METHOD AND ARRANGEMENT FOR COUPLING A FOUNDATION STRUCTURE AND A VERTICAL PRECAST STRUCTURE

Description

FIELD OF THE INVENTION

The present disclosure generally relates to construction technology. In particular, the present disclosure relates to a method and an arrangement for coupling a foundation structure and a vertical precast structure for use in construction technology.

BACKGROUND OF THE INVENTION

Existing construction technologies involve one-off (e.g., customized) build-on site approaches in which construction material is brought to the construction site where the actual construction is performed. This has been the traditional methodology and approach for many years but has certain inherent challenges, including non-availability of skilled workforce (e.g., manual labor), heavy and expensive on-site machinery, incorrect estimate of completion time of construction projects, delays in delivery of projects, inclement weather, poor quality and wastage of materials, noise and air pollution, and cost involved in disposal of debris. This approach is also “one-off” as it provides no repeatability or scalability leverage. Each building is constructed, and each project is performed differently, and results vary widely, which may be undesirable considering present day demand for symmetrical construction projects with enhanced look and feel. However, constructing or casting each individual component of a building on site incurs significant expenditures in time and resources. It also increases a project's vulnerability to unforeseen factors, such as poor weather, worksite accidents, improper pour, etc.

Such traditional methodology and approach use connection methods that typically include placing rebars and lapping them together with adjacent bars during formwork. However, such connection methods are time and manpower intensive during installation. Further, on-site rebar binding makes such connection methods quite cumbersome to handle. Besides, substantial waiting time has to be allowed for using such connection methods to gain sufficient strength before starting the next level of work.

In order to address the aforesaid shortfalls of such build or cast-on site approaches, some construction projects use precast modules. Examples of the precast modules may include walls, beams, slabs, and the like, that are built in factories under factory scaling, repeatability, and in-factory conditions. The precast modules are then delivered to a building site and installed using standard connection mechanisms. Such standard connection mechanisms take less time as compared to the connection methods for the build-on site approaches.

However, even standard connection mechanisms have different challenges for different types of coupling mechanisms. In an example for foundation-to-wall connections, skilled labor is required for non-shrink grouting and pressure grouting. Further, waiting time needs to be allowed until the grout, with a color different from concrete color, achieves sufficient strength.

Accordingly, there remains a need in the art for an improved connection assembly mechanism that not only requires lesser skilled workers on site and saves cost and time in the installation process, but also ensures the structural continuity of the whole structure and transfer of forces between the prefabricated building modules during ultimate load conditions.

SUMMARY OF THE INVENTION

Embodiments for a connection assembly mechanism for coupling a foundation structure and a vertical precast structure in construction technology are disclosed that address at least some of the above challenges and issues.

In an aspect, the present disclosure is directed to a connection assembly mechanism. The connection assembly mechanism includes a threaded connector configured for embedding in a foundation structure. The connection assembly mechanism further includes a hollow box section member having a base including a threaded cavity configured for receiving the threaded connector, the hollow box section member configured for flush mounting with an internal bottom edge of a vertical precast structure. The connection assembly mechanism further includes a set of elongated connectors positioned at opposite vertical sides of the hollow box section member, wherein each of the elongated connectors is configured for embedding within the vertical precast structure. The connection assembly mechanism further includes a connection mechanism coupling the hollow box section member and the threaded connector, for thereby coupling the vertical precast structure and the foundation structure.

In an embodiment of the present disclosure, the hollow box section member and the threaded connector are mechanically coupled using a mechanical fastener for coupling the vertical precast structure with the foundation structure at a construction site.

In an embodiment of the present disclosure, the connection assembly mechanism further includes a plate member with a cavity adaptable to receive the threaded connector. The plate member is configured to distribute a load under the mechanical fastener when the vertical precast structure is affixed with the foundation structure at the construction site.

In an embodiment of the present disclosure, the hollow box section member is flush-mounted with the internal bottom edge of the vertical precast structure such that the hollow box section member is accessible for the mechanical coupling with the foundation structure from an internal side of the vertical precast structure.

In an embodiment of the present disclosure, the threaded connector corresponds to a cast-in-place anchor bolt.

In an embodiment of the present disclosure, the threaded connector corresponds to a post-installed anchor bolt set onto anchoring adhesive.

In an embodiment of the present disclosure, the foundation structure corresponds to a monolithic cast-in-place foundation structure.

In an embodiment of the present disclosure, the connection assembly mechanism further includes a sealant sealing a gap between the hollow box section member flush-mounted with the internal bottom edge of the vertical precast structure and a top surface of the foundation structure.

