Systems and Methods for Building Elevated Structures

This patent application claims the benefit of U.S. Provisional application Ser. No. 63/644,143, filed May 8, 2024, which is hereby expressly incorporated by reference in its entirety herein.

This disclosure relates generally to construction of elevated structures, such as buildings with multiple floors, where the floors of the buildings require additional support to the floors via shoring during their construction.

Concrete structures can require temporary support until the concrete sets to support loads. This temporary support is generally known as shoring. Generally, shoring is a method of temporarily using a system of vertical supports configured to and placed to sufficiently support the load of fresh concrete and construction loads. Shoring is removed upon completion of the construction process, when the floor is sufficiently completed to support its own weight and the construction load (e.g., floors and other loads above it). Shoring can be categorized into two different processes: (1) backshoring and (2) reshoring.

Generally, backshoring, also known as preshoring, is generally understood to be an essential technique in the construction of multi-level or multi-floor buildings (i.e., buildings that have multiple floors). It involves placing temporary vertical supports beneath freshly poured concrete slabs after the original formwork and shores have been removed. As generally understood, this process is needed to ensure that the concrete has adequate time to gain strength before bearing its own weight and supporting additional construction loads. Generally, the primary purpose of backshoring is to prevent premature deflection or failure of the new concrete slabs. To implement backshoring, vertical supports are installed through the formwork while it is carefully removed, maintaining stability and integrity. Safety considerations are critical, as the arbitrary removal of posts can lead to structural instability, requiring proper authorization before adjustments. Widely used in high-rise construction, backshoring is generally understood as necessary to enhance structural integrity.

In backshoring, shores (vertical supports) are placed snuggly under a concrete slab or structural member after the original formwork and shores are then removed from a small area at a time without allowing the slab or member to deflect. Accordingly, backshores support the slab (or other member) that does not yet support its own weight or existing construction loads from above.

In reshoring, shores are placed snuggly under a concrete slab or other structural member after the original forms and shores have been removed from a large area, requiring the new slab or structural member to deflect and support its own weight. Thus, in reshoring, the slab or structural member can support its own weight. existing construction loads can be applied before installation of reshores.

Accordingly, backshoring differs from reshoring. That is, backshoring directly supports the fresh concrete to allow the concrete to set, whereas reshoring is for transferring loads to lower floors (or levels).

Traditional method of constructing multi-level (i.e., multi-floor) building requires both backshoring and reshoring during construction. In particular, for traditional concrete floor slabs that form traditional pour strips, more shoring may be required at regions near the traditional pour strips. As additional floors are added vertically, greater number of shores can be necessary when traditional methods are used.

In some aspects, the techniques described herein relate to a self-supporting concrete slab, including: a concrete body having a thickness, a length, and a width; and a plurality of reinforcing steel bars at least partly embedded within the concrete body, wherein the concrete slab is configured to support its own weight and additional loads without requiring temporary backshoring during construction.

In some aspects, the techniques described herein relate to a self-supporting concrete slab, wherein the reinforcing steel bars are arranged to span substantially the entire length and/or width of the concrete slab.

In some aspects, the techniques described herein relate to a self-supporting concrete slab, wherein at least two of the reinforcing steel bars are connected via a splicing device.

In some aspects, the techniques described herein relate to a self-supporting concrete slab, wherein the reinforcing steel bars are arranged to not span substantially the entire length and/or width of the concrete slab.

In some aspects, the techniques described herein relate to a self-supporting concrete slab, wherein the reinforcing steel bars are also at least partly embedded within a second concrete body and arranged to be movable relative to the second concrete body.

In some aspects, the techniques described herein relate to a multi-floor building, including: the self-supporting concrete slab.

In some aspects, the techniques described herein relate to a multi-floor building, further including: at least five floors stacked vertically, wherein the at least five floors are configured such that, during the construction of a top-most floor, four floors below the top-most floor does not include any shoring.

In some aspects, the techniques described herein relate to a multi-floor building, further including: at least five floors stacked vertically, wherein the at least five floors are configured such that, during the construction of a top-most floor, four floors below the top-most floor does not include any backshoring.

In some aspects, the techniques described herein relate to a multi-floor building, further including: at least five floors stacked vertically, wherein the at least five floors are configured such that, during the construction of a top-most floor, four floors below the top-most floor does not include any reshoring.

In some aspects, the techniques described herein relate to a multi-floor building, further including: at least five floors stacked vertically, wherein the at least five floors are configured such that, during the construction of a top-most floor, a bottom-most floor does not include any shoring.

In some aspects, the techniques described herein relate to a multi-floor building, further including: at least five floors stacked vertically, wherein the at least five floors are configured such that, during the construction of a top-most floor, a bottom-most floor does not include any backshoring.

