WO2012096639A1 - Appareil de moule à construction modulaire et procédé pour construire des structures et des bâtiments en béton - Google Patents

Appareil de moule à construction modulaire et procédé pour construire des structures et des bâtiments en béton Download PDF

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Publication number
WO2012096639A1
WO2012096639A1 PCT/US2011/000048 US2011000048W WO2012096639A1 WO 2012096639 A1 WO2012096639 A1 WO 2012096639A1 US 2011000048 W US2011000048 W US 2011000048W WO 2012096639 A1 WO2012096639 A1 WO 2012096639A1
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WO
WIPO (PCT)
Prior art keywords
wall
encasement
panel
connector
steel
Prior art date
Application number
PCT/US2011/000048
Other languages
English (en)
Inventor
Frank K. Johnson
Minhaj KIRMANI
Original Assignee
Johnson Frank K
Kirmani Minhaj
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Johnson Frank K, Kirmani Minhaj filed Critical Johnson Frank K
Priority to PCT/US2011/000048 priority Critical patent/WO2012096639A1/fr
Publication of WO2012096639A1 publication Critical patent/WO2012096639A1/fr

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Classifications

    • 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
    • E04B1/161—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, both 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
    • E04B2/00—Walls, e.g. partitions, for buildings; Wall construction with regard to insulation; Connections specially adapted to walls
    • E04B2/84—Walls made by casting, pouring, or tamping in situ
    • E04B2/86—Walls made by casting, pouring, or tamping in situ made in permanent forms
    • E04B2/8635—Walls made by casting, pouring, or tamping in situ made in permanent forms with ties attached to the inner faces of the forms
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
    • E04B2/00—Walls, e.g. partitions, for buildings; Wall construction with regard to insulation; Connections specially adapted to walls
    • E04B2/84—Walls made by casting, pouring, or tamping in situ
    • E04B2/86—Walls made by casting, pouring, or tamping in situ made in permanent forms
    • E04B2/8652—Walls made by casting, pouring, or tamping in situ made in permanent forms with ties located in the joints of the forms
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
    • E04B2/00—Walls, e.g. partitions, for buildings; Wall construction with regard to insulation; Connections specially adapted to walls
    • E04B2/84—Walls made by casting, pouring, or tamping in situ
    • E04B2/86—Walls made by casting, pouring, or tamping in situ made in permanent forms
    • E04B2002/867—Corner details

Definitions

  • the present invention relates generally to the building arts, and more particularly to the means and methods of constructing large dimensioned monolithic composite concrete and steel buildings and structures underwater and on dry land.
  • the finished concrete slab is supported on the top flanges of the wide flange structural steel members. Studs welded to the top flange protrude into the concrete slab to make the two different building materials act as a single composite structure.
  • Composite design results in savings by requiring fewer columns, beams and connections, producing longer spans and larger rooms in buildings, and providing more flexible, and saleable floor plans.
  • the downside of this type of construction is that the steel beams supporting composite floor slabs are exposed and must be fireproofed, another labor intensive, time consuming and costly activity.
  • the '262 patent discloses a panelized mold apparatus for containing, shaping and permanently encasing monolithically cast reinforced concrete walls, footings, beams and floor slabs using interlocking panel assemblies to form foundation, cavity wall and roof deck void spaces.
  • the perforated steel sheets used to attach parallel wall assemblies together and prevent the two sides of the cavity walls from separating during the casting process are not considered as reinforcing steel when calculating the tensile requirements for the structure.
  • the perforated steel sheets in the footings and truss assemblies considered as reinforcement.
  • the '262 patent does not disclose how horizontal and vertical reinforcing steel rods are to be installed within the void spaces when the perforated sheet steel attachments are spaced at such close intervals. Nor does the patent disclose how . vertical wall assemblies are to be supported against hydrostatic loads when distance between the inside and outside wall assemblies forming the void space is excessive as in the case of large dimensioned pile caps, deep deck, floor and roof slabs, foundations and piers supported on piles; nor does the '262 patent disclose how the horizontal platform assemblies are to be supported to carry gravity loads associated with casting reinforced concrete slabs over very long spans without intermediary supports or shoring.
  • the '262 patent does not disclose how the panelized assemblies are to be erected and rebars installed when the work site is under water.
  • the work site must be made dry in order for the workers to erect formwork and install rebar.
  • Making a work site dry in the middle of a body of water requires construction of a water tight enclosure, dewatering and other tasks prior to commencing concrete work, tasks that add considerable time and cost to a construction project.