In an aspect, the present disclosure is directed to a connection method that includes anchoring a threaded connector in a foundation structure, and flush-mounting a hollow box section member with a bottom surface of a vertical precast structure. A set of elongated connectors, positioned at opposite vertical sides of the hollow box section member, is embedded within the vertical precast structure. A base of the hollow box section member includes a threaded cavity adaptable to receive the threaded connector. The connection method further includes coupling the hollow box section member and the threaded connector using a connection mechanism for coupling the vertical precast structure with the foundation structure.

In an embodiment of the present disclosure, the connection method further includes determining a type, quantity, and size of a connection assembly mechanism for coupling the foundation structure and the vertical precast structure based on a first set of parameters associated with the connection assembly mechanism and a second set of parameters associated with at least one of the foundation structure and the vertical precast structure.

In an embodiment of the present disclosure, the first set of parameters includes material specifications of the connection assembly mechanism.

In an embodiment of the present disclosure, the material specifications of the connection assembly mechanism correspond to at least tensile strength and hardness of the connection assembly mechanism. The second set of parameters includes at least one of a location, an orientation, and a weight of at least one of the foundation structure and the vertical precast structure and environmental conditions.

In an embodiment of the present disclosure, the hollow box section member and the threaded connector are mechanically coupled using a mechanical fastener for coupling the vertical precast structure with the foundation structure at a construction site.

In an embodiment of the present disclosure, the hollow box section member further comprises a plate member with a cavity that is adaptable to receive the threaded connector. The plate member is configured to distribute a load under the mechanical fastener when the vertical precast structure is affixed with the foundation structure at the construction site.

In an embodiment of the present disclosure, the hollow box section member is flush-mounted with the internal bottom edge of the vertical precast structure such that the hollow box section member is accessible for the mechanical coupling with the foundation structure from an internal side of the vertical precast structure.

In an embodiment of the present disclosure, the threaded connector corresponds to a cast-in-place anchor bolt.

In an embodiment of the present disclosure, the threaded connector corresponds to post-installed anchor bolt set onto anchoring adhesive.

In an embodiment of the present disclosure, the foundation structure corresponds to a monolithic cast-in-place foundation structure.

In an embodiment of the present disclosure, the method further includes sealing a gap between the hollow box section member flush-mounted with the internal bottom edge of the vertical precast structure and a top surface of the foundation structure with a sealant.

BRIEF DESCRIPTION OF THE DRAWINGS

Further advantages of the disclosure will become apparent by reference to the detailed description of preferred embodiments when considered in conjunction with the drawings. In the drawings, identical numbers refer to the same or a similar element.

FIG. 1 is a perspective view of an enclosure structure, in accordance with some embodiments.

FIG. 2A is an enlarged, detailed view of a connection assembly mechanism, in accordance with some embodiments.

FIG. 2B is a side view of the connection assembly mechanism coupling the foundation structure and the first wall structure, in accordance with some embodiments.

FIG. 3 illustrates a block diagram of an exemplary system in accordance with some embodiments.

FIG. 4 illustrates the steps of a method of coupling a wall structure and a foundation structure in accordance with some embodiments.

DETAILED DESCRIPTION

The following detailed description is presented to enable any person skilled in the art to make and use the disclosure. For purposes of explanation, specific details are set forth to provide a thorough understanding of the present disclosure. However, it will be apparent to one skilled in the art that these specific details are not required to practice the disclosure. Descriptions of specific applications are provided only as representative examples. Various modifications to the preferred embodiments will be readily apparent to one skilled in the art, and the general principles defined herein may be applied to other embodiments and applications without departing from the scope of the disclosure. The present disclosure is not intended to be limited to the embodiments shown but is to be accorded the widest possible scope consistent with the principles and features disclosed herein.

With modernization in construction-related methodologies and technologies, there has been a rapid shift from normal customized build on-site construction methodologies to construction using modules or blocks that may be built off-site and then assembled on-site to form a construction or a building. However, in the latter case, suitable connection assemblies for each use, under different environmental and ultimate load conditions are of utmost importance. The role of a connection assembly mechanism is not only to fix the prefabricated structures together, but also to ensure the structural continuity of the whole structure and to transfer forces between the prefabricated structures when the system is loaded.

Conventional connection methods for build or cast-on site approaches may be too time consuming and labor intensive for execution. Further, on-site rebar binding makes such connection methods quite cumbersome to handle. Furthermore, substantial waiting time has to be allowed while using such connection methods for foundation and wall elements to gain sufficient strength before starting the next level of work.