In some aspects, the techniques described herein relate to a multi-floor building, further including: at least five floors stacked vertically, wherein the at least five floors are configured such that, during the construction of a top-most floor, a bottom-most floor does not include any reshoring.

In some aspects, the techniques described herein relate to a method of constructing a multi-floor building, wherein the multi-floor building includes at least four floors stacked vertically, the method including: forming a concrete floor slab at a top-most floor that includes reinforcing steel rebars arranged to span the concrete floor slab, wherein the concrete floor slab is configured to support its own weight without requiring any temporary backshoring during the forming of the concrete floor slab.

In some aspects, the techniques described herein relate to a method, wherein the method does not include any shoring four floors below the top-most floor during the forming step.

In some aspects, the techniques described herein relate to a method, wherein the method does not include any backshoring four floors below the top-most floor during the forming step.

In some aspects, the techniques described herein relate to a method, wherein the method does not include any reshoring four floors below the top-most floor during the forming step.

In some aspects, the techniques described herein relate to a method, wherein the method does not include any shoring at a bottom-most floor during the forming step.

In some aspects, the techniques described herein relate to a method, wherein the method does not include any backshoring at a bottom-most floor during the forming step.

In some aspects, the techniques described herein relate to a method, wherein the method does not include any reshoring at a bottom-most floor during the forming step.

In some aspects, the techniques described herein relate to a building construction, including: a plurality of floors stacked vertically, each of the plurality of floors including a self-supporting concrete slab, wherein the self-supporting concrete slab includes: a concrete body having a thickness, a length, and a width, and a plurality of reinforcing steel bars at least partly embedded within the concrete body, wherein the concrete slab is configured to support its own weight and additional loads without requiring temporary backshoring during construction.

Shoring is generally necessary in multi-floor building construction that has concrete floors. Generally, shoring is necessary for the concrete floor slabs because the construction methods must include a building design which is code compliant. Traditional methods generally requires a leave-outs (gaps) for the concrete floor slabs during construction to allow for the concrete floor slabs to shorten. Because of the leave-outs (gaps) form disconnecting regions between the floor slabs, the floor slabs, generally, cannot be self-supporting. Thus, backshoring is necessary during the construction of the floor slabs.

shows a schematic diagram of a traditional buildingconstruction at a time when nine floors,,,,,,,,are built vertically. The top floor, which is the floor being formed, includes concrete floor slabs separated (i.e., disconnected) by a leave-out. Each of the other floors,,,,,,below the top flooralso include similar leave-outs.

The leave-outcan be 3 feet to 8 feet in distance, or greater distances. The leave-outhave been incorporated in traditional concrete slab (e.g., post-tensioned concrete slabs) as being necessary to minimize cracking caused by concrete shrinkage restrained by vertical elements of the lateral system. Accordingly, the floor(and each of the slabs separated by the leave-out) are not self-supporting. Likewise, all of the lower floors-that have leave-outsare not self-supporting. Additionally, they cannot support the load from the floors above them.

The leave-outsare filled at a later time, after the concrete slabs are fully formed (no longer shrinking). Only then is the entire concrete floor slab connected together forming a one contiguous floor of the building. At this time, the floor may become self-supporting, and the reshoringsystems can be removed.

Generally, leave-outis located at an inflection point of the span. Accordingly, a very careful design and execution of the design is necessary to ensure the location of the leave-out. Backshoringis thus necessary to support the concrete floor slabs, especially near the leave-out.

Further, as the multi-floor buildingis constructed, each additional floor adds additional load to the lower (already completed) floors. Accordingly, it can become necessary to add reshoringto all or nearly all of the lower floors. For example, while the top flooris being formed, backshoringis provided to support that floorat the immediate floor below. The floors-below these upper floors,can require substantial reshoringto support the load of the upper floors. As such, at the lower floors, e.g., floors,, an increased number of reshoringmay be necessary, in particular near the areas where the leave-outstill exist and have not been filled in yet. When the number of reshoringare extensive, that floor or areas near the leave-outmay not be reasonably accessible to other workers. Thus, there can be significant delay in the project's completion due to the required backshoringand reshoring.

shows a schematic diagram of a multi-floor buildingconstruction according to exemplary embodiments.shows its construction, at a time when nine floors,,,,,,,,are built vertically. The top floor, which is the floor being formed, includes concrete floor slabs that is not by a traditional leave-out (seein comparison). Each of the other floors,,,,,,,below the top flooralso do not include traditional leave-outs.

The concrete slabs at each of the floors-are connected mechanically to be fully self-supporting. Accordingly, when the top-most flooris being constructed, the flooris configured to be self-supporting. Thus, backshoring is not necessary. That is, according to some embodiments, the system and methods do not include backshoring.

shows that the flooris supported by reshoringfrom floor(immediately beneath floor) to support the load on the floorwhile the flooris being constructed. Some of the load can be further supported by additional reshoringat floor. Some of the load can also be further supported by additional reshoringat floor.

