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WO2012106650A1 - Appareil et procédé de construction préfabriquée - Google Patents

Appareil et procédé de construction préfabriquée Download PDF

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Publication number
WO2012106650A1
WO2012106650A1 PCT/US2012/023850 US2012023850W WO2012106650A1 WO 2012106650 A1 WO2012106650 A1 WO 2012106650A1 US 2012023850 W US2012023850 W US 2012023850W WO 2012106650 A1 WO2012106650 A1 WO 2012106650A1
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WIPO (PCT)
Prior art keywords
wall
joint
walls
precast
finger
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PCT/US2012/023850
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David W. Powell
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    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
    • E04B5/00—Floors; Floor construction with regard to insulation; Connections specially adapted therefor
    • E04B5/02—Load-carrying floor structures formed substantially of prefabricated units
    • E04B5/04—Load-carrying floor structures formed substantially of prefabricated units with beams or slabs of concrete or other stone-like material, e.g. asbestos cement
    • E04B5/043—Load-carrying floor structures formed substantially of prefabricated units with beams or slabs of concrete or other stone-like material, e.g. asbestos cement having elongated hollow cores
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
    • E04B1/00—Constructions in general; Structures which are not restricted either to walls, e.g. partitions, or floors or ceilings or roofs
    • E04B1/02—Structures consisting primarily of load-supporting, block-shaped, or slab-shaped elements
    • E04B1/04—Structures consisting primarily of load-supporting, block-shaped, or slab-shaped elements the elements consisting of concrete, e.g. reinforced concrete, or other stone-like material

Definitions

  • This invention is related to a building system comprising a combination of pre-cast structural elements.
  • Conventional construction generally consists either cast-in-place construction with obstructive and costly formwork, or of interconnected stick or panel framing that relies on diagonal bracing or shear walls for lateral stability.
  • This specification describes an example set of joint configurations, the assembly process for building each joint type, and a detailed process for assembling a building using the LadderBlock wall system. Steps in this process are repetitive, and are planned and sequenced with the aid of a 3D model that is used to produce 3D erection drawings that are clear and concise.
  • This innovate building process is executed by a small professional crew that advances the work with confidence, safety, and speed.
  • FIGS. 1-164 show example construction elements, modules, and structures.
  • the most basic wall joint is a corner formed by two intersecting walls.
  • Figure 1 shows the components required to build such a joint: two wall ends with precision cast fingers that interlace shown at a 300mm vertical spacing with a standard vertical erection tolerance of 30mm between fingers. Joint details are shown here for a cutaway section, where each wall is cut at 500mm from the center of the joint, so this and following details generally show what can be thought of as a 1 meter square joint "building block". In reality, the wall continues to a similar joint at the far end of the wall, and may have intermediate walls framing into it between its ends.
  • the finger joint configuration shown is for a floor to floor height of 3.3 meters, where the walls support 200mm thick hollow core.
  • the set of details shown here can be used to build a wall of any height.
  • heights are adjusted in 300mm increments by the addition or omission of whole fingers, but any intermediate height can be delivered by also incorporating partial height fingers.
  • a centering pipe and a vertical rebar pin are required to assemble the joint.
  • Figure 2 shows two panel ends with their fingers laced together and aligned to allow the insertion of the centering pipe, which is shown partially inserted here.
  • Figure 3 shows the centering pipe fully inserted, the rebar pin inserted through the centering pipe and through all of the interlaced fingers.
  • the rebar pin is shown with a coupler pre-attached to the top of the bar, as would be installed at a joint that aligns with a wall intersection at the level above. The pin simply drops into an oversized hole that is predrilled in the slab, and is grouted in after the erection is complete and the crane is off the site.
  • the finger joint pattern leaves a gap at the base of the wall. This gap offers access required to make the connection of the vertical pin to the foundation or other supporting structure, and is ultimately filled in the grouting process described below.