Further, standard connection mechanisms for standard precast modules are also not able to address the aforesaid shortfalls of conventional connection methods. By way of an example, the standard connection mechanisms require skilled labor for non-shrink grouting and pressure grouting for foundation-to-wall connections, and the like. Further, standard connection mechanisms demand waiting time till connection or grout strength is achieved.

Clearly, current connection assemblies and technologies fail to address many concerns, as described hereinbefore. This is especially true for advanced precast structures, which are lightweight due to less material requirements, are more economical (due to less labor, accelerated manufacturing, and reduced cost), and have better performance, factors that together meet today's requirements of enhanced, efficient, and robust connection assemblies.

The embodiments of the present disclosure address these concerns by providing improved and better-quality connection assemblies, requiring lesser-skilled workers on site and saving cost and time in the installation process. Further, such connection assemblies also ensure the structural continuity of the whole structure and the transfer of forces between the prefabricated structures during ultimate load conditions.

The disclosed architecture/solution provides several other objects and advantages, some of which are discussed below. The present disclosure supports rapid construction of a structure including precast (prefabricated) modules accommodating erratic site constraints/conditions and/or tight construction schedules. Further, the present disclosure provides at least pre-compression forces across such connection assemblies, thus improving the durability of a building structure. Additionally, an increase in the load resistance of the structure may be obtained by means of embodiments in accordance with the present disclosure. At the least, this durability makes the structure economical and also helps reduce the construction times.

Connection assemblies in accordance with the embodiments provide advantages in their simplicity of manufacture and system performance, and hence require little or no future maintenance. By leveraging a controlled environment production, these connection assemblies ensure quality, cost reduction, and speedy installation.

Further, the connection assembly mechanism in accordance with the present disclosure exhibits substantial fire resistance owing to metallic body, which in turn reduces insurance costs due to increased safety, security, reliability, and structural soundness.

Structurally, the connection assembly mechanism in accordance with the present disclosure provides substantial loading capacity and further offers the building structure a very high resistance to wind, hurricanes, floods, and other damaging environmental occurrences.

Certain terms and phrases have been used throughout the disclosure and will have the following meanings in the context of the ongoing disclosure.

“Cast-in-place concrete” or “Cast-in-situ concrete” is a building-construction technology where elements of a building structure are cast at the site in formwork.

“Pre-cast structure” refers to a construction product produced by casting concrete in a reusable mold or form which is then cured in a controlled environment at an offsite location, transported to a construction site, and maneuvered into a targeted place. Examples may include pre-cast beams, slabs, wall panels, and the like.

“Wall panel” refers to a prefabricated multi-layered wall fabricated at an offsite location and installed on-site, wherein “on-site” denotes a construction site and “offsite” denotes away from the construction site. The wall panel may be with or without door or window openings based on the design of the building structure.

“Slab” refers to a prefabricated structure formed at an offsite location and installed on-site. A slab includes a concrete base and a structural topping. The structural toppings, also referred to as topping screeds, are specialized materials applied to an existing concrete base of the slab to enhance performance, durability, and aesthetics.

“Beam” refers to a construction element that is made by casting concrete into a mold and then curing it in a controlled environment at the offsite location. Beams may be used for both load-bearing and non-load bearing applications and may be made in a variety of shapes and sizes.

“Foundation” refers to a monolithic cast-in-place foundation that is poured in one piece, typically 4-6 inches thick. It is commonly used in areas with shallow soil frost depths and is known for its durability and efficiency.

“Grout” is a filling, which when poured into a receptacle will fill in the receptacle and consolidate the adjacent edges into a solid mass, such as cementitious mortar or other cement-based materials, bentonite, bentonite/sand mixtures, graphite-based materials, carbon nanotubes and nanofibers, or similar materials.

“Sealant” refers to substances used to seal, block, or close gaps between various modules of the building structure to prevent fluids, air, and pests from passing through. These materials seal joints where dissimilar materials meet, filling gaps regardless of any irregularities that may exist between the two joint surfaces.

“Backer Rod” refers to a backing in joints. It controls the sealant thickness and amount of sealant needed to fill a gap between joints. The backer rod forces the sealant to the sidewalls to ensure contact and proper adhesion of the sealant.

“Modular” refers to individual and independent blocks or any mechanism or procedure for arranging them.

