US20090151298A1 - Method of Making Monolithic Concrete Structures - Google Patents

Method of Making Monolithic Concrete Structures Download PDF

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Publication number
US20090151298A1
US20090151298A1 US12/359,371 US35937109A US2009151298A1 US 20090151298 A1 US20090151298 A1 US 20090151298A1 US 35937109 A US35937109 A US 35937109A US 2009151298 A1 US2009151298 A1 US 2009151298A1
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United States
Prior art keywords
slab
portions
columns
central
flange
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Abandoned
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US12/359,371
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English (en)
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Omar Abdul Jazzar
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Individual
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Individual
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    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04C—STRUCTURAL ELEMENTS; BUILDING MATERIALS
    • E04C3/00—Structural elongated elements designed for load-supporting
    • E04C3/30—Columns; Pillars; Struts
    • E04C3/34—Columns; Pillars; Struts of concrete other stone-like material, with or without permanent form elements, with or without internal or external reinforcement, e.g. metal coverings
    • 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
    • E04B1/16—Structures made from masses, e.g. of concrete, cast or similarly formed in situ with or without making use of additional elements, such as permanent forms, substructures to be coated with load-bearing material
    • E04B1/164—Structures made from masses, e.g. of concrete, cast or similarly formed in situ with or without making use of additional elements, such as permanent forms, substructures to be coated with load-bearing material with vertical and horizontal slabs, only the horizontal slabs being partially cast in situ
    • 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
    • E04B1/348—Structures composed of units comprising at least considerable parts of two sides of a room, e.g. box-like or cell-like units closed or in skeleton form
    • E04B1/34815—Elements not integrated in a skeleton
    • E04B1/34823—Elements not integrated in a skeleton the supporting structure consisting of concrete
    • 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
    • E04B5/43—Floor structures of extraordinary design; Features relating to the elastic stability; Floor structures specially designed for resting on columns only, e.g. mushroom floors

