different examples, the standard connection mechanisms require pull out bar connection for slab-to-wall, require skilled labor for non-shrink grouting and pressure grouting, and the like. Further, standard connection mechanisms demand waiting time till connection or grout strength is achieved. Also, the overall aesthetic look of the interior of the building is hampered due to pull-out bars and different colored grouts by such standard connection mechanisms.

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 assemblies.

Accordingly, there is a need in the art for an improved 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.

The embodiments of the present disclosure address these concerns by providing improved and better-quality connection assembly mechanisms, 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 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 at least pre-compression forces across such connection assembly mechanisms, 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. At the least this durability makes the structure economical and helps reduce the construction times.

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

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

Structurally, the connection assembly mechanism in accordance with the present disclosure provides substantial loading capacity and further offers 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 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.

“Grout” is a filling, which when poured into a receptacle will fill in the receptacle and consolidate the adjacent edges into a solid mass, such as cementitious mortar or other cement-based materials, bentonite, bentonite/sand mixtures, graphite-based materials, carbon nanotubes and nanofibers, or similar materials.

“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, filling gaps regardless of any irregularities that may exist between the two joint surfaces.

“Backer Rod” refers to a backing in joints. The Backer Rod controls the sealant thickness and amount of sealant needed to fill a gap between joints. The backer rod forces the sealant to the sidewalls to ensure contact and proper adhesion of the sealant.

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

“Lattice girders” refers 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.

illustrates a first viewA of an enclosure structure, in accordance with some embodiments.illustrates a second viewB of the enclosure structurewith only a portion of a vertical precast structure and a horizontal precast structure, in accordance with some embodiments. Referring to, there is shown the first viewA of the enclosure structurethat includes at least a foundation structure, a wall structure, another wall structure, a slab structure, a beam structure, and a staircase slab. There are further shown various connecting members, such as a connection assembly mechanism. It will be appreciated that various enclosure structures, such as the wall structure, the other wall structure, the slab structure, the beam structure, and the staircase slab, may be precast structures prefabricated at an offsite location away from a construction site and installed on-site at the construction site. Referring to, there are further shown portions of the wall structure, such as a pocket memberin the top portion of the wall structure, a baseof the pocket member, and a chamfered portionalong a vertical portion adjacent to the baseof the pocket member. There is further shown a horizontal precast structurethat represents both the slab structureand the beam structurefor brevity. Various portions of the horizontal precast structureinclude a horizontal plankA and a horizontal toppingB. There is further shown a recess.

Referring back to, in some embodiments, the foundation structurecorresponds 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.

In some embodiments, the wall structurecorresponds to a level-1 wall which is installed directly on the foundation structure. In some embodiments, the wall structureis 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 wall structureobtained due to the construction technology is high quality, forming repeatable and scalable building structures. The wall structuremay form an IECC energy compliant high-performance envelope. In some embodiments, the wall structureis, for example, an 8 inches precast insulated wall. It will be appreciated that in other embodiments, the wall structurehas other thicknesses and dimensions.