“Lattice girders” are three-dimensional, industrially prefabricated reinforcing elements. They consist of an upper chord, two lower chords, and continuous truss wires (e.g., diagonal chords). Typically, the continuous truss wires are connected to the chords by means of electric resistance welding.

FIG. 1 is a perspective view of an enclosure structure 100, in accordance with some embodiments. The enclosure structure 100 includes precast structures including a foundation structure 102, a first wall structure 104, a second wall structure 106, a slab structure 108, a beam structure 110, and a staircase slab 112. The enclosure structure 100 further includes a connection assembly mechanism 114. The precast structures may be prefabricated at an offsite location away from a construction site and installed on-site at the construction site.

The foundation structure 102 may correspond to a monolithic cast-in-place foundation structure. The foundation structure 102 is the lowest part of the enclosure structure 100 that is in direct contact with the soil and transfers loads from the enclosure structure 100 to the soil safely. To construct the foundation structure 102, trenches are dug deeper into the soil till a hard stratum is reached. Reinforcement cages are incorporated, and concrete is poured. Because the foundation structure 102 is a cast-in-place module and is poured all at once, it is erected much faster, thereby keeping labor costs low. The foundation structure 102 is designed to account for the characteristics of the underlying soil and local environment (e.g., slope of underlying soil, soil type, compactness, local weather conditions, etc.) such that the underlying soil below the foundation structure 102 does not undergo shear failure.

The first wall structure 104 may correspond to a level-1 wall which is installed directly on the foundation structure 102, whereas the second wall structure 106 may correspond to a level-2 wall which is installed directly on the first wall structure 104. The first wall structure 104 and the second wall structure 106 may be multi-layered precast structures that can withstand load, climate changes, and daily wear and tear as may be subjected to the enclosure structure 100. It will be appreciated that the first wall structure 104 and the second wall structure 106 obtained due to their construction technology are high quality, forming repeatable and scalable building structures. It will be appreciated that the enclosure structure 100 is merely illustrative of some embodiments. For example, in some embodiments, the first wall structure 104 may be installed indirectly on the foundation structure 102, such as by intermediate elements, the second wall structure may be installed indirectly on the first wall structure 104, or both.

The slab structure 108 may correspond to a precast structure that includes a concrete base and a structural topping. The structural topping may be specialized materials applied to an existing concrete base of the slab structure 108 to enhance performance, durability, and aesthetics. In some embodiments, the slab structure 108 may be a lattice girder slab that may act as permanent formwork and as precast soffits for robust, high-capacity composite slabs. The slab structure 108 may be cast with most, if not all, of the bottom reinforcement; the top reinforcement may be fixed in situ.

The beam structure 110 may correspond to a precast horizontal structure that may be able to withstand vertical loads, shear forces, and bending moments. The beam structure 110 may transfer loads that are imposed along its length to its endpoints, such as the foundation structure 102, the first wall structure 104, and the like. The beam structure 110 may be used for both load-bearing and non-load bearing applications and may be made in a variety of shapes and sizes.

The staircase slab 112 may be a precast structure designed to provide a vertical access from one level to another in the enclosure structure 100. The staircase slab 112 may be made up of reinforced concrete that eliminates the trouble of adjusting the number of steps, rise, run and width of each stair flight. The staircase slab 112 may include a single precast unit containing all the flights and landings or separate precast flights and landings.

The connection assembly mechanism 114 may correspond to various brackets and shear connectors that are embedded in different precast structures (such as the first wall structure 104), and cast-in-place structures (such as the foundation structure 102), which when coupled at the construction site, results in a robust installation of a base portion of level-1 of the enclosure structure 100. The structure and installation of the connection assembly mechanism 114 is described in detail below.

Once the aforesaid precast structures, such as the first wall structure 104, which are prefabricated, reinforced, and layered concrete elements, have been constructed in a factory setting, they are subsequently transported to the construction site where the foundation structure 102 is already in place and hardened. At the construction site, the precast structures, e.g., the first wall structure 104, are mechanically positioned in accordance with a pre-designed layout for the enclosure structure 100 and coupled with the foundation structure 102 using multiple instances of the connection assembly mechanism 114.

With reference to the building blocks disclosed in FIG. 1, in some embodiments, various connection methodologies and/or technologies, such as the connection assembly mechanism 114, are utilized to couple the foundation structure 102 and the first wall structure 104 and make the enclosure structure 100 structurally and environmentally seamless. The connection assembly mechanism 114, as described herein, may speed up installation processes and reduce the need for skilled labor.