  • the centering pipe is a simple but innovative tool that works well with the LadderBlock wall system to enable a superior method for assembling a precast building, as described in detail below.
  • the centering pipe is made with a short length of nominal 25mm (1") diameter standard (Schedule 40) steel pipe that is flared at its top end. It naturally nests (Fig. 4) with a consistent fit but little free play into the nominal 32mm (1 1 ⁇ 4") diameter standard (Schedule 40) steel pipe sleeve that is cast into each finger joint. Both pipes are typically of galvanized steel, although they could be of other materials. They end up encapsulated in grout that further protects them from corrosion.
  • the second wall When the second wall is hoisted into place, its fingers are floating free within the joint as it is aligned and the centering pipe is stabbed into the top finger of the hoisted panel.
  • the top of the centering pipe is flared to prevent it from falling through the top finger, and the flare also presents something of an oversized nail head to facilitate driving the top of the pipe down with a hammer, if that is required to fully seat the centering pipe.
  • the second function of the centering pipe then comes into play.
  • the pipe serves as a lateral brace to both walls, so the crane hoisting lines can be released immediately and the crane can go pick the next wall block.
  • For the joint to fail would require the shearing of the steel pipe across the gapped joint.
  • longer centering pipes can be specified to engage additional fingers and additional pipe shearing planes.
  • the centering pipe yields a safe and stable joint immediately. This allows the grouting process, which further solidifies and locks the geometry of the joint, to follow on after the erection of the structure is complete and the crane is off the site. As crane time represents a major expense, this innovation offers significant cost savings in comparison with conventional precast construction.
  • the centering pipe serves its third function - as a hollow conduit for the passage of the vertical rebar joint pin (Fig. 6).
  • the centering pipe could accommodate steel strands to enable the vertical post- tensioning of the assembly.
  • a further innovation is introduced in the detailing of variable length centering pipes.
  • centering pipes are provided with holes that accommodate a steel stop pin, shown here as a J hook.
  • Figure 8 shows a "four finger" centering pipe that is lowered through a cutaway section of the two topmost fingers of what will ultimately be a four wall finger joint. The centering pipe is held at that height by the stop pin so that it does not extend into the open joint, which awaits the insertion of the third wall.
  • the stop pin is moved to the next hole up on the centering pipe, which is lowered into the newly aligned third wall (Fig.9).
  • the stop pin is pulled and saved for re -use, and the centering pipe is lowered fully to engage the fourth finger and wall. Then the rebar joint pin is inserted, and work moves to the next joint to be assembled.
  • each structural joint is built in three stages: it is positioned and temporarily braced by the centering pipe, it is threaded through with a continuous vertical rebar pin that is ultimately tied to the foundation, and then it is grouted solid to perform like monolithic construction, but in a fraction of the time and at a lower cost.
  • the preferred embodiment of this system provides an insulated sandwich panel with an exterior concrete face.
  • Figure 11 shows the components required to build such a joint.
  • the insulation and exterior face of wall nest into a 100mm deep ledge formed in the ground slab. This improves the water resistance of the assembly and serves to extend the insulation to below the floor level.
  • Figure 12 shows the two walls assembled and braced by the centering pipe
  • Figure 13 shows the vertical rebar pin and coupler installed.
  • this embodiment of the invention eliminates the joint cover by extending the insulation and exterior face of concrete as shown.
  • FIG. 14 through 16 A common T joint between two walls, one continuous and one intersecting, is shown in Figures 14 through 16.
  • Figure 20 The components required to build a three wall T joint are shown in Figure 20. These include the three walls, a four finger centering pipe, and the vertical joint pin. Although other assembly methods are possible, the preferred method places the wall with the topmost finger in the joint first (Fig. 20).
  • Figure 21 shows the second wall, which offers the second finger from the top, installed.
  • the centering pipe is installed through the top three fingers in the joint with the stop pin holding it above the gap that awaits a finger from the third wall, shown installed in Figure 22.
  • Figures 23 through 25 show a comparable assembly of a three wall insulated T joint.