Definitions

  • This invention relates to concrete building units that may comprise both pre-cast and cast-in-situ portions to provide a continuous cementitious structure that distributes loads and moments so that less concrete is needed.
  • a disadvantage of this method is that its reliance on laterally extensive prefabricated wall members restricts its use to structures, such as apartment dwellings, that have relatively small openings in those wall modules, and precludes its use for structures, such as garages, warehouses and industrial buildings, that commonly provide relatively large open spaces by using spaced apart columns to support a ceiling or roof.
  • Schmidt teaches a method of fabricating a multi-storey cementitious structure in which spaced-apart columns support the above-grade levels.
  • Schmidt's columns are pre-fabricated with flanges extending laterally by nearly one half of the inter-column spacing. A row of such columns is erected and the flanges on adjacent columns are grouted together to define a horizontal beam.
  • Pre-fabricated concrete planks are then laid between two parallel beams and the planks are grouted together and to the beams so as to form a monolithic structure.
  • a disadvantage of Schmidt's method is that the load imposed by the concrete planks is distributed one dimensionally, rather than in both lateral dimensions. This requires the beams and columns to be heavier and stronger than would be the case if the loads and moments were distributed in two dimensions.
  • One aspect of the invention is that it provides a method of making a monolithic reinforced concrete upper slab portion of a building supported by four or more precast columns.
  • the columns are generally erected above a lower slab to define one or more generally rectangular bays having a respective column at each of its corners.
  • each of the precast columns has a reinforced rigid flange portion extending out horizontally at the selected height from the upper slab.
  • Each flange portion which is preferably square in a plan view, has rebar cast into it and extending outward from portions of all four of its edges.
  • each flange portion has two edges parallel to and facing respective edges of the flange portions of two other columns so as to define four rectangular border areas, each of which extends between a respective pair of the flange portions.
  • a temporary support is placed in the middle of the bay defined by a set of four columns and a rectangular precast central slab preferably having rebar extending outward from all four edges is placed on it.
  • the dimensions of the central slab are chosen so that the slab covers most of the bay and abuts, or slightly overlaps, all four border areas and the respective corner portions of all four associated columns.
  • Formwork supported from the lower slab is placed beneath the border areas and concrete is poured to form the desired monolithic slab portion comprising the central slab and all four flange portions. This system distributes the loads and moments to all four sides, rather than only two sides, thus allowing for thinner slabs, which reduces weight, materials costs and labor.
  • each of the precast columns comprises an anchor that is preferably a metal member cast into the column at a height about half way between the lower and upper slabs.
  • the formwork deployed beneath the border areas may be supported during casting by means of support arms connected to these anchors.
  • each anchor is directly connected to two support arms, one of which extends from the anchor outward and upward to the formwork and the other of which extends from the anchor outward and downward to a load bearing point on the lower slab.
  • Another aspect of the invention is that it provides a method of using a relatively low weight slab member for making a monolithic reinforced concrete portion of a building comprising a monolithic slab supported by a plurality of columns. These columns are preferably erected at the four corners of one or more rectangular bays. The low weight slab or slabs are then placed atop the columns and are cemented thereto.
  • the low weight slab members comprise a plurality of reinforced beam portions extending parallel to each of the edges of the slab member and an array of low-density regions disposed intermediate the beam portions. Rebar preferably extends along each reinforced beam portion and protrudes outwardly from each end thereof.
  • the slab member is formed by setting the rebar in position in a mold that defines the beam portions, placing blocks of polymeric foam in the regions between the rows of rebar and then casting the slab member.
  • the weight is further reduced by providing that much of the precast slab member is thinner than the final slab. This minimizes the weight of precast pieces that need to be lifted and lowered into position and allows the builder to bring the entire slab up to a final specified thickness by pouring additional concrete on top of the pre-cast slab member.
  • the slab member comprises stepped or rabbeted edges in which an upper portion of the edge region extends all the way to the edge of the slab member and the lower portion of the edge region is stepped back therefrom.
  • each corner of the slab can be placed in abutting contact with a respective flange prior to cementing the slab member to the column.
  • FIG. 1 is a schematic perspective view of an intermediate step in forming a slab.
  • FIG. 2 is a cross-sectional view of an upper portion of a flanged column, the section taken as indicated by the arrow 2 - 2 in FIG. 1 .
  • FIG. 3 is a detail view, as indicated by the phantom circle 3 in FIG. 1 , the view showing a corner of a column flange disposed beneath a corner of a central slab member.
  • FIG. 4 is a plan view of a preferred central slab.
  • FIG. 5 a is a cross section of a central slab having raised beam sections, the section taken as indicated by the arrow 5 a,b - 5 a,b in FIG. 4 .
  • FIG. 5 b is a cross section of a preferred central slab having some rebar held in place with stirrups, the section taken as indicated by the double-headed arrow 5 a,b - 5 a,b in FIG. 4 .
  • FIG. 6 a is another cross section of the slab of FIG. 5 a , the section taken as indicated by the arrow 6 a,b - 6 a,b in FIG. 4 .
  • FIG. 6 b is another cross section of the preferred central slab, the section taken as indicated by the arrow 6 a,b - 6 a,b in FIG. 4 .
  • FIG. 7 is a sectional view showing temporary support arms used to support formwork used in casting a border area, the section taken as indicated by the arrow 7 - 7 in FIG. 1 .
  • FIG. 1 one finds a schematic depiction of an intermediate step in a process of forming a slab 10 by joining a plurality of flange portions 12 of respective columns 14 with a central precast slab portion 16 and by casting border areas 18 , which extend outward from the bay 20 , in situ.
  • the drawing depicts only a single bay 20 , the reader will understand that the process herein described is applicable to a multi-bay arrangement.
  • the depicted single bay has a column at each corner, the reader should recognize that flanged wall members, as described by the inventor in his U.S. Pat. No. 7,121,061 can be substituted for pairs of the depicted columns.
  • the disclosure of U.S. Pat. No. 7,121,061 is fully incorporated herein by reference.
  • each column 14 comprises both a vertically extensive portion 22 and a flanged portion 12 that preferably comprises a stepped or rabbeted edge region 24 in which a lower portion 26 of the edge region extends further outward from the vertically extensive portion 22 than does an upper portion 28 .
  • This rabbeted edge arrangement is similar to that used on wall members described in the inventor's U.S. Pat. No. 7,121,061, and has the same preferred height ratios, set-back distances and protrusion lengths for rebar 29 .
  • the rabbeted arrangement aids in transferring shear loads from a supported portion of the slab to the rigid flange, and thence to the vertically extensive portion of all of the columns and to neighboring bays.
  • the lower portion of the rabbet extends ten to twenty centimeters outward beyond the upper portion of the rabbet.
  • rebar does not protrude from the corners 30 of the flange portions.
  • each column 14 is depicted in the drawing as having a flat top surface, which accords with a process of making a single storey above grade, the reader should realize that many other arrangements are possible and that, more generally, the top of each column may comprise attachment means for mounting the base of another column used to support a yet higher storey in the structure.
  • the preferred central slab 16 has a complementary rabbeted edge region in which an upper portion of the edge region 32 extends further outward than does a lower portion 34 . This allows each corner 35 of the slab member 16 to rest upon a respective corner of a column flange 12 , as depicted in FIG. 3 . As described above with respect to the flange portions, although the central slab member preferably has rebar extending outward from all its edges, there is no rebar extending outward from the corner portions that overlap with the flange portions.
  • FIG. 4 one finds a plan view of a preferred central slab member, which is configured as a “waffle”.
  • the preferred central slab member comprises a rim portion 36 having the rabbet edge features described above.
  • the slab 16 comprises a grid of reinforced beam portions 38 running parallel to the edges of the slab 16 .
  • the upper portion of the beam portions 38 may have rebar cast into them, as depicted in FIGS. 5 a and 6 a .
  • the reinforced beam portions comprise rebar cast into lower portions of the beam and other rebar held on top of the beam portions by means of stirrups 39 .
  • the rebar retained in stirrups is preferably cast into the center section during a single concrete pour that tops off the waffle section and forms the border area portions of the slab.
  • Rebar preferably protrudes through and outward from the ends of these beam portions as depicted in FIGS. 5 a,b and 6 a,b .
  • the areas between the beam portions are preferably only about half the maximum thickness of the central slab member 16 , and may be filled, at least partially, with foamed plastic blocks 40 or other lightweight items.
  • the central slab 16 is pre-cast using foamed plastic blocks 40 having outwardly protruding ears or lugs 42 .
  • the blocks 40 are held in position by the mold (not shown).
  • the lugs 42 prevent the heavy concrete above the blocks from pushing the blocks out through the bottom of the precast slab 16 .
  • other means of locking the low density blocks into the concrete may also be employed and that these include, without limitation, providing a recessed region in the foam and inserting rebar through the foam and into adjacent areas prior to casting.
  • the columns 14 and wall members are erected on a hardened bottom slab 44 or are supported above a bottom slab by being attached to another column or wall at a lower level in the structure—i.e., a column or wall associated with a building storey below the bottom slab.
  • Free-standing temporary supports 46 are then placed in the central portion of each bay and respective central slab members are placed onto each one of them. As described above, in preferred arrangements, corners of the slabs are supported not only by the temporary support 46 , but also by the corners of respective column flanges, as depicted in FIG. 3 .
  • the preferred process calls for the erection of formwork 47 in the border areas.
  • additional rebar 29 may be introduced into the border areas and preferably fastened to rebar protruding from a slab or flange by clamping, welding, or by any other known means.
  • the formwork in the border areas is supported by a combination of temporary trusses 48 and support arms 50 .
  • a first support arm 50 is fastened between a truss 48 and a respective anchor 52 in a column adjacent to the truss, as depicted in FIG. 7 .
  • Each such column may then be connected to a load bearing point 54 on the bottom slab 44 .
  • the preferred process allows for a single concrete pour to complete the slab by filling in the forms in the border areas and by also filling in those portions of the central slabs that have a reduced thickness.