Since the enclosure structure 100, as proposed by the present disclosure, is a modular construction, the precast structures are installed in an ordered manner so as to not create a decompression load, the precast structures sequentially erected vertically, increasing the height of the enclosure structure 100 as per the pre-designed layout for the enclosure structure 100. Once the installation corresponding to the structural work has finished, the placement of doors and windows, bathroom fittings are then carried out in order for a final paining job. It may be contemplated by the present disclosure that the connection assembly mechanism 114 may be employed in any commercial or residential structure having a variety of dimensions and stories.

FIG. 2A is an enlarged, detailed view 200A of the connection assembly mechanism 114, in accordance with some embodiments. FIG. 2B is a side view 200B of the connection assembly mechanism 114 coupling the foundation structure 102 and the first wall structure 104, in accordance with some embodiments.

Referring to FIG. 2A, there are shown a hollow box section member 202, a set of elongated connectors 204A and 204B, a threaded connector 206, a plate member 208, and a mechanical fastener 210. Referring to FIG. 2B, there are shown compacted fill 212, cast-in-place (CIP) foundation footing 214A, CIP slab on grade 214B, slab reinforcement 216, drilled hole 218, anchoring adhesive 220, recess 222, backer rod 224, sealant 226, rebars 228, and vapor barrier 230. FIGS. 2A and 2B have been described in conjunction with each other.

Referring to FIG. 2A, there is shown the hollow box section member 202 flush-mounted with an internal bottom edge of a vertical precast structure, e.g., the first wall structure 104. The hollow box section member 202 may be flush-mounted with the internal bottom edge of the first wall structure 104 such that the hollow box section member 202 is accessible for the mechanical coupling with the foundation structure 102 from an internal side of the first wall structure 104. The hollow box section member 202 may be flush-mounted with the internal bottom edge of the first wall structure 104 during casting of the first wall structure 104 in a controlled environment of the factory setting. In some embodiments, a base of the hollow box section member 202 may include a threaded cavity adaptable to receive the threaded connector 206. The locations and the spacing between various instances of the hollow box section member 202 along the bottom surface of a vertical precast structure, e.g., the first wall structure 104, may be as per the pre-designed layout of the enclosure structure 100, or as recommended by an automated system, such as system 300, as described in FIG. 3.

There are also shown the set of elongated connectors 204A and 204B that are positioned at opposite vertical sides of the hollow box section member 202. The set of elongated connectors 204A and 204B are embedded within the first wall structure 104 during casting of the first wall structure 104 in the controlled environment of the factory setting. In an exemplary embodiment, the spacing between the set of elongated connectors 204A and 204B may be at the most 8 inches. It will be appreciated that though only two connectors in the set of elongated connectors 204A and 204B have been shown, the disclosure is not so limited and more than two elongated connectors may also be possible, without any deviation from the scope of the disclosure.

The threaded connector 206 may correspond to a connector that fixedly engages with the foundation structure 102 of the enclosure structure 100. In some embodiments, the threaded connector 206 may correspond to a cast-in-place anchor bolt member. In other words, the threaded connector 206 may be embedded in the foundation structure 102 while being cast at the construction site. In other embodiments, the threaded connector 206 may correspond to a post-installed anchor bolt set onto the anchoring adhesive 220. In such embodiments, a correct hole size and depth may be drilled in the foundation structure 102. The drilled hole is cleaned and the anchoring adhesive 220 may be injected from the bottom of the hole upwards. The threaded connector 206 (which may be a stud, bolt, anchor, rebar, or a threaded rod) may be inserted and rotated into the hole and left until the anchoring adhesive 220 has hardened and cured.

The locations and the spacing between adjacent instances of the threaded connector 206 along the length of the foundation structure 102 may be as per the pre-designed layout of the enclosure structure 100. It will be appreciated that the locations and the spacing between adjacent instances of the threaded connector 206 along the length of the foundation structure 102 must conform to the locations and the spacing between adjacent instances of the hollow box section member 202 along the bottom surface of the first wall structure 104, as the threaded cavity of each hollow box section member 202 is designed to receive corresponding threaded connectors 206 for a proper interconnection.

