This application claims priority to U.S. Provisional Patent Application No. 61/366,781 filed Jul. 22, 2010 to John Hanback and titled “ADVANCED CONSTRUCTION USING PRECISION ADJUSTMENT, JOINING AND STRENGTHENING TECHNIQUES,” the content of which is incorporated by reference in its entirety.
BACKGROUND I. Field
This disclosure relates to advanced construction techniques.
II. Background
Basically, the art of construction has varied little since the Roman times, where buildings were constructed by placing bricks upon bricks using some form of mortar to join and hold the bricks together, and by casting concrete structures on a building sight. Some of the few innovations include the development of modular housing, and the creation of double-wide trailers.
While there has been some real innovation with a number of “modern” building techniques, such as those that were used to construct the world trade towers, the art of construction is rife with stagnation. Architects, structural engineers and construction companies are loathe to innovation in order to minimize risks and cost overruns. While constant improvement has been made incrementally with respect to items such as cheaper building materials, e.g., particle board, better insulation and so on, the art of construction has natural barriers to inventiveness when it comes to new paradigms of construction.
SUMMARY Various aspects and embodiments of the invention are described in further detail below. In an embodiment, an improved building technique includes setting at least one wall (or portion of a wall) for a building to a final position, and then subsequently match-casting a foundation and/or a floor for the building using special concretes, the foundation/floor being in contact with the base of the wall and operable to secure the position of the wall.
BRIEF DESCRIPTION OF THE DRAWINGS The features and nature of the present disclosure will become more apparent from the detailed description set forth below when taken in conjunction with the accompanying drawings in which reference characters identify corresponding items.
FIG. 1 depicts an exemplary fluid storage tank capable of being constructed using some of the disclosed building techniques.
FIG. 2 is a plan view of two circular trenches usable to create a foundation for the tank of FIG. 1.
FIG. 2B depicts a profile of the trenches of FIG. 2.
FIG. 3 is a plan view of an exemplary footing track segment for the tank of FIG. 1 placed in the outer trench of FIGS. 2 and 2B.
FIG. 4 depicts a footing locking-pour for the exemplary footing track segment of FIG. 3.
FIG. 5 is an exemplary connecting/adjustment plate embedded in the foundation track segment of FIGS. 3 and 4.
FIG. 6 is a plan view of an exemplary base wall segment in context with a footing track segment.
FIG. 7 is a section perspective of an exemplary adjustment block in context with an adjustment plate.
FIGS. 7B and 7C are plan views of alternative configurations for leveling/plumbing screws.
FIG. 8 depicts details of the end of a leveling/plumbing screw together with a leveling plate.
FIG. 8B is a plan view of another useful leveling/plumbing screw arrangement.
FIG. 9A is a plan view of two adjacent adjustment blocks.
FIGS. 9B and 9C are plan views of joining portions of horizontally adjacent wall segments showing two types of seals.
FIGS. 9D and 9E depict joining portions of vertically connecting wall segments with two different types of seals.
FIG. 10 depicts an inner and outer-wall of a wall segment.
FIG. 10B depicts an inner and outer-wall of a bifurcated wall segment.
FIG. 10C is an elevation view of several vertically connecting wall segments with alignment structures.
FIG. 11 depicts details of a portion of a footing track segment in context with an adjustment block and a post-tension cable.
FIG. 12 the components of Fig, 12 secured in a locking-pour.
FIG. 13 depicts the addition of an interior elastomeric liner.
FIG. 14 depicts vertically connecting wall segments that may be placed upon base wall segments including a number of threaded bolts in concert with respective embedded nuts operable to prevent separation of stay-in-place forms when the core defined by the stay-in-place forms is filled with concrete.
FIGS. 15A and 15B depict two embodiments of the embedded nuts of FIG. 14.
FIG. 16 depicts the void between inner and outer-walls being filled with concrete along with a number of cables that may be used to compress the outer-wall inward so as to increase strength and to allow for greater internal pressures generated by internal stored fluids.