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  • Engineering & Computer Science (AREA)
  • Architecture (AREA)
  • Civil Engineering (AREA)
  • Structural Engineering (AREA)
  • Physics & Mathematics (AREA)
  • Electromagnetism (AREA)
  • Panels For Use In Building Construction (AREA)
  • Joining Of Building Structures In Genera (AREA)
  • Rod-Shaped Construction Members (AREA)
  • On-Site Construction Work That Accompanies The Preparation And Application Of Concrete (AREA)
  • Reinforcement Elements For Buildings (AREA)
  • Conveying And Assembling Of Building Elements In Situ (AREA)
  • Working Measures On Existing Buildindgs (AREA)
US12/359,371 2006-08-16 2009-01-26 Method of Making Monolithic Concrete Structures Abandoned US20090151298A1 (en)

Applications Claiming Priority (3)

Application Number Priority Date Filing Date Title
EGPCT/EG2006/000032 2006-08-16
EG2006080448A EG27117A (en) 2006-08-17 2006-08-17 Pre-cast cast in-situ suspended concrete building system
PCT/EG2006/000032 WO2008019699A1 (en) 2006-08-16 2006-08-24 Precast concrete building units

Related Parent Applications (1)

Application Number Title Priority Date Filing Date
PCT/EG2006/000032 Continuation-In-Part WO2008019699A1 (en) 2006-08-16 2006-08-24 Precast concrete building units