  • Figure 26 shows a joint configuration for walls that form a crossing or "X", where one wall is continuous across the joint and two others connect into the joint. Again, the first wall to be erected is typically the one that present the uppermost finger in the joint (Fig. 26). As with the three-wall T joint, the assembly of this joint utilizes the four finger centering pipe as shown in Figures 27 and 28.
  • Figure 29 shows the first two walls in place, with the four finger centering pipe dropped into two fingers, waiting for the third wall to be set in place so the pipe can drive down into the third finger, as shown in Figure 30.
  • the fourth wall is centered using the centering pipe to complete the joint (Fig. 31). Note the two formed recesses in the base of the third and fourth walls. These combine to provide access to the wall base connection of the vertical pin, and standard wall base blockouts provide similar access at each joint that would otherwise be enclosed and inaccessible.
  • the wall base blockouts will later be filled in the grouting process, and will then generally be concealed by a depth of floor screed and a baseboard or skirting.
  • Beam End on Corner Joint It is a common condition for a beam to frame into a wall corner.
  • the beam end shown in Figure 32 will more often than not be the free end of a beam that is a cantilevered extension from another wall block, or it could be an independent precast beam. In either case, the free end of the beam is generally placed on a bearing pad that is of the same 30mm thickness as the erection tolerance between fingers. The joint around the pad is then typically filled in the grouting process.
  • Figure 33 shows the beam in position, and the three finger centering pipe inserted into the top joints and held at that level by the stop pin. The assembly is completed as shown in Figure 34.
  • FIG. 35 shows the two walls aligned and braced by the centering pipe, and Figure 37 shows the rebar joint pin installed.
  • Figure 38 shows the joint and where the vertical tie down of that wall to the supporting structure is desired.
  • Figure 39 shows the beam set and positioned with the centering pipe, which is shown not yet fully inserted.
  • the vertical tie down of the assembly to the foundation is provided through a vertical sleeve in what is effectively a single tall finger, as shown in Figure 40.
  • FIG. 41 An example of a precast stairwell that is built using the joint details described above is shown in Figure 41.
  • the upper level walls appear to float in this image because the hollow core planks, upon which the upper walls bear, are omitted from this view to more clearly show the walls.
  • the other key feature of these walls yields the closure of the continuous horizontal wall joint within the stairwell as shown.
  • the tops of the back and side walls shown in Figure 41 are raised, over the full width of the back wall and the inner half of the side walls.
  • the height of the concrete curbs shown on each sidewall is equal to half of the hollow core depth and half of the wall width, so these curbs are 100mm high and 75mm wide.
  • the back wall is raised across its full width because it effectively has a curb on both faces; it is a dividing wall between back-to-back stairwells.
  • Each of the upper walls also has a similar extension of its base, so the curbs bear on one another at mid-height of the hollow core floor that surrounds them.
  • Figure 42 shows a set of precast stair blocks in what would be their supported positions, but the walls have been omitted for clarity.
  • This set uses three block types: the ground floor stair, the upper floor stair, and the return stair.
  • the ground floor stair block has a squared first riser and a vertical base extension below the typical riser height, where the extension depth is equal to the height of the planned floor screed. This yields a first riser height that is the same as remainder of the risers.
  • the ground floor stair block also has a precast bearing tongue extension that inserts into the back wall for support as described above. The tongue is notched at the left edge with a horizontal erection tolerance relative to the slot in the back wall.
  • the upper floor stair unit is identical, except that its base extension reaches down to the support beam that is omitted from this view.
  • the full width of the stair unit bears on the supporting beam or wall, but it must share the bearing surface with the hollow core that builds the floor at each level, so it stops just short of the beam or wall centerline.
  • a dowel tongue extends another 75mm to cover the full width of the supporting beam as shown.
  • the dowel tongue is cast with a sleeve that receives the vertical pin described above, and the abutting hollow core units are notched with an erection clearance to receive the tongue.
