PRECAST STRUCTURE AND METHOD OF CONSTRUCTION
Precast structures are formed of precast walls fitted between precast posts extending from cast in place footings, prior to the pouring of a slab. During pouring of the slab, anchors may tie together the panels, posts and slab. Precast concrete, tension fabric or traditional roofing members may be added to form a post and beam construction that spans large open areas providing for flexible manufacturing, storage, hangar, office, schools, institutional, or residential interior design features, due to the structural integrity and cost advantages of structures produced using this method of precast construction.
This application claims the benefit of the filing date of U.S. Provisional Patent Application No. 61/169,585 filed Apr. 15, 2009, the disclosure of which application is hereby incorporated by reference.
FIELD OF THE INVENTIONThe field relates to construction methods using precast concrete elements.
BACKGROUND OF THE INVENTIONPrecast panels and posts are known for highway sound barriers and the like. These systems use posts projecting upwards from cement footings as frames for precast panels that are erected between the posts.
U.S. Pat. No. 5,570,549 discloses a known anchoring system. These anchoring systems are costly in both materials and labor costs and do not always prevent structural damage caused by natural disasters.
U.K. Pat. Appl. GB 2,423,533 discloses a process for making a slab for a conservatory. The slab is cast in place and is then fixed to structural members of the conservatory.
U.S. Pat. No. 6,385,933 discloses a method for making precast concrete wall panels and for erecting the precast concrete walls on a slab that was previously cast in place.
U.S. Pat. No. 7,275,348 discloses a precast, prestressed concrete truss and method of manufacture and use in construction of structures that reduces the need for interior columns.
The entirety of the descriptions and drawings of each specification summarized above is incorporated herein by reference for the purpose of providing background.
SUMMARY OF THE INVENTIONA method of construction for structures comprises erecting precast concrete posts in foundation footings, fitting precast concrete panels between each pair of the posts, and then pouring a slab that has an upper slab surface extending a distance beyond a bottom surface of the precast concrete panels and a lower slab foundation surface extending a distance below the bottom surface of the precast concrete panels. In one example, anchors may extend from a surface of the precast concrete panels and from the footings for the posts, and the method includes tying the anchors to the slab or slab foundation portion. For example, the anchors may overlap and tie into reinforcements within the cast in place slab, such as metal reinforcing bars.
A precast structure produced by one example of the method has improved structural rigidity and damage tolerance compared to known construction methods. Surprisingly, the improvement in structural rigidity and damage tolerance with the casting of the slab after erection of the walls reduces costs, labor and construction delays of known methods of construction that require the slab to be cast prior to erecting walls and the roof. By inserting isolating and/or expansion barriers between panels and posts or between panels and the slab, vibrations may be isolated and thermal expansion may be addressed.
By tying together the posts, panels, slab, and roofing elements, an integrated structural framework is formed that has exceptional rigidity and damage tolerance from earth quakes, storms and blasts.
Surprisingly, the new construction method requires no temporary bracing, pour back strips and the like as required by known construction methods, resulting in a reduction of costs of materials and labor.
The following drawings are merely examples of precast structures and methods of construction, and the claims are not limited to the features represented in the drawings.
The examples described and drawings rendered are illustrative and are not to be read as limiting the scope of the invention as it is defined by the appended claims.
The following examples describe a precast structure and a method for construction of a precast structure, but the invention is not limited to the specific examples described. Instead, it should be understood that the features in the examples and the methods disclosed are merely illustrative. The claims that eventually issue should be interpreted in light of the specification, but the claims should not be limited by the description and drawings of the examples presented. The illustrations use the same illustration numbers to identify identical and similar features.
A method of construction for structures comprises erecting precast concrete posts in foundation footings, fitting a precast concrete panel between each pair of the posts, and pouring a slab. The slab is poured after the step of fitting each of the precast concrete panels between the posts. The step of pouring the slab ties the slab to the posts and panels providing a surprising and unexpected integrity and strength of the structure. The slab is poured with an upper slab surface extending a depth above a bottom surface of the precast concrete panel and having a lower slab foundation surface extending a distance below the bottom surface of the precast concrete panel. In one example, a plurality of anchors extend from a surface of the precast concrete panels. The plurality of anchors extend from the surface of the precast concrete panels such that the plurality of anchors extend into the slab after the step of pouring is completed, further locking the panels to the slab. Such a structure is much more resistant to damage by explosion, earthquake, impact or the like.
In one example, at least one anchor extends from a footing of the precast concrete posts, and the method includes tying the at least one anchor from each of the footings of the precast concrete posts to the slab or slab foundation portion after the step of pouring. Thus the footings are tied into the slab. At least one anchor from each of the footings of the precast concrete posts may overlap and tie into reinforcements within the slab after the step of pouring, for example. The plurality of anchors extending from the surface of the precast concrete panels may be comprised of metal reinforcing bars. For example, metal reinforcing bars may be the normal reinforcing bars internal to the precast concrete panels and reinforcing the structure of the precast concrete panels. Then, these metal reinforcing bars may extend, exposed, from the bottom portion of the precast concrete panels, at least one-third of a meter, more preferably at least one meter. Structures prepared according to examples of the method have a unique structure and unexpectedly improved damage tolerance and strength compared to conventional structures. The pouring of the slab/foundation after the positioning of the precast walls allows the entire structure to be tied together in situ during setting of the slab/foundation.