In some embodiments, the hollow box section member 202 and the threaded connector 206 may be mechanically coupled using a connection mechanism for coupling the vertical precast structure, e.g., the first wall structure 104, with the foundation structure 102. For example, the hollow box section member 202 and the threaded connector 206 are mechanically coupled using a mechanical fastener, such as a screw or a nut, for coupling the first wall structure 104 with the foundation structure 102 at the construction site. In some embodiments, the plate member 208 with a cavity adaptable to receive the threaded connector 206 may also be used. The plate member 208 may be sandwiched between the top surface of the base of the hollow box section member 202 and base of the mechanical fastener 210. Accordingly, the plate member 208 may distribute a load under the mechanical fastener 210 when the first wall structure 104 is affixed with the foundation structure 102 at the construction site. Though the mechanical fastener 210 is shown and described herein to be a nut member, it should be noted that the disclosure should not be limited to the nut member only, and other forms of the mechanical fastener 210 may also be used, without any deviation from the scope of the disclosure.

In some embodiments, there may be gaps between the hollow box section member 202 flush-mounted with the internal bottom edge of the first wall structure 104 and a top surface of the foundation structure 102. Such gaps may be sealed with the sealant 226.

Referring to FIG. 2B for further details, for site preparation of the enclosure structure 100, an area is cleared of vegetation, debris, and any potential obstructions, and then leveled and compacted to ensure a stable and even base, referred to as the compacted fill 212. A wooden or metal formwork may be then set up to define the shape and dimensions of the CIP foundation footing 214A and the CIP slab on grade 214B. The formwork may also act as a barrier, preventing the poured concrete from spreading beyond the desired area. Before pouring concrete, plumbing and electrical lines are laid out and attached to the formwork. Further, to reinforce the concrete and enhance its strength and durability, slab reinforcement 216, rebars 228, steel rebar or wire mesh may be placed within the formwork. In some embodiments, such reinforcement is important for handling the load and stress imposed on the foundation structure 102. Vapor barrier 230 may also be arranged to prevent moisture from entering the CIP foundation footing 214A and the CIP slab on grade 214B, and to further avoid flooring problems.

Once the preparation is complete, the concrete is poured into the formwork, ensuring it is evenly distributed to achieve a uniform thickness. While pouring, a recess 222 or a pocket may be provided where the first wall structure 104 is to be installed. In some embodiments, the size of the recess 222 may be in accordance with the thickness of the first wall structure 104 and any additional indentation for assembling the connection assembly mechanism 114. Further, after assembling, the recess 222 may further enable a worker to fill the gap underneath the bottom of the first wall structure 104 and the top surface of the foundation structure 102 by using the backer rod 224 and the sealant 226. In some embodiments, the thickness of the first wall structure 104 may be 8 inches, and the recess may be 10 inches wide. The poured concrete may be then leveled and smoothed to create a seamless surface. It will be appreciated that in other embodiments, the first wall structure 104 and the recess may have other thicknesses and dimensions.

Once the CIP foundation footing 214A and the CIP slab on grade 214B are set, the threaded connector 206, such as a bolt, may be post-anchored in the foundation structure 102 as per the pre-designed layout of the enclosure structure 100 and later allowed to cure. Thereafter, the first wall structure 104 with the hollow box section member 202 flush-mounted with the internal bottom edge may be positioned to conform (e.g., align) with the threaded connector 206 along the length of the foundation structure 102. The threaded connector 206 may be received at the threaded cavity provided at the base of the hollow box section member 202 followed by the cavity of the plate member 208. Once the arrangement is in place, the mechanical fastener 210, such as a nut member, may be screwed onto the threaded connector 206 and the first wall structure 104 may be affixed with the foundation structure 102 at the construction site. Post affixing, gaps formed underneath the bottom surface of the first wall structure 104 and the top surface of the foundation structure 102 may be fitted with the backer rod 224 that controls the thickness, spread, and amount of the sealant 226 needed to fill the gap. The backer rod 224 may be fitted both towards the internal and the external sides of the first wall structure 104. Afterwards, the sealant 226 may be used to completely fill such gaps to ensure contact and proper adhesion.

FIG. 3 illustrates a block diagram of an exemplary system 300 in accordance with embodiments of the present disclosure. The system 300 includes a processor 302, a memory 304, input/output devices 306, a network interface 308, and a Computer-Aided Utilities (CAU) module 310 that includes an intelligent recommendation module 312 and a computer-aided manufacturing module 314. The system 300 may be further communicatively coupled with a computer numerical control (CNC) machine 318 via a communication network 316.

The processor 302 may comprise suitable logic, circuitry, and interfaces that may be configured to execute instructions stored in the memory 304 or commands provided by a user. The processor 302 may also collect information for processing, store it in the memory 304, and may transmit to other modules, such as the CAU module 310 and the I/O devices 306. In accordance with some embodiments, the computing functionalities of the processor 302 disclosed herein may be implemented in one or more silicon cores in a RISC processor, an ASIC processor, a CISC processor, FPGAs, and other semiconductor chips, processors, or control circuits.