  • Two return stair units are shown in Figure 42.
  • FIG. 45 The top edges of upper floor stair and return stair units are detailed to interface with the hollow core planks that share their supports (Fig. 45), and they top out at an elevation that is above the top of hollow core by a height equal to that of the planned floor screed.
  • Figure 46 is a cross section that shows the pinned and bearing connections that support the precast stair units; where a single stairwell is being built, the back wall notches extend only halfway through the wall as shown. Where back-to-back stairwells are being built, as in a duplex or office arrangement, the back wall features a full slot to receive precast landing tongues from both sides of the wall (Fig. 47).
  • Hollow core planks are supported on bearing surfaces presented by the tops of wall panels at the level below. Planks bear on wall blocks at each end, and are generally detailed to lap over intermediate walls and the edges of parallel end walls (Fig. 48). Hollow core planks are typically notched in the factory at each location where a wall joint occurs to provide a chase for the spliced connection and grouting of the vertical rebar joint pins (Fig. 49). Before shipping from the factory, hollow core cells that are exposed at cut ends and notches are plugged or otherwise sealed where required to prevent inflow during the grouting operation.
  • FIG. 50 At interior conditions, the upper walls bear on the hollow core planks (Fig. 50). But at perimeter walls, the hollow core planks bear in a ledge that is formed by wall panels that bear end to end, as shown in Figures 51 and 52. Similar conditions occur at continuous interior walls, such as at a stairwell or atrium space.
  • Figure 53 shows a hollow core panel bearing at a roof corner.
  • the parapet corner can be easily constructed using the pilastered parapet wall end joints shown. These maintain a strip of wall on either side of each joint that shares the full 250mm thickness of the insulated wall below to form corner pilasters.
  • the wall shown is thinned to 100mm between ends, except for a bottom of wall horizontal lug. With that lug, the base of the parapet wall matches the 175mm width of insulated wall below where it passes outside of the 75mm wide hollow core ledge.
  • Figure 55 shows the first wall set in place. As before, it is braced by a connection to another wall elsewhere along its length or, if it is the first wall at this level to be erected, it is braced with temporary diagonals.
  • the inside view of the complete parapet corner joint is shown in Figure 56.
  • a pilaster can be provided as shown in Figures 61 and 62. Unlike a typical wall block that frames into other joints, the pilaster, by definition, has no other wall end to anchor it. Engineering analysis is required for a given condition to determine the anchoring requirements of the pilaster. It might be anchored with grout that comes later into a blockout in the hollow core planks as indicated here, or higher load capacities can be generated by anchoring the pilaster into an aligning wall below.
  • pilaster walls may rely on grout that has not yet been installed for their anchorage, temporary loads and stability must be analyzed for the condition during construction when the pilaster is unanchored. On the basis of that analysis, temporary bracing or mechanical anchorage to an underlying wall can be detailed for applications that require it.
  • Simpler still is a parapet that rises only a short distance above the structural deck, as might be used on an inaccessible roof. This can be built with a simple vertical extension of the top of each wall panel.
  • the parapet is not a separate precast element but a monolithic extension of the insulated wall block below.
  • the components required to build a corner joint of such wall blocks is shown in Figure 66.
  • the two joining walls are shown assembled in Figure 67, and Figure 68 shows how the hollow core plank bears on the ledge created by the walls.
  • the final step in the refinement of the model shown is to detail the mechanical, electrical, and plumbing features: blockouts, conduits, and junction boxes that will be cast into each building block.
  • the resulting model is then translated into precision precast parts in the factory, and delivered to the jobsite ready to erect. Detail is provided below regarding the steps required to build this structure, but that will come after taking a closer look at the structural connections. It is the innovative connections of this system that enable the speed of construction and tie the building blocks together to yield a building with strength and structural performance that is superior to conventional precast. Structural Connection Details
  • the LadderBlock wall system interlaces precision precast concrete fingers from two or more panels and then pins them together with a vertical rebar joint pin (Fig. 79), shown here without the centering pipe described above but with a bar coupler at its top end.
