Method and Arrangement for Coupling Vertical Precast Structures

The present disclosure generally relates to construction technology. In particular, the present disclosure relates to a connection assembly mechanism for coupling 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 workforce (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 are time and manpower intensive during installation. Further, on-site rebar binding and requirement for shuttering for slab and wall makes such connection methods quite cumbersome to handle. Furthermore, substantial waiting time may also be observed by using such connection methods for slabs 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, that 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 wall-to-wall connection, such standard connection mechanisms require pull out bar connection. Waiting time is to be allowed until 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 structures, such as vertical 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 hollow box section member having a first set of elongated connectors. The first set of elongated connectors extends from an outer surface of a first vertical member of the hollow box section member and is configured for embedding within a horizontal precast structure. An outer surface of a second vertical member of the hollow box section member is configured for flush-mounting on a lateral side of the horizontal precast structure. The connection assembly mechanism further includes a first wall bracket having a first horizontal flange and a first vertical flange orthogonal to each other. A first set of shear connectors extending from inner surfaces of the first horizontal flange and the first vertical flange is configured for embedding within a base portion of a pocket member of a first vertical precast structure. An outer surface of the first horizontal flange is configured for flush-mounting with the base portion of the pocket member of the first vertical precast structure. The connection assembly mechanism further includes a second wall bracket having a second horizontal flange and a second vertical flange orthogonal to each other. A second set of shear connectors extending from inner surfaces of the second horizontal flange and the second vertical flange is configured for embedding towards the bottom end of a second vertical precast structure. An outer surface of the second horizontal flange is configured for flush-mounting with a base portion of the second vertical precast structure. The connection assembly mechanism further includes at least two connection mechanisms configured for coupling the outer surface of the first horizontal flange of the first wall bracket with an outer surface of a first horizontal member of the hollow box section member, and the outer surface of the second horizontal flange of the second wall bracket is coupled with an outer surface of a second horizontal member of the hollow box section member, thereby coupling the first vertical precast structure and the second vertical precast structure.

In some embodiments of the present disclosure, the connection mechanism further comprises a first clastic pad configured for slab bearing between the outer surface of the first horizontal flange of the first wall bracket and the outer surface of the first horizontal member of the hollow box section member.

In some embodiments of the present disclosure, the connection mechanism further comprises a second elastic pad configured for slab bearing between the outer surface of the second horizontal flange of the second wall bracket and the outer surface of the second horizontal member of the hollow box section member.

In some embodiments of the present disclosure, the first wall bracket further comprises a first angular elongated connector configured embedding within the first vertical precast structure, and the second wall bracket further comprises a second angular elongated connector configured embedding within the second vertical precast structure.

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

In some embodiments of the present disclosure, the outer surface of the first vertical flange of the first wall bracket is configured for flush-mounting at a vertical portion orthogonal to the base portion of the pocket member of the first vertical precast structure.

In some embodiments of the present disclosure, the second horizontal flange and the second vertical flange of the second wall bracket conform with an edge portion of the base portion of the second vertical precast structure.

In some embodiments of the present disclosure, the outer surface of the second vertical flange of the second wall bracket is configured for flush-mounting at a vertical portion orthogonal to the base portion of the second vertical precast structure.

In some embodiments of the present disclosure, each connection mechanism of the at least two connection mechanisms corresponds to one of a welded connection using a flat bar, a direct welded connection, a fastening mechanism, or a chemical affixture.

In some embodiments of the present disclosure, a recess is formed between inner wall of the pocket member of the first vertical precast structure and the outer surface of the second vertical member of the hollow box section member flush-mounted on the lateral side of the horizontal precast structure.

In some embodiments of the present disclosure, the recess is filled with non-shrink grout.

In some embodiments of the present disclosure, the first set of elongated connectors comprises base-side connectors configured for embedding within a concrete portion of the horizontal precast structure. The first set of elongated connectors further comprises top-side connectors configured for embedding within a structural topping of the horizontal precast structure.

In some embodiments of the present disclosure, the horizontal precast structure is one of a precast slab or a precast beam.

In some embodiments of the present disclosure, the first vertical precast structure is a bottom wall, and the second vertical precast structure is a top wall.