After erecting the posts 30 on or in the footings 10, the panels 20 are inserted, with or without a barrier 26, and beams 40 and roofing panel 50 may be added to complete the structural components above grade. Then, the slab 60 may be poured, as illustrated in the example of
The footings 10 may include pilings that extend downward into the ground a distance sufficient to withstand flooding and erosion caused by hurricane force winds and tsunamis, such as ten feet in one example, making the structure 1 suitable for marinas, such as for dry dock boat storage structures, for example. The post and beam construction can provide a space suitable for use as an aircraft hangar, a gymnasium, a manufacturing plant, flexible office space, housing, schools and other institutional buildings to name a few of the structures that would benefit from the structural integrity and cost advantages of this method of construction.
In
In the example of
An isolation and/or expansion barrier 66 is illustrated in
A jig may be used to drill holes for the footings 10 and to cast in place the footings 10 with the reinforced concrete precast posts 30 cast into the footings 10 and properly spaced and aligned one to the other.
In
Alternative combinations and variations of the examples provided will become apparent based on this disclosure. It is not possible to provide specific examples for all of the many possible combinations and variations of the embodiments described, but such combinations and variations may be claims that eventually issue.
Claims
1. A method of construction for structures comprises:
- erecting a plurality of precast concrete posts;
- fitting a precast concrete panel between a pair of the plurality of posts; and
- pouring a slab, after the step of fitting, the slab having an upper slab surface extending a depth above a bottom surface of the precast concrete panel and having a lower slab foundation surface extending a distance below the bottom surface of the precast concrete panel.
2. The method of claim 1, wherein a plurality of anchors extend from a surface of the precast concrete panels and the plurality of anchors extend from the surface of the precast concrete panels such that the plurality of anchors extend into the slab after the step of pouring is completed.
3. The method of claim 2, wherein at least one anchor extends from a footing for supporting one of the pair of the plurality of precast concrete posts, and tying the at least one anchor from the footing of the precast concrete posts to the slab or slab foundation portion after the step of pouring.
4. The method of claim 3, wherein the at least one anchor from each of the footings of the precast concrete posts overlap and tie into reinforcements within the slab after the step of pouring.
5. The method of claim 3, wherein the plurality of precast concrete posts have reinforcing bars and the reinforcing bars extend exposed from a lower portion of the plurality of precast concrete posts are inserted into the footing during the step of erecting, prior to setting of a cementitious material of the footing.
6. The method of claim 2, wherein the plurality of anchors are reinforcing bars internal to the precast concrete panels, reinforcing the structure of the precast concrete panels, and the reinforcing bars extend exposed from the surface of the precast concrete panels at least one-third of a meter.
7. The method of claim 6, wherein the metal reinforcing bars extend exposed from the surface of the precast concrete panels at least one meter.
8. A structure manufactured according to the method of claim 1, comprising:
- a plurality of posts;
- a plurality of precast concrete panels, each of the plurality of precast concrete panels being inserted between two of the plurality of posts, and each of the plurality of precast concrete panels comprise at least one anchor extending beyond a surface of each of the plurality of precast concrete panels; and
- a plurality of footings, each of the plurality of footings supporting one of the plurality of precast concrete posts; and
- a poured slab, such that the at least one anchor of the plurality of precast concrete panels are tied into the slab.
9. The structure of claim 8, wherein each of the plurality of footings has at least one anchor extending from a surface of each of the plurality of footings such that the anchor is tied into the slab.
10. The structure of claim 9, further comprising a plurality of beams, and the beams tie the posts together, forming an integrated structural support frame for the structure.
11. The structure of claim 1, wherein the plurality of precast concrete panels include a waffle pattern.
12. The structure of claim 1, further comprising an expansion barrier inserted between each of the plurality of panels and the posts.
13. The structure of claim 12, wherein the expansion barrier comprises an elastic membrane.
14. The structure of claim 12, wherein the expansion barrier comprises an adhesive layer.
15. The structure of claim 12, wherein the expansion barrier comprises a gel.
16. The structure of claim 12, wherein the expansion barrier comprises a foam.
17. The structure of claim 12, wherein the expansion barrier comprises a felt.
18. The structure of claim 12, wherein each of the plurality of panels comprises a panel tongue, and the panel tongue is embedded at least 4 inches into a recess formed in the post.
19. The structure of claim 8, further comprising a coil rod, wherein the coil rod is inserted through the precast or machined hole.
20. The structure of claim 19, further comprising a beam, wherein the coil rod comprises a horseshoe washer placed on either end of the coil rod, and a coil nut secures one or more of the plurality of panels to the beam.
21. The structure of claim 8, further comprising a channel in fluid communication with the hole surrounding the coil rod, providing a means for filling the hole and channel with a pourable grout.
22. The structure of claim 8, wherein a pair of the plurality of panels are stacked one over the other between the two of the plurality of posts, forming a wall between the two of the plurality of panels.
Type: Application
Filed: Apr 14, 2010
Publication Date: Feb 3, 2011
Applicant: Duratek Precast Technologies, Inc. (Brooksville, FL)
Inventors: R. Barry Stem (Ocala, FL), Jeffrey M. Davis (Fruitland Park, FL), Manuel R. Linares, III (Riverview, FL)
Application Number: 12/760,334
International Classification: E02D 27/42 (20060101); E04G 21/04 (20060101);