  • the resulting high joint strength is provided very cost effectively, and can be won without sacrificing the speed of construction that distinguishes the LadderBlock system.
  • dozens of these joints work in unison at every level to ensure the strength and stability of the structure.
  • the unseen features are grout form tie wires and optional finger joint shear keys (Fig. 83).
  • the tie wires occur at the same three levels in every joint, near the top, middle and bottom of the wall as shown.
  • the wires are embedded into the fingers that occur at these three levels in every joint, and they are used to secure the temporary grout forms as described below.
  • the optional shear keys that are precast into each finger (Fig. 84), shown here in the form of truncated cones, are of a more structural nature.
  • each finger may be roughened or cast with intentional texture to enhance grout bond within the joint and on exposed joint faces.
  • the wall joints that align from level to level are provided with continuous vertical reinforcement using standard bar couplers (Fig. 87).
  • the tops of joint pins might simply terminate and then be encased in grout, or where analysis indicates the need, the top of these bars can be terminated with an anchor that develops the strength of the bar (Fig. 88).
  • a discontinuous wall that is supported on a hollow core plank span and requires base anchorage can have its joint pin fitted with a bottom end anchor that is grouted into the floor to develop limited uplift resistance;
  • Figure 89 is a view from below that demonstrates this concept.
  • Precast stair blocks are built slightly narrower than the stairwell walls that house them to preserve the necessary erection tolerance. They are hoisted into position to first engage the notch in the back wall of the stairwell at the landing level and gain a bearing support there (Fig. 90). At back-to-back stairwells, the stair landing precast tongues engage the full depth slot in the back wall to gain bearing just short of its centerline (Fig. 91). This leaves an erection tolerance that avoids conflict with the abutting landing on the far side of the wall.
  • the precast stair block is lifted into position and bearing is gained at the landing, it is lowered to gain support at the stair entrance from either the ground slab or a structural wall or beam (Fig. 92). Stair blocks are doweled there to restrain lateral movement in the interim before the hollow core planks and floor screed, if any, is installed.
  • the hollow core planks transfer their gravity loads directly through bearing on the precast wall panels. Lateral loads are transferred through the grouted interlock and confinement of hollow core diaphragms.
  • the hollow core planks at a given level are fully erected, they are confined within a perimeter of interconnected precast walls that extend vertically to the mid-depth of the plank (Fig. 93), and by the continuous vertical walls in stair wells and atrium spaces. This is in addition to the shear capacity of the grouted vertical cells which occur at every wall joint and are reinforced with continuous vertical bars (Fig. 94) or post-tensioning strands.
  • the keyways between hollow core planks are grouted as described below to establish diaphragm action, and to force load sharing so the planks act as a slab unit.
  • the keyway can include reinforcing steel.
  • a reinforced structural screed can also be specified to develop composite action and significantly increase both gravity and lateral load resistance of the floor.
  • Figure 96 shows a typical parapet wall corner.
  • the top of the rebar joint pin is fitted with an end anchor.
  • the joint pin is also tied at its base by a standard bar coupler to the joint pin below.
  • the joint is grouted solid as described below, the result is an interlocked parapet structure whose walls bear directly on supporting structure and span horizontally to deliver lateral loads to perpendicular walls or pilasters.
  • This independently stable system of parapet walls is tied down at every joint with a continuously reinforced and grouted vertical core.
  • Figure 97 shows the base of a parapet pilaster joint.
  • the figure shows the pilaster block with notches at both edges for base connection access, leaving a center foot that reaches down to bear on the hollow core roof deck.
  • the vertical bar in the pilaster with an end anchor penetrating down into what will be the grouted core.
  • the plugs that prevent the flow of grout into the hollow core cell could be pushed down the cell a short distance.
  • the resulting grout plug within the hollow core cell could be reinforced if needed, and would serve to engage more of the deck in providing uplift resistance to the pilaster.