  • the steel grillage It is also an object of the present invention for the steel grillage to provide tensile strength to the permanently encased monolithic composite concrete and steel structure, thereby eliminating the necessity, and costs of installing rebar at the work site.
  • Another object of the present invention is to pre-assemble encasement panels and connectors off-site and attach them to the grillage to form a modular unit of a steel-framed construction mold apparatus, which can be transported to the site ready for immediate installation, greatly reducing construction activity at the work site and making underwater construction of composite concrete and steel structures both practical and economical.
  • Another object of the present invention is to reduce the costs and facilitate construction of permanently encased monolithic composite concrete and steel structures underwater by eliminating the need for constructing temporary watertight structures typically used to create a dry work area in a submerged work site.
  • panelized encasement assemblies integrally attached to vertical and horizontal members of a structural steel grillage that can be used to advantage for underwater construction of large monolithically cast concrete and steel civil engineering works that include bridge abutments, piers, decks and superstructures, piles and pile caps, foundation, floor and roof slabs, shear walls, core walls, retaining walls and footings, deep foundation walls, seawalls, box culverts, flood protection cofferdams, off-shore barrier reefs and coastal islands.
  • steel While steel is referred to herein it will be understood that for particular applications steel sheets, I-beams, angles, and channels and other shapes used as purlins, girts, columns, connectors, girders and bollards can be made of other metals and/or be substituted with fiber reinforced composites where fibrous reinforcements are metal, carbon or glass and the matrix is plastic, metal or carbon.
  • the present invention can be used to advantage in providing strength to hold panelized encasement assemblies in place before and during the casting process, and after casting providing tensile strength and rigidity to composite structures without recourse to conventional steel reinforcement rods typically employed for this purpose,
  • the present invention in any of the cited or other such dry land applications can be used with reinforcing rods or the like in the construction of permanently encased monolithic composite concrete and steel structures to provide additional tensile or bending strength, as specified by the design engineer.
  • the construction mold for forming, casting, and encasing the above composite concrete and steel structures is comprised of foundation/footing, cavity wall and roof deck encasement sub-assemblies joined together to act as a single structural unit that forms structured void spaces for receiving wet concrete in situ underwater and on dry land.
  • the panelized encasement assembly component of the modular steel-frame construction mold apparatus is comprised of interlocking encasement panels and connectors that are integrally attached to a corresponding structural steel grillage component.
  • T-shaped tension keys protruding from the end walls of encasement panels matingly interlock with keyways formed in the body of connector brackets.
  • the reverse is also feasible, i.e. keys on the brackets and keyways formed on the end walls.
  • connector brackets are the means of removeably and integrally attaching the encasement assemblies to the structural steel grillage.
  • Concrete is cast into the foundation, cavity wall and roof deck void spaces formed by the modular steel-framed construction mold apparatus in a substantially continuous fashion to produce a monolithic permanently encased composite concrete and steel structure.
  • the encasement assemblies remain in place after the wet concrete has been cast into them, protecting the inner and outer surfaces of the composite concrete and steel foundations, walls and columns, and the under surface of composite concrete and steel floor and roof slabs.
  • the structural steel grillage becomes permanently embedded in the wet concrete during the casting process and provides tensile strength complementing the co.mpressive strength of concrete in the resulting structure.
  • the advantage of the present invention is that the structural steel I- beams, angles, channels and other standard sections making up the grillage component provide a strong and rigid means of supporting the encasement assemblies during fabrication, shipping, handling, installation and casting. Another advantage is the structural steel grillage component facilitates construction of composite concrete and steel structures underwater.
  • the structural steel grillage provides is to enable forming and casting of very wide horizontal structures such as piers and pile caps, and very long unsupported horizontal spans such as bridges, box culverts, and box girders.
  • the structural steel grillage provides a stronger and more practical means of supporting encasement assemblies than the perforated steel tie sheets called for in the '262 patent, eliminates the need for installing reinforcing steel at the work site, and makes construction of composite concrete and steel structures simpler, safer, and more economical, both on dry land and underwater.
  • FIG. 1 is a phantom view showing a modular segment of an open-ended monolithic composite concrete and steel structure.
  • Fig. 2A is a perspective view showing the steel grillage component for a modular unit of a steel-framed construction mold apparatus used to form, cast and encase the segment of an open-ended monolithic composite concrete and steel structure shown in Fig. 1.