The memory 304 may comprise suitable logic, circuitry, and interfaces that may be configured to store data supporting various functionalities performed by the processor 302 and the CAU module 310. The memory 304 may store information and/or instructions, various application programs or applications, and a set of data and commands for various operations performed by the processor 302 and the CAU module 310. The memory 304 may include volatile and non-volatile memory, such as a random-access memory (RAM) and a read only memory (ROM). Several program modules may be stored on the hard disk, external disk, the RAM, or the ROM, including an operating system, one or more application programs, and program data. The RAM may be of any type, such as SRAM, DRAM, or SDRAM. A BIOS containing the basic routines that may transfer information between elements within the system, such as during start-up, may be stored in the ROM.

The I/O devices 306 may include input devices, such as keyboard, mouse, microphone, camera, light pen, gesture recognition devices, scanner, touch screen and the like, that may be used to provide input to the system 300. The input may include a layout of the enclosure structure 100, a weight of the first wall structure 104, a quality of the concrete, and the like. The I/O devices 306 may further include output devices, such as touch screen, printer, display screen, and the like. The output may include recommendations for the type, quantity, size, location, and spacing pertaining to multiple instances of the connection assembly mechanism 114 to be used for coupling the foundation structure 102 with the first wall structure 104.

The network interface 308 may be configured to transmit/receive the data from the I/O devices 306 over the communication network 316 to/from other network interfaces of other devices. In some embodiments, the network interface 308 may transmit the code files to other platforms, such as the CNC machine 318, for fabricating or manufacturing the connection assembly mechanism 114 with desired geometry, structure, and design. The network interface 308 may include wired communication interfaces, wireless communication interfaces, cellular communication interfaces, and other communication interfaces to provide communication via other modalities, known in the art.

The CAU module 310 may comprise suitable logic, circuitry, and interfaces that may be configured to perform various functionalities to intelligently handle the fabrication and/or manufacturing of the connection assembly mechanism 114 based on the requirement and the layout of a structure, such as the enclosure structure 100.

In some embodiments, the CAU module 310 may include the intelligent recommendation module 312 programmed, for example, with a rules-based algorithm retrieved from the memory 304 and user-defined settings received from the I/O devices 306. Accordingly, the CAU module 310 may automatically incorporate local rules, knowledge, geographical information, and content for indicating type, quantity, and sizes of different components of connection assembly mechanism 114 for coupling the foundation structure 102 with the first wall structure 104 based on a first and a second set of parameters. The types of materials for the connection assembly mechanism 114 may be based on carbon content, content based on different alloying elements, or environmentally safe content. The quantity of the connection assembly mechanism 114 may correspond to how many connection assemblies are required for coupling the foundation structure 102 with the first wall structure 104. The size of the connection assembly mechanism 114 may refer to the dimensions of each component in proportion to each other. In some embodiments, the intelligent recommendation module 312 of the CAU module 310 may further recommend locations and the spacing between various instances of the connection assembly mechanism 114 along the first wall structure 104 and the foundation structure 102 based on the first and the second set of parameters.

The first set of parameters may include, for example, material specifications of the metal used for the connection assembly mechanism 114. Material specifications may include, for example, tensile strength, yield strength, minimum elongation, and hardness of the connection assembly mechanism 114. For example, if the tensile strength of the material is low, then a greater number of connection assemblies may be required and vice versa. The second set of parameters may include, for example, at least one of a location, an orientation, and a weight of the vertical precast structure, i.e., the first wall structure 104, and various environmental conditions, such as those corresponding to hurricane sensitive or earthquake sensitive zones. For example, if the enclosure structure 100 is in a hurricane sensitive zone, then a greater number of connection assemblies of higher tensile strength may be required. Thus, the intelligent recommendation module 312 may automatically apply local rules to conform with regulations, building codes, local preferences, and user-defined settings for the manufacture, fabrication, and/or installation of the connection assembly mechanism 114.

The intelligent recommendation module 312 may save the information relating to the recommendation of the connection assembly mechanism 114 to computer files that may be stored in the memory 304.

In some embodiments, the computer-aided manufacturing module 314 may translate the information, relating to the recommendation of the connection assembly mechanism 114 corresponding to the fabrication and installation of the connection assembly mechanism 114, to a machine tool code language. By way of non-limiting example, G-Code, based on the RS-274 standard, may be used as a machine tool code language. The computer-aided manufacturing module 314 may save the information relating to the machine tool code language in code files that may be stored in the memory 304.