  • supplemental features may be required to transfer shear forces downward through the structure.
  • One option available to the design engineer is the addition of keying elements at the top and bottom of selected walls to achieve additional interlock and shear interface across each level, as shown in Figure 98.
  • the ground slab at this location is thickened, and the dowel hole for the joint pin is drilled into the bottom of a slab blockout that is oversized to provide erection tolerance for the precast wall. Extensions of the bottom of the wall then fit into the slab blockout, and top extensions interface with similar oversized blockouts on the hollow core planks that bear on the wall (Fig. 99).
  • Upper walls can be configured similarly (Fig. 100). As with any wall, these could be precast with supplemental sleeves that house additional continuous vertical reinforcement or post-tensioning strands, if required for a given application.
  • the 3D models are of high value in designing a structure with features such as these shear keys, as the models facilitate the sequencing and study of the erection process to avoid potential conflicts. They demonstrate that the installation of a wall with a keyed base into an existing joint would require an oversized floor blockout to avoid a conflict, as the base key extension would otherwise tend to prevent the alignment and interlacing of the fingers. So in general, a wall which features base shear keys such as those shown should be the first wall erected at the joint, and then receive other standard wall ends to complete the joint. Where multiple keyed ends must frame into a joint, floor blockouts can be oversized as required to enable their assembly.
  • any standard diagonal brace that is common to precast construction could be used with this system, but because the system generally requires only one wall to be braced per floor level, it is convenient to build dedicated braces for each wall height and incorporate simple connections that are consistent with the building system. If the same steel pipe sleeve that lines each precast finger is taped over and cast into the top of the wall at a standard distance from the joint (Fig. 101), then the same centering pipe that is used to erect the structure will slide cleanly into the resulting dowel hole. If that centering pipe is, in this case, welded into a simple bent plate and pipe diagonal brace assembly (Fig. 102), it serves as a quickly established and easily disassembled top connection for a temporary diagonal brace. The top end of the brace is pinned to the wall by dropping the brace into the sleeve, and the bottom end is then field drilled and secured to the slab or hollow core plank with an expansion bolt per standard practice.
  • a temporary top brace can be specified to engage two panels independent of the centering pipe connection.
  • the temporary top brace utilizes the same connection strategy as the temporary diagonal brace: steel pipe sleeves at a standard distance from the joint (Fig. 103) to receive a brace that utilizes centering pipe dowels. But in this case the centering pipe is at both ends of a short steel angle (Fig. 104).
  • Fig. 104 steel angle
  • each bearing surface in the superstructure is lined with a thin continuous strip of adhered bearing pad material (Figs. 105 through 107). The bearing pads are installed just before erection, or may be installed before leaving the factory if the travel distance is short.
  • Figure 108 shows a four wall joint where the two walls at the far side of the joint are of standard 150mm thickness, and the two nearer walls have each been thinned to 100mm in the field of the wall by using a 50mm thick coffered form on a flat casting table with standard shuttering.
  • the far side of the thinned walls remains flat, and is the troweled top surface in the manufacturing process.
  • the thinning of these walls leaves a full thickness band at the perimeter of the wall, protecting the strength of the finger joint and presenting a top of wall that is still wide enough to be the bearing surface for end to end hollow core planks.
  • the walls might be thinned as shown in Figure 109.
  • the walls thin to 100mm after leaving a full thickness pilaster adjacent to the finger joint, shown here as a 150mm wide vertical strip on the face of the wall.
  • this could be cast using a void form in a standard form set.
  • it could alternatively be cast with the far, flat face down by using 100mm shuttering for the top and bottom edge in combination with a standard finger form and a hanging top form at the change in wall thickness.
  • the third thinning strategy is intended for non structural walls.
  • the full-thickness band adjacent to the finger joint is abandoned, and the whole face of wall is thinned to 100mm.
  • the fingers themselves maintain standard dimensions so they can complete the finger joint, and are offset from the wall centerline so that they project from one face of the thinner wall.