  • Fig. 2B is a perspective view showing the panelized encasement assembly component for a modular unit of a steel-framed construction mold apparatus used to form, cast and encase the segment of an open-ended monolithic composite concrete and steel structure shown in Fig. 1.
  • Fig. 2C is a perspective view showing the panelized encasement component of Fig. 2B integrally attached to the steel grillage component of Fig. 2A forming a modular unit of a steel-framed construction mold apparatus
  • Fig. 3A is an end view of the modular unit shown in Fig. 2C.
  • Fig. 3B is a detail view showing the interlocking corner connection between the roof deck encasement sub-assembly and inner wall of the cavity wall encasement sub-assembly shown in Fig. 3A.
  • Fig. 3C is a detail view showing the variable width center section of the roof deck sub-assembly shown in Fig. 3A;
  • Fig. 3D is a detail view showing the pedestal connection between the foundation encasement sub-assembly and the cavity wall encasement sub-assembly shown in Fig. 3A.
  • Fig. 4A is a perspective view showing the end walls of a modular steel- framed construction mold apparatus used to form, cast, and encase an open-ended permanently encased monolithic composite concrete and steel structure of finite length.
  • Fig. 4B is a detail view showing the connection between the roof deck encasement sub-assembly and the roof deck end wall shown in Fig. 4A.
  • Fig. 5A is a cross-section of a multi-cell hollow-core reinforced polymer encasement panel.
  • Fig. 5B is a cross-section of a composite foam-core encasement panel with reinforced polymer end connectors integrally attached.
  • Fig. 5C is a cross-section of a hollow-core reinforced polymer encasement panel connector bracket.
  • Fig. 5D Is a cross-section of a hollow-core reinforced polymer panel connector with bracket keyway.
  • Fig. 5E is a cross-section of a hollow-core reinforced polymer inside corner connector bracket.
  • Fig. 5F is a cross-section of hollow-core reinforced polymer outside comer connector bracket.
  • Fig. 5G is a cross-section of a reinforced polymer connector cap.
  • Fig. 6A is a perspective view showing a three unit segment of a modular steel-framed construction mold apparatus used for constructing an open-ended monolithic composite concrete and steel structure.
  • Fig. 6B is a perspective view showing the steel grillage component of the modular construction mold apparatus segment shown in Fig. 6A without the
  • Fig. 6C is a perspective view showing the steel grillage component for a two bay three-unit segment of a modular construction mold apparatus during in situ installation without the corresponding panelized encasement component.
  • Fig. 6D is a perspective view of the encasement component for a two bay single unit segment of a modular steel-framed construction mold apparatus without the corresponding steel grillage component.
  • Fig. 6E is a perspective view of the encasement component for a two bay three unit segment of a modular steel-framed construction mold apparatus without the corresponding steel grillage component.
  • Fig. 7 is a flow chart identifying the steps involved in the preferred method for constructing permanently encased monolithic composite concrete and steel structures underwater using a modular steel-framed construction mold apparatus.
  • Fig. 8 is a perspective view of a partially submerged modular steel-framed construction mold apparatus in situ underwater prior to casting concrete fill.
  • Corresponding housings formed within the bodies of various encasement elements are likewise identical in configuration and size and capable of slidably interlocking and engaging all protruding elements.
  • FIG. 1 shows a phantom view of an open-ended monolithic composite concrete and steel segment of a box structure 63 composed of foundation slab 631 , side walls 632 and roof slab 633 formed and cast using a modular unit of a steel-framed construction mold apparatus.
  • the encasement component of the mold apparatus is not shown for clarity.
  • the steel grillage component 40 of said modular unit is shown embedded within the concrete segment 63.
  • Steel bollards 471 supporting the grillage component extend downward beneath the concrete foundation into the sub-base material 612 supporting the segment.
  • Fig. 2A shows the preferred embodiment of the steel grillage component of a modular steel-framed construction mold apparatus without concrete fill or the corresponding encasement component.
  • Each column 41 is supported by and integrally attached to a steel pedestal 47 comprised of two bollards 471 and integrally joined at the top by cross beam 472.
  • Roof girder, joist or truss member 42 integrally joins the top portion of two opposing columns 41 to form a rigid bent.
  • Base beam 43 integrally joins the pedestals 47 of two opposing columns 41.
  • a plurality of evenly spaced horizontal beams or girts 441 are integrally attached to the outside flange of columns 41 in each row.
  • a plurality of girts 442 are likewise attached to the inside flange of columns 41 in each row spaced opposite to the outside girts 441.
  • a plurality of roof beams or purlins 452 are integrally attached to the lower flange of the roof girders 42.