FIGS. 17 and 17B show exemplary ledges that may be molded in an integral way to the wall of FIG. 16.
FIG. 18 depicts an alternative approach to running perimeter cables using the bifurcated wall system of FIG. 10B.
FIG. 19 depicts an optional wear-plate secured to the interior of the structure of FIG. 1 usable to protect an internal liner in concert with castellated wall segments and wedge-shaped roof Tees
FIG. 20 shows details of the cap and the upper, inside corner of the wear-plate of FIG. 19.
FIG. 21 shows the viewpoints for FIGS. 22 and 24.
FIG. 22 depicts another view of wear-plates, castellated wall units and roof Tees viewed from the inside of the structure of FIG. 1.
FIG. 23 is a plan view of the wedge-shaped roof Tees shown in FIG. 22.
FIG. 24 depicts wear-plates for the inner-wall of the structure of FIG. 1, which may be constructed in a fashion similar to the outer-wall.
FIGS. 25 and 25B depict a flowchart outlining a number of operations for constructing structures.
DETAILED DESCRIPTION The disclosed methods and systems below may be described generally, as well as in terms of specific examples and/or specific embodiments. For instances where references are made to detailed examples and/or embodiments, it should be appreciated that any of the underlying principals described are not to be limited to a single embodiment, but may be expanded for use with any of the other methods and systems described herein as will be understood by one of ordinary skill in the art unless otherwise stated specifically.
It is to be appreciated that, while the primary examples of the present disclosure are directed to a radial structure, those skilled in the art will readily appreciate that the underlying approaches can be used for non-radial structures. For example, while most of the measures and adjustments in the following disclosed example may be best described in radial (r, θ) or cylindrical (r, θ, z) coordinates, when such techniques are applied to a generally rectangular building, Cartesian (x, y, z) measures and adjustments may be applied. Similarly, spherical measurements and adjustments may be applied when applying the disclosed techniques to spherical structures. That is, the various disclosed methods and devices lend themselves to construction generally, and may be applied to virtually any building type.
For the purpose of clarity, the following definitions are provided:
Member: (noun): a structure that may be made of concrete, steel or any combination of materials useful in the construction arts that is formed prior to integration into a building. For example: a concrete T-shaped beam formed at a molding/casting plant, then transported to be integrated into a bridge may be referred to as a structural “member”.
Pour (noun): a structure formed in-situ by pouring concrete or other similar material (e.g., a geopolymer) into a retaining area (e.g., between two stay-in-place forms) and later allowed to harden into a solid structure. For example: concrete placed into an area defining a floor of a building at the exact building location may be considered a floor “pour”.
Building (noun): any of a broad category of man-made structures used to enclose or store people or objects, such as residential and office spaces, water towers, utility and power plants, and so on.
FIG. 1 depicts an exemplary fluid storage tank 10 capable of being constructed using some or all of the disclosed building techniques. As shown in FIG. 1, the fluid storage tank 10 has a generally cylindrical structure. The fluid storage tank 10 may optionally include a number of pilasters 11 operable to provide locations from which to adjust tension on cables circumventing the fluid storage tank 10 (explained below). The fluid storage tank 10 is but an example of one possible structure that may be assembled using some or all of the various approaches outlined and described below as will be apparent to those skilled in the relevant arts
FIG. 2 depicts two circular trenches 12 and 14 usable to create footings and a foundation for the tank of FIG. 1. The outer trench 12 has a width of (R2−R1) while the inner trench 14 has a width of (R2−R1). As is implied by FIG. 2, there may be two major walls, including an inner-wall to be placed in trench 14 and an outer-wall to be placed in trench 12. FIG. 2B depicts a side-view prospective of the trenches of FIG. 2 noting that the width and depth of each trench 12 and 14 may vary from structure to structure as functions of engineering decisions and preferences. It is to be appreciated that the bottom of each trench 12 and 14 may be lined with fine gravel, sand or other stone particulate matter, and readily leveled to within 1/8th of an inch using modern laser guided construction equipment.