Publications (1)

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US20090151298A1 true US20090151298A1 (en) 2009-06-18

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US12/359,371 Abandoned US20090151298A1 (en) 2006-08-16 2009-01-26 Method of Making Monolithic Concrete Structures

Country Status (10)

Country Link
US (1) US20090151298A1 (ja)
EP (1) EP2061937B1 (ja)
JP (1) JP4991855B2 (ja)
EA (1) EA019161B1 (ja)
EG (1) EG27117A (ja)
ES (1) ES2429565T3 (ja)
MA (1) MA30697B1 (ja)
PL (1) PL2061937T3 (ja)
WO (1) WO2008019699A1 (ja)
ZA (1) ZA200901017B (ja)

Cited By (9)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US20110146198A1 (en) * 2009-08-19 2011-06-23 Paul Meisel Modular seismically restrained distribution system and method of installing the same
US20130305652A1 (en) * 2012-05-18 2013-11-21 Neturen Co., Ltd. Rebar structure and reinforced concrete member
EP2876226A1 (fr) * 2013-11-22 2015-05-27 Julien Lebourgeois Poteau porteur en BFUP intégré à un complexe de façade, ossatures et façades associées
US9970193B1 (en) * 2016-04-28 2018-05-15 Boxer Anaya, LLC System and method for the construction of dwellings
WO2019199317A1 (en) * 2018-04-13 2019-10-17 Boxer Anaya, LLC System and method for the construction of dwellings
US10640970B2 (en) * 2017-08-01 2020-05-05 Nandy Sarda Concrete building elements and assemblies thereof, and related methods
TWI736482B (zh) * 2020-12-03 2021-08-11 潤弘精密工程事業股份有限公司 建築結構之施工方法
US11339561B2 (en) * 2016-07-06 2022-05-24 PT Blink Limited Method of constructing a modular building, a tray-like modular building component, and related method, and a modular building column assembly
CN114607041A (zh) * 2020-12-03 2022-06-10 润弘精密工程事业股份有限公司 建筑结构的施工方法

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CN101979789B (zh) * 2009-07-15 2015-09-30 默罕默德·奥马尔·贾扎尔 钢筋混凝土建筑结构及其方法
CN107060133B (zh) * 2017-04-29 2019-06-07 福州大学 一种适用于框架剪力墙结构的装配式剪力墙及其安装方法
CN108457506B (zh) * 2018-05-15 2023-12-29 广东怡丰智能车库有限公司 一种立体车库用预制舱及其骨架组件
JP6842011B2 (ja) * 2018-09-26 2021-03-17 太陽技建工業株式会社 工事用単位部材及びその製造方法、部材連結体、コンクリート施工方法
CN111502077B (zh) * 2020-04-03 2021-06-11 中国建筑第八工程局有限公司 不均匀沉降下钢柱与剪力墙交接处的施工方法
JP7278015B1 (ja) 2022-07-04 2023-05-19 太陽技建工業株式会社 工事用単位ブロック及びその製造方法、二次元連結板、コンクリート施工方法

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US915421A (en) * 1908-07-06 1909-03-16 Theodore Augustus Eisen Construction of buildings.
US1516074A (en) * 1922-10-16 1924-11-18 Fredrik G Borg Concrete building construction
US3562979A (en) * 1967-10-23 1971-02-16 Componoform Inc Building construction
US3748805A (en) * 1971-10-18 1973-07-31 Y Boros Building structure and method of erecting same
US3918222A (en) * 1974-06-03 1975-11-11 Bahram Bahramian Prefabricated modular flooring and roofing system
US4065907A (en) * 1970-11-27 1978-01-03 Unicon Parking Structures, Inc. Demountable multiple level building structures
US5809712A (en) * 1996-06-06 1998-09-22 Simanjuntak; Johan Hasiholan System for joining precast concrete columns and slabs
US20040118080A1 (en) * 2001-06-02 2004-06-24 Jazzar Omar Abdul Latif Reinforced concrete building system

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US3788012A (en) * 1972-02-22 1974-01-29 Arnold Ass Inc Modular building structure elements of slabs with central support posts
DE2251613A1 (de) 1972-10-20 1974-05-02 Schmidt Hans J Stahlbetonskelettbau mit unterzugloser decke
SU553335A1 (ru) * 1974-12-03 1977-04-05 Государственный Проектный И Научно-Исследовательский Институт "Казахский Промстройниипроект" Сборный железобетонный каркас многоэтажного здани
SU1709040A1 (ru) * 1988-10-10 1992-01-30 Киевский Зональный Научно-Исследовательский И Проектный Институт Типового И Экспериментального Проектирования Жилых И Общественных Зданий Безригельный каркас
JP2004019330A (ja) * 2002-06-19 2004-01-22 Clion Co Ltd Ａｌｃパネル
ECSP034697A (es) 2003-07-18 2004-06-28 Cabezas Pedro Nel Fernando Ospina Sistema constructivo estructural mixto integral