  • Steel brackets 46 integrally attached to grillage girts 44 and purlins 45, project away from the grillage into the void space 20, integrally attach to corresponding encasement brackets projecting inward to void space 20 from the encasement component of the modular mold unit shown in Fig. 2B.
  • the length of a steel-framed construction mold apparatus modular unit is defined by the horizontal girts 44 attached to the grillage columns 41 and purlins 45 attached to the roof girders 42. Grillage columns 41 define the height of the modular unit, and roof girders 42 and base beams 43 define its width.
  • the structural steel elements comprising the grillage component 40 of the steel- framed construction mold apparatus modular unit, including columns 41 , base beams 43, girts 44, purlins 45, bollards 471 and cross beams 472 may be sized and dimensioned to the design engineers specifications to meet the loading and functional requirements of the resulting composite concrete and steel structure, existing site considerations, availability of equipment and resources at the work site, and other variable parameters associated with usage and construction activities.
  • FIG. 2B shows the preferred embodiment of the panelized encasement component 30 of a modular unit of a steel-framed construction mold apparatus corresponding to the grillage component that supports the panelized encasement component sub-assemblies.
  • the panelized encasement component consists of foundation 31 , cavity wall 32 and roof deck 33 panelized subassemblies which define and form foundation 21 , cavity wall 22 and roof deck 23 void spaces respectively.
  • the foundation encasement sub-assembly 31 which defines and forms the foundation slab void space 21 is comprised of a plurality of encasement panels 1 integrally connected together to form a sold wall by panel connector brackets 2.
  • the panel connector brackets 2 integrally attach to corresponding steel brackets 46 attached to the structural members 44, 45 of the grillage component by bolts and nuts or other such mechanical means [not shown).
  • edge of one encasement panel 1 is integrally connected to the edge of a second encasement panel 1 as described later along their longitudinal axes by slidably interlocking t-shaped tongues or keys 121 extending outward from end wall 12 of the panel into mating keyways 203 formed in the body 202 of panel connector brackets 2.
  • the height of the vertically aligned panels 1 and connectors 2 comprising the foundation encasement sub-assembly is specified by the design engineer.
  • the cavity wall encasement sub-assembly 32 which forms and defines the cavity wall void space 22 consists of an outer side wall 322 and an inner side wall 321 each wall integrally attached by connector brackets 2 to the corresponding outside 441 and inside 442 girts of grillage component 40 of the modular unit shown in Fig. 2A.
  • the outer side wall 441 is vertically aligned in the preferred embodiment to facilitate joining the modular construction unit to a second previously installed modular construction unit at the work site and forming the outer wall 331 of the roof deck encasement sub-assembly 33.
  • the inner side wall 321 of the cavity wall encasement sub-assembly 32 is aligned horizontally in the preferred embodiment to facilitate and secure the inside corner connection 4 between the cavity wall sub-assembly 321 and the roof deck sub-assembly 33.
  • An inside corner connector bracket 4 integrally connects the horizontally aligned corner panel 1 of the inner side wall 321 to the outside corner panel 1 of the roof deck subassembly 33.
  • panels 1 and connector brackets 2 comprising the corner section of the roof deck encasement assembly 33 are integrally connected to panels 1 and connector brackets 2 comprising the cavity wall inner side wall 321 with an inside corner connector bracket 4.
  • Panels 1 and connector brackets 2 comprising the center section 333 of the roof deck encasement sub-assembly 33 are aligned 90° to the comer section panels 334 to accommodate variable roof width dimensions.
  • Cap connectors 6 connect the center section sub-assembly 333 to the corner section sub-assemblies 334.
  • Fig 2C shows the preferred embodiment of a modular unit of a steel-framed construction mold apparatus used to form, cast and encase the segment of an open-ended monolithic composite concrete and steel box structure shown in Fig. 1 comprised of the panelized encasement component shown in Fig. 2B integrally attached to the steel grillage component shown in Fig. 2A.
  • Fig. 2C shows foundation void space 21 formed by foundation wall encasement sub-assembly 31 comprised of panels 1 and connector brackets 2 integrally attached to steel brackets 46 projecting away from girts 473 affixed to pedestal bollards 47.
  • Fig. 2C also shows cavity wall void space 22 formed by cavity wall encasement sub-assemb!y 32 consisting of outside walls 322 comprised of panels 1 and connector brackets 2 integrally attached to steel brackets 46 projecting into void space 22 from outside girts 441 attached to columns 41 which are supported on pedestals 47 and inside cavity wall 321 panels 1 and connector brackets 2 integrally attached to steel brackets 46 projecting into void space 22 from inside girts 442 attached to columns 41.