FIG. 3 is an exemplary footing track segment 101 for the tank of FIG. 1 placed in the outer trench of FIGS. 2 and 2B. As shown in FIG. 4, the track segment 101 includes an inner track rail 110 and an outer track rail 112 connected by a number of interconnecting single footing blocks 122 and a connecting (double) footing block 120. Each single footing block 122 includes a single adjustment plate P, and the connecting footing block 120 includes two plates P positioned next to one another. The track segment 101 may be fitted to other track segments via fittings 130. For the present embodiment, the exemplary outer-wall incorporates thirteen track segments arranged in a circle.
It should be appreciated that each foundation track segment 101 can be cast in an on-sight or off-sight casting facility whereby various metal additions (e.g., adjustment plates P) may be embedded, and whereby casting dimensions can be controlled to within a few thousandths of an inch. Also, assuming that such segments 101 are cast in a controlled facility, the strength of the concrete may be improved from 6,000 PSI to 9,000 PSI (considered typical to high-quality for commercial concrete) material to concrete having strength well beyond 25,000 PSI, if desired. Thus, architects and structural engineers may take advantage of far stronger concrete materials, which can lead to substantial weight and costs savings, especially in the context of a base/bottom component of a structure where a high load would be bearing down upon it. Also, it may allow for the construction of concrete structures having strengths and reliabilities competitive to steel structures while avoiding the corrosive interactions that some fluids, e.g., bio-fuels and alcohols, have on steel and other metals.
FIG. 4 depicts a footing locking pour 102 match-cast to the exemplary footing track segment 101 of FIG. 3. The footing locking pour 102 may be poured in the interior of the various footing track segments 101 and used to lock the footing track segments 101 in place, lock the footing track segments 101 securely together, and to provide additional strength to the foundation formed by the track segments 101. While not shown in FIG. 4, it is to be appreciated that rebar may be made part of the pour 102 noting that both rebar and concrete may pass through various portions of the track segments 101, such as the footing blocks 120 and 122 discussed with respect to FIG. 3
FIG. 5 is an exemplary connecting/adjustment plate P embedded in the foundation track segment 101 of FIG. 3 at a footing block (120 or 122). As shown in FIG. 5, plate P includes a number of anchors 530 (securing plate P to the respective footing block 120 or 122), a number of leveling/plumbing plates 520, and a lateral adjustment device 540. In operation, as will be discussed below, the leveling plates 520 can be used to precisely plumb walls and/or level other structural elements within a few-thousandths of an inch and/or a few seconds of arc, while the lateral adjustment device 540 may be used to precisely position a wall and/or other structure within a few thousandths of an inch.
While FIG. 5 depicts the use of two leveling/plumbing plates 520 (and thus implies two leveling devices), and a single lateral adjustment device 540 (and thus implies a single lateral adjustment device in a single direction), it is to be appreciated that, depending on the particular engineering decisions required or otherwise desired, the particular number of a given type of adjustment/plumbing/leveling devices may vary. Leveling/plumbing plates 520 may or may not be welded or otherwise fastened to plate P, or may be coupled so as to be secured to plate P while capable of traveling limited distances. It is to be further appreciated that, as will be discussed below, other precision adjustment devices may be used in concert with the adjustment devices 520 and 540 of FIG. 5.
Continuing to FIG. 6, the exemplary footing track segment 101 of FIG. 4 is shown in relation to a base-wall segment 600 noting that each base-wall segment 600 may overlap each footing track segment 101. For the example of FIG. 6, base-wall segment 600 overlaps track segment 101 by an amount that may be thought of as an angle e or some equivalent distance.
Note that the exemplary base-wall segment 600 includes a stay-in-place form (SIPF) that includes a SIPF inner-wall 610 and a SIPF outer-wall 612, and a number of connecting structures 640. The exemplary base-wall segment 600 also includes a number of base adjustment blocks 650 lying atop of respective adjustment plates P. For the present embodiment, it is to be appreciated that the SIPF inner-wall 610 is to be placed at a distance R6 from the center of structure 10.