  • the two nearer walls that have been exploded out of the joint in Figure 110 have been thinned in this manner.
  • the walls are assembled into the joint in Figure 111. Note that if the thinning is applied radially about the joint as shown in these figures, the corners of each room remain square after the joint is grouted. Note the 50mm offset between walls at the thinned face and the absence of any projections or corner pilasters, so that the thinning of the wall is transparent to the finished space.
  • Preparation Phase o LadderBlock engineer coordinates and distributes slab interface plans and details during design. These specify critical dimensions and rebar clearance at drilling locations for integration into foundation engineering and construction by others.
  • LadderBlock engineer performs pre -pour observation of slab on grade. Objectives are to spot check critical dimensions and confirm that rebar is clear of drilling locations in accordance with the slab interface plans. o Once the slab is cast and forms are stripped, LadderBlock slab prep crew verifies that as-built
  • o Slab prep crew lays out vertical pin dowel points and face of wall lines on slab (Fig. 112).
  • o Slab prep crew drills, cleans and caps oversized dowel hole in slab for each vertical pin (Fig. 113).
  • o Slab prep crew surveys setting points for ground floor walls and installs standard plastic precast shims as required to provide consistent stetting level for first floor wall blocks - tape shim stacks in position (Fig. 114)
  • Steps outlined in this phase are performed by an erection crew consisting of a crane operator, trailer man, pin man, and two floor men. Multiple cranes and crews can be employed to multiply the speed of construction progress. o Ship and offloaded wall blocks in sequence to enable each block to be immediately erected when it is picked (Fig. 115). Hoist first wall block into position and install diagonal braces to slab (Fig. 116)
  • Centering pipe can be pre-loaded into the top finger of the first block erected at each joint before it is hoisted, and vertical rebar joint pins can be preloaded into the fingers of the completing block of each joint.
  • Second wall is now laterally braced to first wall by the centering pipe pinning the top two fingers together. Confirm alignment of the base of the wall with its slab layout line, and immediately release hoisting lines so the crane can swing into position to pick the next block.
  • tops of pins can be pre-fitted with bar end anchors (Fig. 144) if required by analysis.
  • Parapet walls resist wind by spanning horizontally to wall ends that are braced by intersecting walls or pilasters (Fig. 145).
  • o Hollow core slab joints (Fig. 148) are grouted at each level (Fig. 149).
  • o Seal exterior wall joints with backer rod and caulk (Fig. 150). Note that two lines of backer rod are shown. One is pushed deep into the joint as a dam for the subsequent grouting operation, and the other is pushed a standard depth from the outside face into the joint to back up the caulk or other elastomeric sealant.
  • o Feed tie wires through grout corner and face form slots (Fig. 151), then tighten and secure wires to seal forms tight against the wall blocks (Fig. 152), ensuring that each form is pulled tightly into the joint near the top, mid-height, and bottom of the wall (Fig. 153).
  • Reusable wedges in the preferred embodiment are precision cut from neoprene or other suitable elastomeric sheet material whose thickness matches the form slot.
  • Top wedges as grout level overtops form top slot (Fig. 157).
  • Top wedges may be precut from elastomeric sheet, or may optionally be of plate steel or other material that can be hammered into a tight slot.
  • Reusable wedges in the preferred embodiment are precision cut from neoprene or other suitable elastomeric sheet material whose thickness matches the pump slot.
  • Grout forms as soon as grout reaches stripping strength (Fig. 159).
  • Grout forms can provide edges that are flush as shown, or they could provide mitered edges or other aesthetic treatment.
  • Grout mix could take a number of forms; one option being a fiber reinforced pumpable mix whose strength is based on engineering requirements.
  • "soft grout" joints can be engineered to enable disassembly. This is accomplished by using grout that offers enough strength to resist Code specified forces in the assembled joint, but which is intentionally soft material in comparison with the structural concrete of the walls and fingers. This is to enable pin and grout removal without damage to the walls.