  • Fig. 2C also shows roof deck void space 23 formed by the center section 333 of roof deck sub-assembly 33 comprised of panels 1 and connector brackets 2 integrally attached to steel brackets 46 extending down from purlins 452 attached to the bottom flange of girders 42 and corner sections 334 of roof deck sub-assembly 33 comprised of panels 1 and connector brackets 2 integrally attached to steel brackets 46 extending downward from purlins 452 attached to the bottom flange of girders 42.
  • FIG. 3A shows the end view of the foundation 21 , cavity wall 22 and roof deck 23 void spaces defined and formed by a panelized encasement assembly component 30 integrally attached to the structural steel component 40 of a modular steel-framed construction mold apparatus 10.
  • the dimensions and configuration of the void spaces vary depending on the design engineer's specifications.
  • foundation void space 21 is formed by foundation encasement sub-assembly 31 integraaly attached to steel brackets 46 extending away from girt 473 integrally attached to column pedestal 47 integrally joined at the ends of the module 10 by base beam 43.
  • cavity wall void space 22 is formed by inside wall 321 and outside wall 322 of cavity wall sub-assembly 32 integrally attached to steel brackets 46 extending away from inside girts 442 and outside girts 44 integrally attached to inside and outside flanges respectively of columns 41.
  • roof deck void space 23 is formed by corner sections 334 and center section 333 of roof deck sub-assembly 33 integrally attached to brackets 46 extending away from purlins 452 attached to the underside of girders 42 and and roof deck outer wall assemblies 331 integrally attached to brackets 46 extending away from outside girts 441 integrally attached to columns 41.
  • Fig. 3B shows a detail view of the corner section 334 of roof deck sub-assembly 33 integrally attached to brackets 46 extending downward from purlins 452 integrally attached to girders 42 integrally connected by inside corner connector bracket 4 to the inside wall 321 of cavity wall sub-assembly 32 integrally attached to brackets 46 affixed to inside girts 442 integrally attached to columns 41.
  • Fig. 3C shows a detail view of the center section 333 of roof deck sub-assembly 33 integrally attached to steel brackets 46 integrally attached to purlins 452 integrally attached to girders 42 and connected to the corner sections 334 of roof deck sub-assembly 33 by cap connectors 6.
  • FIG. 3D shows a detail view of the contiguous nature of foundation void space 21 and cavity wall void space 22.
  • Foundation void space 21 is formed by foundation encasement sub-assembly 31 integrally attached to bracket 46 extending out from girt 473 integrally attached and supported by steel pedestal 47 comprised of two bollards 471 and cross beam 472 supporting column 41 and integrally joined to base beam 43.
  • the base of bollard 471 rests on undisturbed sub-base 611 and embedded in stone or gravel backfill material 612 which supports foundation concrete fill 631 (not shown) cast into void space 21.
  • Cavity wall void space 22 is formed by inside wall 321 and outside wall 322 of cavity wall sub-assembly 33 integrally attached to steel brackets 46 extending away from inside girts 442 and outside girts 441 respectively integrally attached to and supported by columns 41.
  • FIG. 4A shows a phantom view of the preferred embodiment of a modular steel-framed construction mold apparatus 10 for forming, casting and encasing an open-ended monolithic composite concrete and steel box structure.
  • the modular unit forming foundation 21, cavity wall 22, and roof deck 23 void spaces is comprised of a panelized encasement assembly component 30 with end walls 34 integrally attached to a structural steel grillage component 40 supported on bollards 471 ready for installation at the work site.
  • Foundation girts 473 and bollards 471 spaced across the opening of the structure support end walls 341.
  • End wall panels 342 define and enclose cavity wall void space 22.
  • End wall encasement panels 343 define and enclose roof deck void space 23.
  • Fig. 4B shows a detail view of the end wall encasement subassembly 341 connection to roof deck encasement sub-assembly 33 using cap connector 6 and the corresponding girder 42, outside girt 441 and purline 452 members of the grillage component 40 supporting the encasement assemblies.
  • FIG. 5A shows a cross section view of the preferred embodiment of a hollow core reinforced polymer encasement panel 1 of constant width, roughly 24", and depth 3" and variable length supported by interlocking panel connector brackets 2 matingly connected to t-shaped tongues 11 protruding outward from the distal end walls 12 of said panel that form the panel edges.