FIG. 7 is a sectional perspective of an exemplary adjustment block 650 atop of an adjustment plate P. The exemplary adjustment block 650 includes two leveling screws 710 and 712 each making contact with a respective leveling/plumbing plate 520 of FIG. 5, a number of slide plates 730, and a complementary lateral adjustment device 542 for use with the lateral adjustment device 540 of FIG. 5. An internal path 720 is also available for use with post-tension cables as will be discussed below.
While FIG. 7 depicts an adjustment block 650 having two leveling screws 710 and 712, in practice it may be advantageous for an adjustment block to employ more leveling screws as is shown in FIGS. 7B and 7C. By employing three or more screws 710/712 arranged so as to define a plane, adjustment block 650 may be leveled/plumbed in two angular dimensions while providing stability to the adjustment block 650 as whole. Note that it may be possible that one or more adjustment screw 710/712 to be replaced with a fixed point while allowing the remaining screws 710 or 712 to remain adjustable. For example, in FIG. 7B screw 710 may be replaced with a fixed member while the two top adjustment screws 712 may be used may be used for leveling/plumbing. Note that for the tank example of FIG. 1, only two leveling/plumbing screws may be necessary as leveling/plumbing screws associated with other adjustment blocks of the same base-wall segment 600 may provide added stability. However, such leveling/plumbing screw configurations as found in FIGS. 7B and 7C would provide great utility for a structural member having only a single adjustment block, or when the mechanical coupling between adjustment blocks is insufficient to guarantee the appropriate stability.
FIG. 8 depicts details of the end of one of the leveling/plumbing screws 712 together with a leveling plate 520. As shown in FIG. 8, the end of leveling screw 712 has a “bull-nose” end 812 which may be inserted into depression 810 of leveling plate 520. Such a configuration can allow adjustment of a leveling/plumbing screw 712 while making sure that any such adjustment does not cause block 650 to “travel” as screw 712 rotates.
FIG. 8B shows an alternative leveling/plumbing adjustment screw 712 ending in a ball 714 to form a ball-in-socket joint 750 in concert with plate 520-P. In the present example of FIG. 8B, the socket is formed using an outer structure 754 made of a high-strength material, such as steel, and an inner structure 752 made of a softer material, such as plastic, lead, brass or aluminum. The ball-in-socket joint 750 can advantageously be formed by placing the ball 714 in the hollow cavity of the an outer structure 754, then pouring an appropriate metal, plastic or other suitable material into the an outer structure 754 to form the inner structure 752, which forms the ball-in-socket joint 750 by match-casting.
The arrangement of FIG. 7B may have advantage over the example of FIG. 7 when plate 520-P is not anchored into a pre-formed structural member, but when plate 520-P is anchored (using anchors 530) into a pour set in-situ or used without anchors as a pre-attached/attachable leveling plate placed on a graded foundation (of dirt, gravel or another material) as shown in FIG. 8B.
FIG. 9A depicts two adjacent adjustment blocks 650-1 and 650-2 that can be used at the connecting footing blocks 120 of FIGS. 3 and 4. As shown in FIG. 9A, the two adjacent adjustment blocks 650-1 and 650-2 may be secured together and adjusted relative to one another via block connecting screws 910 and 912. For the present embodiment, note that such an adjustment enabled by screws 910 and 912 may be generally orthogonal relative to the lateral adjustment enabled by devices 540 and 542 of FIG. 7.
The present inventors have envisioned an advantage in allowing the base-level wall segment 600 to be self-sealing to one another, as well as allowing the base-level wall segment 600 to be self-sealing to pre-cast wall segments placed atop of the various base-level wall segments 600. Accordingly, the inventors have designed optional sealing structures shown in detail for the vertical joined portions of walls 610-1 and 610-2 (see area 950) noting that the same concepts and structures may also be optionally applied to walls 612-1 and 612-2.
