Simplified precast concrete system with rapid assembly formwork
View Patent ↗The disclosed system divides the precast and cast-in-place construction into vertical and horizontal components. The vertical components are precast, permitting rapid vertical building construction without a delay for concrete to set. The three primary precast components are a column, a horizontal slab, and a central panel placed diagonally between the slabs. By separating the columns from the horizontal slabs, the molds required to precast are simplified and transportation of the precast elements is streamlined. The resulting precast components are also of a weight and size that is readily manageable using a standard construction crane. The horizontal components are a combination of cast-in-place, and precast components. The result creates a continuous unitary floor structure that carries larger loads with less thickness that purely simple span pre-cast construction.
1. A method of erecting a multi-story structure, the method comprising the steps of:
excavating a building site to create an excavated surface;
placing one or more base members against the excavated surface, each base member comprising:
a horizontal slab;
placing a precast column atop each of the one or more base members, each precast column comprising:
a column portion; and
one or more upwardly-protruding rebar;
placing a precast slab atop each precast column, each precast slab comprising:
a horizontal slab;
a column foot protruding from a top of the horizontal slab,
one or more foot risers protruding from a top of the column foot;
placing a precast spanning member, the precast spanning member resting atop the horizontal slabs of two or more precast slabs, each spanning member comprised of:
a perimeter wall;
a multiplicity of individual cavities;
one or more formwork support rods affixed to a base of the precast spanning member;
affixing a rotating formwork panel to the one or more formwork support rods of the precast spanning member, each rotating formwork panel comprised of:
a solid panel;
fixed hooks adapted to rotate around the formwork support rods of the spanning member;
slideable hooks to affix to formwork support rods after rotation of the panel into place;
pouring concrete on top of the rotating formwork panels;
pouring concrete across the precast slabs and precast spanning members;
repeating steps “placing a precast column” through “placing a precast spanning member,” each time completing a floor of the multi-story structure, stopping when the multi-story structure is the desired number of floors.
2. The method of erecting a multi-story structure of claim 1 , wherein:
the base member further comprises:
a shear key receiving cavity located on top of the vertical column; and
a vertical column extending from the horizontal slab;
the precast column further comprises;
a shear key located beneath the column portion;
wherein the shear key interfaces with the shear key receiving cavity when the precast column is placed atop the base member.
3. The method of erecting a multi-story structure of claim 1 , wherein the spanning member further comprises:
a continuous central member upper rebar that includes a portion within the spanning member and a portion that extends beyond the spanning member; and
a continuous central member lower rebar that includes a portion within the spanning member and a portion that extends beyond the spanning member.
4. The method of erecting a multi-story structure of claim 1 , wherein the multiplicity of individual cavities of the spanning member further comprise:
a lightweight fill material that substantially fills the individual cavities.
5. A hybrid precast and cast-in-place concrete building system comprising:
an upper precast column and a lower precast column, each comprising:
a column portion;
one or more upwardly-protruding rebar;
a bottom-mounted metal connection plate with penetrations; and
a precast slab comprising:
a horizontal slab;
a column foot protruding from a top of the horizontal slab;
one or more foot risers protruding from a top of the column foot, thus creating space for the later placement of rebar;
each of the one of more foot risers surrounding a riser penetration;
whereby, during assembly the precast slab is placed on top of the lower precast column, the upwardly-protruding rebar of the lower precast column passing through the riser penetrations, and through the bottom-mounted metal connection plate of the upper precast column, after which concrete is poured on top of the precast slab, thereby creating a hybrid precast and cast-in-place structure.
6. The system of claim 5 , wherein the upwardly-protruding rebar of the upper precast column and lower precast column is threaded, thereby permitting the use of nuts to mechanically connect the upper precast column to the lower precast column.
7. The system of claim 5 , further comprising:
a precast spanning member comprising:
a multiplicity of individual cavities;
a perimeter wall surrounding the individual cavities;
a projection extending from the perimeter wall;
whereby the precast spanning member rests upon two or more precast slabs, the projection interlocking with the horizontal slab to support the precast spanning member, and following placement, concrete is poured on top of the precast spanning member and precast slabs, thereby creating the hybrid precast and cast-in-place structure.
8. The system of claim 6 , wherein the precast spanning member further comprises:
a lightweight fill material that substantially fills the multiplicity of individual cavities.
9. A method of erecting a multi-story structure, the method comprising the steps of:
excavating a building site to create an excavated surface;
placing one or more base members against the excavated surface, each base member comprised of:
a horizontal slab;
a vertical column extended from the horizontal slab;
placing a precast column atop each vertical column of each of the one or more base members, each precast column comprising:
a column portion; and
one or more upwardly-protruding rebar;
placing a precast slab atop each precast column, each precast slab comprising:
a horizontal slab;
a column foot protruding from a top of the horizontal slab;
one or more foot risers protruding from a top of the column foot;
placing a precast spanning member, the precast spanning member resting atop the horizontal slabs of two or more precast slabs, each spanning member comprised of:
a perimeter wall;
a multiplicity of individual cavities;
one or more formwork support rods affixed to a base of the precast spanning member;
hanging a rotating formwork panel from one formwork support rods of the spanning member, each rotating formwork panel comprised of:
a solid panel;
fixed hooks adapted to rotate around the formwork support rods of the spanning member;
slideable hooks to affix to formwork support rods after rotation of the panel into place;
lifting the rotating formwork panel into a horizontal position;
sliding the slideable hooks of the rotating formwork panel into an adjacent formwork support rod;
pouring concrete on top of the rotating formwork panels, thereby filling the spaces between the precast slabs and precast spanning member;
pouring concrete into the multiplicity of individual cavities of the precast spanning member, thereby filling the individual cavities;
repeating the steps of “placing a precast column” through “pouring concrete into the multiplicity of individual cavities” each time completing a floor of the multi-story structure, stopping when the multi-story structure is the desired number of floors.
10. The method of erecting a multi-story structure of claim 9 , wherein:
the base member further comprises:
a shear key receiving cavity located on top of the vertical column; and
the precast column further comprises;
a shear key located beneath the column portion;
wherein the shear key interfaces with the shear key receiving cavity when the central member is placed atop the base member.
11. The method of erecting a multi-story structure of claim 9 , wherein the spanning member further comprises:
a continuous central member upper rebar that includes a portion within the spanning member and a portion that extends beyond the spanning member; and
a continuous central member lower rebar that includes a portion within the spanning member and a portion that extends beyond the spanning member.