  • Said panel is comprised of two parallel interior 13 and exterior 14 walls connected by spaced apart web walls 15 forming a plurality of interstices 16 that exist along the entire longitudinal axes of the panels;
  • T-shaped tensile keys or tongues 11 protruding from the end walls 12 of the panel are situated in the wall section above the panel cross-section centerline 121 to fully resist the tensile forces imposed upon the panel during the casting process.
  • the section of the end wall of the panel below the centerline of the panel section 122 is thickened to fully resist compression forces imposed during casting.
  • Interior 131 and exterior 141 panel walls for the first two cell widths in from the ends of the panel are thicker than the interior 132 and exterior 142 panel walls in the center portion of the panel in order to resist bending without breaking during casting.
  • FIG. 5B shows a cross-section view of the preferred embodiment of a composite foam-core encasement panel 17 of variable width with reinforced polymer end connectors 171 integrally attached to the longitudinal edges of said panel.
  • Said panel is comprised of two parallel internal 173 and external 174 walls made of rigid high strength material separated and bonded together by a rigid foam substance 175 to form a laminated composite structural unit.
  • Hollow-core reinforced polymer end connectors 171 integrally attached to the longitudinal edges of said panel matingly interlock with panel connector brackets 2 (not shown).
  • T-shaped tensile keys 1 protruding from the end walls 12 of the polymer end connector are situated in the wall section above the panel centerline 121 to fully resist the tensile forces imposed upon the panel during the casting process.
  • the section of said end wall below the centerline 122 is thickened to fully resist compression forces imposed during casting.
  • Fig. 5C shows a cross section of a panel connector bracket 2 with one edge of interlocking encasement panel 1 of Fig. 5A integrally connected.
  • the bracket arm 201 extends upward (inward) into the void space 20 from the body of the connector.
  • Two t-shaped keyways 203 formed into the hollow body 202 of the connector facing away from one another at 180° are configured to matingly interlock with the corresponding t-shaped tension-key 11 protruding from the section of encasement pane! end wall above the horizontal centerline of the connector body 121.
  • the section of the hollow connector body wall 202 below the horizontal centerline 205 is thickened to resist compression.
  • Fig. 5D shows a panel connector 3 with external t-shaped bracket keyway 301 in place of the bracket arm 201 shown in Fig. 5B formed into the extended body 302 of the connector with the keyway opening 301 oriented at 90° to the two panel connection keyways 303 for receiving the end of a custom- designed bracket (not shown).
  • the section of the connector body below the centerline 305 is reduced in outside dimension but the walls of the hollow body 302 are increased in thickness to resist compression forces.
  • Fig. 5E shows a cross section of the preferred embodiment of a right triangular-shaped inside corner connector bracket 4 interlocking and integrally connecting two panel connector brackets 2 facing 90° to one another.
  • Bracket arm 401 integrally connects to hypotenuse wall 404 of the hollow body 402 and extends roughly 4" into void space 20.
  • Inside corner connector bracket 4 is a hollow-core reinforced polymer pultruded or extruded structural element consisting of two t-shaped tension keys 403 located above the panel section centerline protruding away from the hollow body 402 at 90° to one another that slidably interlock with corresponding keyways formed into the bodv of the interlocking panel connectors 2.
  • the walls at the apex portion of the hollow body 405 are thickened to resist compression forces.
  • Fig. 5F is a cross section of the preferred embodiment of a square shaped outside corner connector bracket 5 integrally connecting the edges of two encasement panels 1 oriented at 90° to one another.
  • the bracket arm 501 integrally formed and connected to the corner and internal web 502 of the hollow connector body 503 extends roughly 4" into void space 20.
  • the web forms two interstices 504 within the body of the connector that extend the entire longitudinal axis of the connector.
  • Outside corner connector bracket 5 is a hollow-core reinforced polymer pultruded or extruded structural element consisting of two t-shaped grooves or keyways 505 formed at 90° to one another into the square-shaped hollow body 503 of the connector.
  • Keyways 505 are configured to receive t- shaped tension keys 11 protruding form the edges of the two encasement panels 1 interlocked and integrally connected by the connector.
  • the section of the walls of the hollow body opposite the keyways 506 is thickened to resist compression forces.