Continuing to FIG. 9B, a top-down (plan) view of area 950 is depicted. As shown in FIG. 9B, base wall segment 610-1 has a first fitting contour 932-1 to be matched against a complementary second fitting contour 932-2 of base wall segment 610-2 as the two base wall segments 610-1 and 610-2 are brought together in what may be thought of as a formal tongue-in-groove fitting. Seals 920 may be placed in respective seal contours 934-1 and 934-2 to extend beyond base wall segments 912-1 and 912-2 to some distance Ws. As the two base wall segments 610-1 and 610-2 are brought together optionally aided by locating structures (discussed below), seals 920 can make a secure air-tight and liquid-tight seal noting that as the seals 920 are compressed against one another, the void area to the sides of seals 920 may accommodate the displaced material of seals 920.
FIG. 9C shows another example of a sealing structure having the same complementary fitting contours 932-1 and 932-2, but where the sealing contours 934-1 and 934-2 are modified to a complementary male-female structure with seal 922 placed in the female contour 934-1. Depending on the design choices, seal 922 may be designed as a solid, or may tend to take the form of a putty-like substance or a viscous fluid operable to flow to cover a wider area between wall segments 650-1 and 650-2 when displaced by male contour 934-2 noting that seal 922 may be formulated to cure to a solid form afterward. In various embodiments, note that the male contour 934-2 may be made slightly smaller than the complementary female contour 934-1 so as to allow seal 922 an adequate space in which to flow and form a seal as wall segments 650-1 and 650-2 are brought tightly together.
It is to be appreciated that the formal tongue-in-groove contours of FIGS. 9B and 9C are optional, and that in various embodiments other types of fitting contours may be applied or omitted entirely.
It is also to be appreciated that seal 920/922 may run partially or completely around a given wall segment. FIGS. 9D and 9E show the same general fitting and sealing structures for a base wall segment 610-1 and another wall segment 910-1 to be stacked atop of the base wall segment 610-1.
FIG. 10 depicts the top/bottom seal 920/922 of FIGS. 9D and 9E noting that such a seal can run the entire length of a top (or bottom) of wall segments and may even take the form of O-rings completely circumventing the SIPF inner-wall 610 (and optionally the SIPF outer-wall 612). Internal bracing structures 918 are shown connecting SIPT walls 910 and 912.
Note that, for an interior-wall (e.g., a wall placed in trench 14 of FIG. 2), such an interior-wall might have a complementary structure where a SIPF outer-wall (i.e., the SIPF wall in immediate exposure to any fluid stored in tank 10) would have such a liquid-tight seal.
FIG. 10B depicts an inner-wall 910 and an outer-wall 912 of a bifurcated wall segment 900B. In this embodiment, the inner-wall 910 and internal wall bracing structures 918 are integral to one another. A securing bar 1002 may be added to run the height of the bifurcated wall 900B. In various embodiments, the securing bar 1002 may be integral with inner-wall 910 and bracing structures 918, or may be a separate member made of concrete or metal. The outer-wall 912 is a separate member in this embodiment, and may be secured to the inner-wall 910 via threaded bolts 1006 with complementary nuts 1004 embedded with the securing bar.
Note that when securing bar 1002 is a separate (non-integral) member from the inner-wall 910, separate nut/bolt arrangements may be used to attach securing bar 1002 to the inner wall than to the outer-wall. At least two advantages may arise from this configuration compared to a one-piece, double-walled SIPF. First, it allows for ease of inspection during in-situ construction where rebar and/or post-tension cables need to run in-between walls. Second, it makes installing such re-enforcement/strengthening materials easier if one wall is detached and the SIPF is open-faced.
FIG. 10C depicts guiding structures 1002 and 1004 (e.g., wedge cones) that can allow for an easier assembly and seal compression of wall segments 610 and 910 placed upon one another. Note that wall segments 610 and 910 may be placed at angular offsets relative to one another so that wall segments overlap much like standard brick and block work masonry.