According to some embodiments, at four floors below floor(e.g.,), reshoring is not necessary, as that floorcan fully support itself and the load above it. According to some embodiments, at five floors below floor(e.g.,), reshoring is not necessary, as that floorcan fully support itself and the load above it. According to some embodiments, at six floors below floor(e.g.,), reshoring is not necessary, as that floorcan fully support itself and the load above it. According to some embodiments, at seven floors below floor(e.g.,), reshoring is not necessary, as that floorcan fully support itself and the load above it. According to some embodiments, at the lower-most floor below floor(e.g.,), reshoring is not necessary, as that floorcan fully support itself and the load above it. According to some embodiments, at four or more floors below floor(e.g.,-), reshoring is not necessary, as the lower floors-can each fully support itself and the load above it. According to some embodiments, at five or more floors below floor(e.g.,-), reshoring is not necessary, as the lower floors-can each fully support itself and the load above it. According to some embodiments, at six or more floors below floor(e.g.,-), reshoring is not necessary, as the lower floors-can each fully support itself and the load above it. According to some embodiments, at seven or more floors below floor(e.g.,-), reshoring is not necessary, as the lower floors-can each fully support itself and the load above it. According to some embodiments, at eight or more floors below floor(e.g.,), reshoring is not necessary, as the lower floorscan each fully support itself and the load above it.

Yet, the concrete slabs at each of the floors-can be post-tensioned or otherwise to minimize cracking caused by concrete shrinkage restrained by vertical elements of the lateral system. Additionally, as the floors are completed, they can fully support the load from the floors above them. That is, as the multi-floor buildingis constructed, each additional floor adds additional load to the lower (already completed) floors. However, because the floors do not have traditional leave-outs, and further can be mechanically self-supporting, it can be unnecessary to add reshoring to the lower floors. And the shoring (e.g., reshoring) can be removed from the lower floors as the upper floors are being constructed.

For example, while the top flooris being formed, backshoring is not provided to support that floorat the immediate floor below. Instead, some reshoringcan be provided to support the load on the top floor. The floors-below these upper floors,can require some reshoringto support the load of the upper floors,. However, at the lower floors, e.g., floors-, reshoring is not necessary. Thus, any reshoring equipment can be removed from these floors-, allowing for other equipment and workers to have access to the entire floor. This can significantly speed up the project's completion.

shows an exemplary flowchart for a method of constructing a multi-floor building. The multi-floor building includes at least four floors stacked vertically. The method includes, at least, forminga concrete floor slab at a top-most floor that includes reinforcing steel rebars arranged to span the concrete floor slab, wherein the concrete floor slab is configured to support its own weight without requiring any temporary backshoring during the forming of the concrete floor slab.

As an example, the following construction productivity comparison can be expected between a traditional method (e.g.,) versus the embodiments disclosed herein (e.g.,). The TABLE below only considers the pour strip bay/span. Construction assumed to progress 1 level per week. Slabs are expected to be 8 inches (100 psf). Pour back time is assumed 28 days. The table below is a snapshot just before level 7 is cast.

As can be understood from the above TABLE, self-supporting concrete slabs can eliminate the need for temporary backshoring, streamlining the building process, and enhancing productivity. These slabs are engineered to support their own weight and additional loads without relying on external supports, reducing labor and material costs while accelerating construction schedules. The process incorporates advanced reinforcement techniques, including post-tensioning and code-compliant splicing methods, to ensure structural integrity, continuity, and compliance with building codes. By simplifying forming processes and enabling early access for other trades, self-supporting slabs offer significant economic and operational advantages, making them a superior alternative to traditional slab designs.

show schematic diagrams of an exemplary self-supporting concrete floor constructionaccording to some embodiments. The self-supporting concrete floor constructionincludes a first concrete slaband a second concrete slab. The first concrete slaband the second concrete slabare formed one after the other, without a traditional leave-out therebetween. The first concrete slabis formed with a plurality of rebarsconnected to a rebar splicing coupler. A rebarcan be connected to the rebar splicing couplervia a threaded connection. Alternatively, the connection between the plurality of rebarsand thecan be via a weld, a mechanical connection, or other means. The rebar splicing couplerincludes a body defining an internal cavity through which a portion of another rebarcan be inserted. The rebar splicing couplerhas an opening for receiving the portion of the rebar, and the opening and/or the internal cavity is configured in such a way that the rebarcan move vertically and horizontally. That is, the rebar splicing coupleris not configured to support rebarin such a way to prevent vertical movement of the rebarduring the construction and forming of the second concrete slab. That is to say, the coupler and/or coupled connection between the plurality of rebarsand the rebarvia the rebar splicing coupleris non-self-supporting. Thus, the combined system of the plurality of rebars, the rebar splicing coupler, and the rebarforms a non-self-supporting connection for the floor. To compensate for this, a dowel(e.g., a short rebar made of steel, aluminum, or other similarly hard material) that has a smooth surface that is greased and/or inserted inside a sleeve on one sideis provided substantially in a parallel with respect to the rebarand/or the rebar. The dowelprovides sufficient supporting property for the floorto be self-supporting. The smooth surface and the grease and/or the sleeve allows for the dowelto move along with the shrinkage of the one or more slab(s),. That is, the slabs,can move away from each other, relatively speaking, during the curing of the concrete(s). Generally, the later formed concrete slab, e.g., slab, would shrink away from the previously poured slab, e.g., slab. According to this exemplary embodiment, the flooris self-supporting, and there is no need for backshoring to support the floorduring its construction.