  • Fig. 5G shows a cross section of the preferred embodiment of a cap connector profile 6, a reinforced polymer pultruded or extruded structural element comprised of one channel 601 configured to receive the butt end of one encasement panel 1 (not shown), a second channel 602 aligned 90° to the first channel 601 configured to receive the butt end of a second encasement panel 1 (not shown], and tension key 603 extending away from the wall 604 of the first channel 601 at 90° that matingly interlocks with a corresponding keyway 203 formed in the body of an encasement panel connector bracket 2 or keyway 303 formed in the body of panel connector with bracket keyway 3.
  • the lower section of channel wall 604 is increased in thickness to resist compression forces.
  • the lower end of channel wall 604 aligns with the inside face of channel wall 605.
  • Fig. 6A shows a three unit segment of modular steel-framed construction mold apparatus installed at the construction site without end walls.
  • Fig. 6B shows the structural steel grillage component of a three unit segment of modular steel-framed construction mold apparatus shown in Fig. 6A without end wall supports integrally joined together by attaching girts 44 and purlins from one unit to the columns 41 and girders 42 of the adjoining unit during installation at the work site.
  • Fig. 6C shows the steel grillage component of a three unit two bay segment of a modular steel-framed construction mold apparatus during installation without the corresponding panelized encasement assembly component.
  • Fig. 6D shows the panelized encasement assembly component of a two bay single unit segment of a modular construction mold apparatus without the corresponding structural steel grillage component.
  • Fig. 6E shows a phantom view of a panelized encasement assembly component for a three unit two bay segment of a modular construction mold apparatus
  • Fig. 7 shows a flow chart depicting the preferred method for constructing permanently encased monolithic composite concrete and steel structures in situ underwater comprising the off-site steps of:
  • [0102] 2 transporting modular construction unit produced in step C site . and installing said modular units by integrally joining grillage and encasement components of said unit to corresponding components of previously installed units to form a larger segment of the underwater steel-framed construction mold apparatus.
  • Steps A, B, C, and D take place off site under controlled conditions. Steps 1 , 2, 3, 4 and 5 take place on site underwater.
  • the structural steel grillage component of the mold apparatus becomes fully embedded in the cast concrete.
  • the panelized encasement component used to form and contain the wet concrete fill stays in place after the casting process is completed permanently protecting and insulating the submerged monolithic composite concrete and steel structure.
  • a similar reinforced concrete structure constructed underwater using conventional designs, materials, means and methods would involve ten or more on construction site work steps to complete, would take many months longer to construct, and cost many times more than the preferred methodology.
  • said mold apparatus facilitates and accelerates concrete work under water, making underwater concrete construction a practical and economically viable alternative for creating durable and reliable structures that prevent flooding and coastal erosion, and other applications heretofore not considered viable due to cost considerations.

Abstract

L'invention porte sur un appareil de moule à construction à châssis en acier modulaire, lequel appareil comprend une pluralité d'espaces vides de fondation, de paroi de cavité et de plateforme de toit contigus, définis et formés par des ensembles de panneaux de confinement à verrouillage mutuel et des raccords attachés de façon intégrée à un grillage en acier structural pour accepter, contenir et former un remplissage en béton humide, sur un procédé pour former, couler et renfermer des structures et des bâtiments en acier et en béton composite monolithiques in situ à l'aide dudit appareil de moule, et sur une structure en acier et en béton composite monolithique renfermée de façon permanente construite par l'emploi de l'appareil de moule modulaire et du procédé de construction en béton précédents. Le grillage en acier structural supporte les ensembles de confinement avant et pendant le processus de coulée, devenant totalement incorporé à l'intérieur du béton coulé, et procure une résistance à la traction en complément à la résistance à la compression du remplissage de béton. Les ensembles de confinement à panneaux restent en place à la suite de la coulée, protégeant et isolant les structures et les bâtiments en acier et en béton composites résultants.