Taking into consideration: (1) the leveling adjustment facilities (710, 712 and 520) of FIG. 7, which may be used to assure that walls 610 and 612 are correctly oriented (presumably plumb); (2) the lateral adjustment facilities (540, 542, and the connecting threaded screw (unnumbered)); and (3) the block connecting screws 910 and 912 of FIGS. 9A and 9B, it should be appreciated that the adjustment means all together may be used to precisely (within a few thousandths of an inch) position wall 610 to a precise distance R6 relative to a distant point, level/plumb walls 610 and 612, and connect adjacent base-level wall segments 600. This form of adjustment can be thought of analogous to the construction of precision machinery noting that modern laser-based ranging equipment may be used to place a particular wall/wall-segment within a few thousandths of an inch of a desired position.
Continuing to FIG. 11, aspects of post-tensioning of a foundation of the structure 10 of FIG. 1 are discussed. A cable 724 may be passed though passage 720 and through foundation track portions 112, which is raised in this embodiment relative to portions 120/122 and 110. Generally, cable 724 may be stretched to place a substantial amount of tension and fastened securely using cable locking device 726.
Continuing to FIG. 12, a foundation locking-pour/floor structure 1210 may be match-cast to the footing segments 101 and to the base-wall segments 600 noting that such a casting may be made after the appropriate plumbing/leveling/positioning adjustments are made and finalized. Thus, the foundation/floor locking-pour 1210 may be cast not only to form the foundation of structure 10, but also to lock down and prevent further adjustment of devices 710, 712, 540 and 542 and/or to lock walls 610 and 612 securely in place, and/or to lock base segments 600 relative to foundation track segments 101.
Returning to FIG. 11, after the locking-pour/foundation 1210 has set to form a solid member, a substantial amount of tension may be applied to cable 724, which in turn can compress the various structures 112, 120/122, 110, 650 and 1210 together.
Note that holes 142 (shown in footing block 120/122 FIG. 12) may facilitate rebar and allow concrete in the footing locking-pour 102 (discussed above to be generally continuous across structures 120/122 to form a strong and continuous structural member.
Continuing to FIG. 13, upper wall segments may be placed upon base wall segments, and a liner 1310 may be applied to wall inner 610 and the floor formed by the foundation locking-pour 1210. The liner 1310 may be laid down or sprayed down, and the particular material used for liner 1210 may be dependent on what kinds of fluids are stored in structure 10.
Continuing, FIG. 14 depicts the void between walls 610 and 612 along with internal bracing structures 918 and a variety of threaded bolts 1420 in concert with respective embedded nuts 1410. Note that the internal bracing structures 918 have hole (unnumbered) to allow for the vertical passage of concrete.
FIGS. 15A and 15B depict two embodiments of the embedded nuts 1510 of FIG. 14. Note that each embedded nut 1410-1 or 1410-2 has a respective locking portion 1506 or 1508 operable to secure the nuts 1410 within a concrete wall, a threaded portion 1504 and an internal guiding profile 1502 operable to allow for an easier coupling of nut 1410 with a long bolt at the hand of a human construction employee from a distance, e.g., from the far side of a STPF outer-wall.
FIG. 16 depicts the void between SIPF walls filled with concrete 1650. Also shown in FIG. 16, a number of vertical cables 1652 may be placed within the SIPF walls before the concrete 1650 is poured. After concrete 1650 has set/cured, tension may be applied at the top of cables 1652 so as to apply vertical post-tension.
As also depicted in FIG. 16, a number of cables 1610 may be used to compress wall 612 inward so as to increase strength and to allow for greater internal pressures generated by internal stored fluids. Note that, depending on the engineering decisions and design criteria, cables 1610 may be placed on the outside of the SIPF (as shown in FIG. 16) or within the SIPF.