In an aspect, the present disclosure is directed to a connection method that includes flush-mounting an outer surface of a second vertical member of a hollow box section member with a lateral side of the horizontal precast structure. A first set of elongated connectors, extending from an outer surface of a first vertical member of the hollow box section member, is embedded within a horizontal precast structure. The connection method further includes flush-mounting an outer surface of a first horizontal flange of a first wall bracket with a base portion of a pocket member of a first vertical precast structure. A first set of shear connectors extending from inner surfaces of the first horizontal flange and a first vertical flange of the first wall bracket is embedded within the base portion of a pocket member of the first vertical precast structure. The connection method further includes flush-mounting an outer surface of a second horizontal flange with a base portion of a second vertical precast structure. A second set of shear connectors extending from inner surfaces of the second horizontal flange and a second vertical flange is embedded towards the bottom end of the second vertical precast structure. The connection method further includes coupling the outer surfaces of the first horizontal flange of the first wall bracket and the second horizontal flange of the second wall bracket with respective outer surfaces of a first horizontal member and a second horizontal member of the hollow box section member, through at least two connection mechanisms at a construction site, thereby coupling the first vertical precast structure and the second vertical precast structure.

In some embodiments 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 first vertical precast structure and the second 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 first vertical precast structure and the second vertical precast structure and the horizontal precast structure.

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

In some embodiments 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 first and the second vertical precast structures.

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.

To overcome the challenges associated with conventional connection methods, standard connection mechanisms for standard precast modules were developed. However, such standard connection mechanisms were also not able to address the aforesaid shortfalls of the 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.

Clearly, 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 remains a need in the art for an improved connection assembly mechanism that not only requires 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 assemblies that requiring lesser skilled workers on site and saving cost and time in the installation process. Further, such connection assemblies 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 at least pre-compression forces across such connection assemblies, thus improving the durability of enclosure structure. Additionally, an increase in the load resistance of the structure is able to be obtained by means of embodiments in accordance with the present disclosure. In particular, the disclosed connection assemblies 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 assemblies in accordance with the embodiments provide advantages in their simplicity of manufacture and system performance. By leveraging a controlled environment production, these connection assemblies 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 is able to be with or without door or window opening 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 are able to be used for both load-bearing and non-load bearing applications and are able to 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. It 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” are 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 two vertical precast structures and a horizontal precast structure, in accordance with some embodiments. Referring to, the enclosure structureincludes precast structures including a foundation structure, a first wall structure, a second 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 should be noted that various enclosure structures, such as the first wall structure, the second wall structure, the slab structure, the beam structure, and the staircase slab, are able to 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 first wall structure, such as a pocket memberin the top portion of the first wall structure. In some embodiments, the pocket memberhas a base portionand a vertical portion. There is further shown a recess.

Referring 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 until 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 first wall structurecorresponds to a level-1 wall which is installed directly on the foundation structure. In some embodiments, the first wall structureis able to be a multi-layered precast structure that is able to 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. In some embodiments, the first wall structureforms an IECC energy compliant high-performance envelope. In some embodiments, the first wall structureis, for example, an 8 inches precast insulated wall. In some embodiments, the second wall structureis able to be similar to the first wall structureand is able to be installed vertically above the first wall structureat level 2 of the enclosure structure. It will be appreciated that the enclosure structureis merely illustrative of some embodiments. For example, in some embodiments, the first wall structureis able to be installed indirectly on the foundation structure, such as by intermediate elements, the second wall structureis able to be installed indirectly on the first wall structure, or both.

In some embodiments, the slab structurecorresponds to a horizontal precast structure that creates a flat horizontal surface, such as part of a floor, a roof deck, and ceiling. In some embodiments, the slab structureis able to be generally several inches thick and supported by the beam structure, the first wall structure, the second wall structure, column, or the ground. In some embodiments, the slab structureis able to include a concrete base and a structural topping, as further described in. The structural topping is able to be specialized materials applied to an existing concrete base of the slab structureto enhance performance, durability, and aesthetics. In some embodiments, the slab structureis able to be a lattice girder slab that acts as permanent formwork and as precast soffits for robust, high-capacity composite slabs. The slab structureis able to be cast with most, if not all, of the bottom reinforcement; the top reinforcement is able to be fixed in situ.