  • Conduit floor runs are connected to vertical runs that are precast into each wall block, as shown for a representative stack of two rooms depicted in Figure 161.
  • Floor runs connect at precast wall blockouts to wall conduit and through hollow core penetrations as shown in the wireframe view of the same rooms (Fig. 162). Screed and flooring is then installed at each level (Fig. 163).
  • the installation of doors, windows, roof insulation and membrane yields a dried-in building ready to finish.
  • remaining plumbing, wiring, tile work, surface treatments, fixtures and cabinets are then installed to complete the construction process.
  • This system redefines the building construction process, and in doing so offers extraordinary speed, safety, strength, and quality. It enables the construction of a complete precast building (Fig. 164) in days, where conventional precast would take weeks and cast in situ construction would takes months. It yields a stronger, better performing structure, and does so with unprecedented precision.

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  • Engineering & Computer Science (AREA)
  • Architecture (AREA)
  • Physics & Mathematics (AREA)
  • Electromagnetism (AREA)
  • Civil Engineering (AREA)
  • Structural Engineering (AREA)
  • Conveying And Assembling Of Building Elements In Situ (AREA)

Abstract

L'invention concerne un procédé et un système de construction comprenant une combinaison d'éléments structuraux préfabriqués. Des joints d'angle comprennent un tube de centrage. Des blocs pour murs de cage d'escalier et des planches à âme creuse sont utilisés pour les escaliers. Des éléments sont assemblés au moyen de chevilles de liaison et de clavettes de cisaillement à doigts.
PCT/US2012/023850 2011-02-03 2012-02-03 Appareil et procédé de construction préfabriquée Ceased WO2012106650A1 (fr)

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US201161439346P 2011-02-03 2011-02-03
US61/439,346 2011-02-03

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WO2012106650A1 true WO2012106650A1 (fr) 2012-08-09

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Cited By (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2017046365A1 (fr) * 2015-08-14 2017-03-23 Bernd Iglauer Élément de construction plat, plaque de renforcement, module de bâtiment, module de cage d'escalier et bâtiment à plusieurs étages
CN112252488A (zh) * 2019-07-22 2021-01-22 天津天华北方建筑设计有限公司 一种现场组装式预制板
CN113338508A (zh) * 2021-06-21 2021-09-03 中铁十二局集团有限公司 一种装配式建筑pc构件安装施工方法

Citations (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US2921354A (en) * 1956-03-12 1960-01-19 William O W Pankey Apparatus for making precast concrete bridges or the like
US4923339A (en) * 1987-09-14 1990-05-08 Fomico International, Inc. Foldable concrete retaining wall structure
US7086811B2 (en) * 1999-12-29 2006-08-08 Cgl Systems Llc Pre-stressed modular retaining wall system and method
US20080282623A1 (en) * 2007-05-15 2008-11-20 Powell David W Method and apparatus for precast wall and floor block system

Patent Citations (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US2921354A (en) * 1956-03-12 1960-01-19 William O W Pankey Apparatus for making precast concrete bridges or the like
US4923339A (en) * 1987-09-14 1990-05-08 Fomico International, Inc. Foldable concrete retaining wall structure
US7086811B2 (en) * 1999-12-29 2006-08-08 Cgl Systems Llc Pre-stressed modular retaining wall system and method
US20080282623A1 (en) * 2007-05-15 2008-11-20 Powell David W Method and apparatus for precast wall and floor block system

Cited By (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2017046365A1 (fr) * 2015-08-14 2017-03-23 Bernd Iglauer Élément de construction plat, plaque de renforcement, module de bâtiment, module de cage d'escalier et bâtiment à plusieurs étages
CN112252488A (zh) * 2019-07-22 2021-01-22 天津天华北方建筑设计有限公司 一种现场组装式预制板
CN113338508A (zh) * 2021-06-21 2021-09-03 中铁十二局集团有限公司 一种装配式建筑pc构件安装施工方法

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