FIG. 17 shows an exemplary ledge 1710 that may be molded in an integral way to the outside of SIPF wall 612. The ledge 1710 may be used to hold perimeter-running cable 1610 with clips 1720 used to keep cables 1610 secure. For the present embodiment, cables 1610 may be a greased and shielded cable.
FIG. 17B shows an alternative exemplary ledge 1730 that also may be molded in an integral way to the outside of wall 612. The ledge 1730 may be used to hold cables 1610, but instead of clips, a grouting compound 1740 may be used to keep cables 1610 secure.
For either embodiment of FIG. 17 or 17B, perimeter cables may completely circumvent a structure, or as suggested in FIG. 1 partially) (90°) partially circumvent the structure 10 of FIG. 1 with cables being secured by and tightened at pilasters 11.
FIG. 18 depicts an alternative approach to running perimeter cables 1610 using the bifurcated wall 900B of FIG. 10B. Here, securing bar 1002C (here a composite of a number of several securing bars) may be used to hold perimeter cables using any of integrated ledges, such as those shown in FIG. 17 or 17B, ledges inset within securing bar 1002 or holes drilled through securing bar 1002. Alternatively, it may be advantageous to secure perimeter cables 1610 using integral ledges molded within the SIPF at the outside SIPF wall 912.
Returning briefly to FIG. 13, it should be appreciated that in certain embodiments it may be desirable to protect liner 1310 against possible wear. Because there may be situations where a floating roof may be used (e.g., when structure 10 is used to store volatile fuels), and such a floating roof may have a peripheral seal, it should be appreciated that such a seal might make contact and wear on the internal liner 1310. The inventors have envisioned a device to prevent such wear in situations where increased reliability is desired and/or where the liner material (e.g., any elastomeric material resistant to certain petroleum products or certain solvents) is expensive.
FIG. 19 depicts an optional wear plate 1910 secured to wall 610 usable to protect liner 1310. Note that cap 1920 may be added to reduce stress to the upper corner of wear-plate 1910, with FIG. 20 showing details of cap 1920 at the upper, inside corner of wear-plate 1910. The exemplary cap 1920 includes an angled plate 2020 with one or more fins 2022 welded to plate 2020 to help prevent cap 1920 from bending and causing possible damage to wear-plate 1910.
Also note that there may be a void having width W1 between wear-plate 1910 and wall 610.
FIG. 21 depicts viewing aspects (VIEW 1 and VIEW 2) for FIGS. 22 and 24.
FIG. 22 depicts another view of wear-plates 1910 viewed from the inside of structure 10 facing outward (VIEW 1). As seen in FIG. 22, wear-plates 1910 may be placed next to one another. Note that castellated closure units 2220 may be placed atop a wall supporting wear-plates 1910, and roof members 2210 having a single-T shape (hereinafter “roof Tees”) may be place atop the castellated closure units 2220. A top-down view of the roof Tees 2110 is shown in FIG. 22. FIG. 24 depicts wear-plates 1910-2 for the inner-wall of structure 10 of FIG. 1, which may be constructed in a fashion similar to the outer-wall.
FIGS. 25 and 25B depict a flowchart outlining a number of exemplary operations useful for constructing structures, such as the tank structure 10 of FIG. 1. While the various steps outlined in the flowchart occur in a particular order for ease of explanation, it is to be appreciated that the particular order of certain steps relative to other steps may change from embodiment to embodiment as may be readily apparent to those skilled in the construction and structure design arts. Also, it is to be appreciated that, depending on the particular design requirements, limitations and/or available resources, various steps listed below may be omitted or augmented by steps not listed as may be found necessary, advantageous or otherwise desirable.
The process starts in step S100 where various components (e.g., footing structures, base wall structures (with or without a SIPF configuration), and upper-wall structures may be cast. As discussed above, such components may be cast in a special facility to enable the appropriate humidity and heat profiles over time in a curing process usable to create high strength concrete well beyond the 6,000-10,000 PSI concrete that is typically created without such processing. Control continues to step S102.