shows a schematic diagram of an exemplary self-supporting concrete floor constructionaccording to some embodiments. The self-supporting concrete floor constructionincludes a first concrete slaband a second concrete slab. The first concrete slaband the second concrete slabare formed one after the other, without a traditional leave-out therebetween. The first concrete slabis formed with a plurality of rebarsconnected to a rebar splicing coupler. A rebarcan be connected to the rebar splicing couplervia a threaded connection. Alternatively, the connection between the plurality of rebarsand thecan be via a weld, a mechanical connection, or other means. The rebar splicing couplerincludes a body defining an internal cavity through which a portion of another rebarcan be inserted. The rebar splicing couplerhas an opening for receiving the portion of the rebar, and the opening and/or the internal cavity is configured in such a way that the rebarcannot move vertically, but may move horizontally (relative to the floor). That is, the rebar splicing coupleris configured to support rebarin such a way to prevent vertical movement of the rebarduring the construction and forming of the second concrete slab. That is to say, the coupler and/or coupled connection between the plurality of rebarsand the rebarvia the rebar splicing couplerbecomes and/or is self-supporting. Thus, the combined system of the plurality of rebars, the rebar splicing coupler, and the rebarforms a self-supporting connection for the floor. In addition, a dowelthat has a smooth surface that is greased and/or inserted inside a sleeve on one sideis provided substantially in a parallel with respect to the rebarand/or the rebar. The dowelprovides additional supporting property for the floorto be self-supporting. The smooth surface and the grease and/or the sleeve allows for the dowelto move along with the shrinkage of the one or more slab(s),. That is, the slabs,can move away from each other, relatively speaking, during the curing of the concrete(s). Generally, the later formed concrete slab, e.g., slab, would shrink away from the previously poured slab, e.g., slab. According to this exemplary embodiment, the flooris self-supporting, and there is no need for backshoring to support the floorduring its construction.

shows a schematic diagram of an exemplary self-supporting concrete floor constructionaccording to some embodiments. The self-supporting concrete floor constructionincludes a first concrete slaband a second concrete slab. The first concrete slaband the second concrete slabare formed one after the other, without a traditional leave-out therebetween. Similar to the floorshown in, first concrete slabis formed with a plurality of rebarsconnected to a rebar splicing coupler. A rebarcan be connected to the rebar splicing couplervia a threaded connection. Alternatively, the connection between the plurality of rebarsand thecan be via a weld, a mechanical connection, or other means. The rebar splicing couplerincludes a body defining an internal cavity through which a portion of another rebarcan be inserted. The rebar splicing couplerhas an opening for receiving the portion of the rebar, and the opening and/or the internal cavity is configured in such a way that the rebarcannot move vertically, but may move horizontally (relative to the floor). That is, the rebar splicing coupleris configured to support rebarin such a way to prevent vertical movement of the rebarduring the construction and forming of the second concrete slab. That is to say, the coupler and/or coupled connection between the plurality of rebarsand the rebarvia the rebar splicing couplerbecomes and/or is self-supporting. Thus, the combined system of the plurality of rebars, the rebar splicing coupler, and the rebarforms a self-supporting connection for the floor. However, the floordoes not include any of the dowels as shown in. That is, the rebars,being connected via the coupleris sufficient for the floorto be self-supporting during construction when at least one of the slabs,moves away from the other, relatively speaking. Generally, the later formed concrete slab, e.g., slab, would shrink away from the previously poured slab, e.g., slab. According to this exemplary embodiment, the flooris self-supporting, and there is no need for backshoring to support the floorduring its construction.

According to some embodiments, any of the methods, systems, and components shown inare combined, as long as the floor itself is self-supporting during the floor's construction. Accordingly, such embodiments do not require backshoring.

Any or all portion(s) of any of the embodiments and/or clauses disclosed herein may be combined with any other portion(s) of any embodiment and/or clauses.