PCT/US2011/000048 2011-01-10 2011-01-10 Appareil de moule à construction modulaire et procédé pour construire des structures et des bâtiments en béton WO2012096639A1 (fr)

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CN103866856A (zh) * 2014-03-20 2014-06-18 北京工业大学 一种节点刚接的装配式钢结构中心支撑咬合拼接体系
EP2942444A1 (fr) * 2014-05-09 2015-11-11 Charcon Limited Procédé et appareil pour une construction monolithique en béton
US9217450B2 (en) 2010-06-22 2015-12-22 Joinlock Pty. Ltd. Key and keyway connectors
CN106836548A (zh) * 2017-03-29 2017-06-13 河北建筑工程学院 预制剪力墙插入式钢板连接结构及其施工方法
CN107030877A (zh) * 2017-05-20 2017-08-11 西咸新区矩阵实业有限公司 一种用于装配式预制构件的钢与混凝土组合结构钢胎模及其制作方法
CN108005114A (zh) * 2017-12-11 2018-05-08 贵州中昇东浩科技有限公司 一种管廊浇筑模具
CN109826194A (zh) * 2019-01-29 2019-05-31 江苏省水利建设工程有限公司 混凝土地连墙的安装式导墙及其施工方法
US20190257094A1 (en) * 2016-06-24 2019-08-22 Southeast University Building based on large-space structure and freestanding external envelope as well as construction method
US10415262B2 (en) 2016-06-24 2019-09-17 Apache Industrial Services, Inc. Modular ledgers of an integrated construction system
US10465399B2 (en) 2016-06-24 2019-11-05 Apache Industrial Services, Inc. Integrated construction system
US10472823B2 (en) 2016-06-24 2019-11-12 Apache Industrial Services, Inc. Formwork system
US11306492B2 (en) 2016-06-24 2022-04-19 Apache Industrial Services, Inc Load bearing components and safety deck of an integrated construction system
CN115107147A (zh) * 2022-05-31 2022-09-27 青岛青建理工建筑工业化研究院有限公司 一种ppvc空间模块构建方法
US11624196B2 (en) 2016-06-24 2023-04-11 Apache Industrial Services, Inc Connector end fitting for an integrated construction system
US11976483B2 (en) 2016-06-24 2024-05-07 Apache Industrial Services, Inc Modular posts of an integrated construction system

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Cited By (20)

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Publication number Priority date Publication date Assignee Title
US9217450B2 (en) 2010-06-22 2015-12-22 Joinlock Pty. Ltd. Key and keyway connectors
CN103866856A (zh) * 2014-03-20 2014-06-18 北京工业大学 一种节点刚接的装配式钢结构中心支撑咬合拼接体系
EP2942444A1 (fr) * 2014-05-09 2015-11-11 Charcon Limited Procédé et appareil pour une construction monolithique en béton
US11306492B2 (en) 2016-06-24 2022-04-19 Apache Industrial Services, Inc Load bearing components and safety deck of an integrated construction system
US11976483B2 (en) 2016-06-24 2024-05-07 Apache Industrial Services, Inc Modular posts of an integrated construction system
US11970873B2 (en) 2016-06-24 2024-04-30 Apache Industrial Services, Inc Bearing plate of an integrated construction system
US11624196B2 (en) 2016-06-24 2023-04-11 Apache Industrial Services, Inc Connector end fitting for an integrated construction system
US20190257094A1 (en) * 2016-06-24 2019-08-22 Southeast University Building based on large-space structure and freestanding external envelope as well as construction method
US10415262B2 (en) 2016-06-24 2019-09-17 Apache Industrial Services, Inc. Modular ledgers of an integrated construction system
US10465399B2 (en) 2016-06-24 2019-11-05 Apache Industrial Services, Inc. Integrated construction system
US10472823B2 (en) 2016-06-24 2019-11-12 Apache Industrial Services, Inc. Formwork system
US10808396B2 (en) * 2016-06-24 2020-10-20 Southeast University Building based on large-space structure and freestanding external envelope as well as construction method
CN106836548B (zh) * 2017-03-29 2023-09-22 河北建筑工程学院 预制剪力墙插入式钢板连接结构及其施工方法
CN106836548A (zh) * 2017-03-29 2017-06-13 河北建筑工程学院 预制剪力墙插入式钢板连接结构及其施工方法
CN107030877B (zh) * 2017-05-20 2024-04-02 西咸新区矩阵住宅工业有限公司 一种用于装配式预制构件的钢与混凝土组合结构钢胎模及其制作方法
CN107030877A (zh) * 2017-05-20 2017-08-11 西咸新区矩阵实业有限公司 一种用于装配式预制构件的钢与混凝土组合结构钢胎模及其制作方法
CN108005114A (zh) * 2017-12-11 2018-05-08 贵州中昇东浩科技有限公司 一种管廊浇筑模具
CN109826194A (zh) * 2019-01-29 2019-05-31 江苏省水利建设工程有限公司 混凝土地连墙的安装式导墙及其施工方法
CN115107147A (zh) * 2022-05-31 2022-09-27 青岛青建理工建筑工业化研究院有限公司 一种ppvc空间模块构建方法
CN115107147B (zh) * 2022-05-31 2023-11-21 青岛青建理工建筑工业化研究院有限公司 一种ppvc空间模块构建方法

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