In step S102, a construction site may be appropriately prepared, which as discussed above may involve the formation of various trenches and the precision leveling of base materials, e.g., fine gravel or sand. Next, in step S104, one or more pre-cast footing segments/members of a footing member (e.g., the footing segments 101 depicted in FIG. 3) may be appropriately placed on the prepared construction site. Then, in step S106, a footing-locking pour may be cast/poured so as to lock the pre-cast footing segments of step S104 together noting that, depending on the particular geometries involved, large holes in the pre-cast footing segments may be used to allow rebar and the locking concrete to pass across certain portions of the footing segments. Control continues to step S108.
In step S108, a number of pre-cast base-wall segments/members may be placed over the footing-segments of step S104 noting that it may be advantageous to have such base-wall segments overlap (by some angle or distance) the footing segments. Next, in step S110, a number of precision adjustments may be made to the base-wall segments so as to plumb the walls (of which the base wall segments are a constituent part) or level some surface related to the base-wall segments, adjust base-wall segments and/or walls relative to a particular point in space, adjust base-wall segments and/or walls relative to one another, and/or secure base-wall segments and/or walls to one another. Note that such adjustments may need to take into account an amount of pressure put on seals incorporated into various wall segments, displacement caused by post-tensioning of floor and wall segments, and so on. Next, in step S112, a foundation/locking pour may be match-cast to the base-wall segments and the footing segments so as to lock the base-wall segments in place and/or preclude further wall/wall-segment adjustment or relative movement. Then, in step S114, tension may be applied to various cables previously placed within the base-wall segments (as well as possibly the footing-segments) to create post-tension forces, and for the present application compress the various footing-segments and/or base-wall segments together. Control continues to step S116.
In step S116, upper-wall segments may be placed over the base-wall segments noting that various integral seals may be incorporated into the base-wall segments and upper-wall segments to create an air-tight and liquid-tight seal between segments. Next, in step S118, various cables may be placed about the perimeter of the structure, either on the outside of the structure or possibly with the interior of the SIPF defined by the base-wall segments and upper-wall segments. Then, in step S120, various tie anchors (see, e.g., FIG. 14) each consisting of a long bolt and embedded nut (with an optional internal guiding contour and locking contour) may be placed so as to reinforce the inner and outer walls of a SIPF formed by the base-wall and upper-wall segments. Control continues to step S122.
In step S122, the interior of the SIPF formed by the base-wall and upper-wall segments may be poured, and in step S124, tension may be applied to vertically-run cables within the SIPF to compress the various vertically-stacked wall segments together. Then, in step S126 tension may be applied to the cables circumventing the structure. Control continues to step S128.
In step S128, an internal liner may be applied to the inside of the tank structure so as to create an air-tight and liquid-tight barrier noting that the type of material of the liner should be suited to the type of fluid stored. Next, in step S130, wear-plates may be installed within the tank structure, such as those wear plates depicted in FIGS. 19, 20, 22 and 24. Control continues to step S132.
In step S132, various castellated closure wall-units suitable to mate with upper-wall units and roof Tees may be installed, and in step S134, an interior portion of such castellated wall-units may be poured. Control continues to step S136.
In step S136, an insulated facade may be applied to the outer-wall of the tank structure. Next, in step S138, a roof system may be installed, such as the roofing system of roof Tees partially depicted and described in FIGS. 22-24. Then, in step S140, a membrane and insulation may be applied to the roof. Control continues to step S150 where the process stops.
What has been described above includes examples of one or more embodiments. It is, of course, not possible to describe every conceivable combination of components or methodologies for purposes of describing the aforementioned embodiments, but one of ordinary skill in the art may recognize that many further combinations and permutations of various embodiments are possible. Accordingly, the described embodiments are intended to embrace all such alterations, modifications and variations that fall within the spirit and scope of the appended claims. Furthermore, to the extent that the term “includes” is used in either the detailed description or the claims, such term is intended to be inclusive in a manner similar to the term “comprising” as “comprising” is interpreted when employed as a transitional word in a claim.