Patent Citations (9)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US915421A (en) * 1908-07-06 1909-03-16 Theodore Augustus Eisen Construction of buildings.
US1516074A (en) * 1922-10-16 1924-11-18 Fredrik G Borg Concrete building construction
US3562979A (en) * 1967-10-23 1971-02-16 Componoform Inc Building construction
US4065907A (en) * 1970-11-27 1978-01-03 Unicon Parking Structures, Inc. Demountable multiple level building structures
US3748805A (en) * 1971-10-18 1973-07-31 Y Boros Building structure and method of erecting same
US3918222A (en) * 1974-06-03 1975-11-11 Bahram Bahramian Prefabricated modular flooring and roofing system
US5809712A (en) * 1996-06-06 1998-09-22 Simanjuntak; Johan Hasiholan System for joining precast concrete columns and slabs
US20040118080A1 (en) * 2001-06-02 2004-06-24 Jazzar Omar Abdul Latif Reinforced concrete building system
US7121061B2 (en) * 2001-06-02 2006-10-17 Omar Abdul Latif Jazzar Reinforced concrete building system

Cited By (15)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US8347585B2 (en) * 2009-08-19 2013-01-08 Kinetics Noise Control, Inc. Modular seismically restrained distribution system and method of installing the same
US20110146198A1 (en) * 2009-08-19 2011-06-23 Paul Meisel Modular seismically restrained distribution system and method of installing the same
US9540815B2 (en) 2012-05-18 2017-01-10 Neturen Co., Ltd. Rebar structure and reinforced concrete member
US20130305652A1 (en) * 2012-05-18 2013-11-21 Neturen Co., Ltd. Rebar structure and reinforced concrete member
US9562355B2 (en) 2012-05-18 2017-02-07 Neturen Co., Ltd. Rebar structure and reinforced concrete member
US9260866B2 (en) * 2012-05-18 2016-02-16 Neturen Co., Ltd. Rebar structure and reinforced concrete member
EP2876226A1 (fr) * 2013-11-22 2015-05-27 Julien Lebourgeois Poteau porteur en BFUP intégré à un complexe de façade, ossatures et façades associées
FR3013747A1 (fr) * 2013-11-22 2015-05-29 Julien Lebourgeois Poteau porteur en bfup integre a un complexe de facade, ossatures et facades associees
US9970193B1 (en) * 2016-04-28 2018-05-15 Boxer Anaya, LLC System and method for the construction of dwellings
US11339561B2 (en) * 2016-07-06 2022-05-24 PT Blink Limited Method of constructing a modular building, a tray-like modular building component, and related method, and a modular building column assembly
US11746520B2 (en) 2016-07-06 2023-09-05 PT Blink Limited Method of constructing a modular building, a tray-like modular building component, and related method, and a modular building column assembly
US10640970B2 (en) * 2017-08-01 2020-05-05 Nandy Sarda Concrete building elements and assemblies thereof, and related methods
WO2019199317A1 (en) * 2018-04-13 2019-10-17 Boxer Anaya, LLC System and method for the construction of dwellings
TWI736482B (zh) * 2020-12-03 2021-08-11 潤弘精密工程事業股份有限公司 建築結構之施工方法
CN114607041A (zh) * 2020-12-03 2022-06-10 润弘精密工程事业股份有限公司 建筑结构的施工方法

Also Published As

Publication number Publication date
EP2061937A1 (en) 2009-05-27
WO2008019699A1 (en) 2008-02-21
EA019161B1 (ru) 2014-01-30
ZA200901017B (en) 2010-07-28
EG27117A (en) 2016-06-23
WO2008019699A8 (en) 2011-03-03
JP4991855B2 (ja) 2012-08-01
EP2061937B1 (en) 2013-07-03
EA200970205A1 (ru) 2009-12-30
EP2061937A4 (en) 2010-01-13
MA30697B1 (fr) 2009-09-01
JP2010518275A (ja) 2010-05-27
PL2061937T3 (pl) 2013-12-31
ES2429565T3 (es) 2013-11-15

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