In some embodiments, the communication network 316 may comprise suitable logic, circuitry, and interfaces that may be configured to facilitate communication of data between different components, systems and/or sub-systems in a computing environment that includes the system 300 and other devices, such as machine tools. In some embodiments, the communication network 316 includes the Internet, a local area network (LAN), or any type of network of one or more computers that communicatively couples multiple computers, to name only a few examples. The communication data may be transmitted or received via at least one communication channel of a plurality of communication channels. The communication channels may include, but are not limited to, a wireless channel, a wired channel, or a combination of wireless and wired channels thereof. The wireless or wired channels may be associated with a data standard which may be defined by one of LAN, a Personal Area Network (PAN), a wireless personal LAN (WPLAN), a Wireless Local Area Network (WLAN), a Wireless Sensor Network (WSN), a WAN, and a Wireless Wide Area Network (WWAN), the Internet, cellular networks, Wireless Fidelity (Wi-Fi) networks, short-range networks (for example, Bluetooth®, WiGig, ZWave®, ZigBee®, IrDA, and the like), and/or any other wired or wireless communication networks or mediums.

The CNC machine 318 may be configured to process a piece of material, such as a metal, to meet specifications by following coded programmed instructions and without a manual operator directly controlling the machining operation. The coded programmed instructions may be received by the CNC machine 318 in the form of a sequential program of machine control instructions, such as G-code or M-code. Such coded programmed instructions may be executed by the CNC machine 318 to control various machine tools, such as drills, lathes, mills, presses, power saws, and the like, for manufacturing various products, such as various components of the connection assembly mechanism 114.

It should be noted that the various components of the connection assembly mechanism 114 may be manufactured automatically by using the machine tools controlled by the CNC machine 318, as described above, in accordance with some embodiments. However, the disclosure is not so limited, and in accordance with other embodiments, the components of the connection assembly mechanism 114 may be manufactured manually by using hand tools as well, without any deviation from the scope of the disclosure.

FIG. 4 illustrates the steps of a method 400 of coupling a wall structure and a foundation structure in accordance with some embodiments of the present disclosure. Although specific operations are disclosed in FIG. 4, such operations are examples and are non-limiting. In different embodiments, to name only a few examples, the method 400 includes other steps, the sequence of the steps is modified, some steps are omitted, or any combination of these variations may be incorporated. The steps of method 400 may be automated or semi-automated. In various embodiments, one or more of the operations of the method 400 can be controlled or managed by software, by firmware, by hardware, or by any combination thereof. FIG. 4 will be explained in conjunction with the descriptions of FIGS. 1-3.

In some embodiments, the method 400 includes processes in accordance with the present disclosure which can be controlled or managed by a processor(s) (e.g., 302) and electrical components under the control of a computer or computing device including computer-readable media containing computer-executable instructions or code. The readable and executable instructions (or code) may reside, for example, in data storage (e.g., 304) such as volatile memory, non-volatile memory, and/or mass data storage, as only some examples.

At a step 402, the method 400 may include determining a type, quantity, and size of the connection assembly mechanism 114 for coupling the foundation structure 102 with the first wall structure 104 based on a first set of parameters associated with the connection assembly mechanism 114 and a second set of parameters associated with the foundation structure 102 and the first wall structure 104. In some embodiments, the processor 302 in conjunction with the CAU module 310 may be configured to determine the type, quantity, and size of the connection assembly mechanism 114. The first set of parameters and the second set of parameters are described in detail in the description of FIG. 3.

In some embodiments, the foundation structure 102 may correspond to a monolithic cast-in-place foundation structure that is cast at the construction site only. However, the first wall structure 104 may be a precast structure that is cast in a controlled environment of the factory setting.

At a step 404, the method 400 may include anchoring the threaded connector 206 in the foundation structure 102. In some embodiments, the threaded connector 206 may correspond to a cast-in-place anchor bolt. In other embodiments, the threaded connector 206 may correspond to a post-installed anchor bolt set onto the anchoring adhesive 220.

At a step 406, the method 400 may include flush-mounting the hollow box section member 202 with the bottom surface of a vertical precast structure, i.e., the first wall structure 104. In some embodiments, the hollow box section member 202 may be flush-mounted with the internal bottom edge of the first wall structure 104 such that the hollow box section member 202 is accessible for the mechanical coupling with the foundation structure 102 from an internal side of the first wall structure 104.

At a step 408, the method 400 may include receiving the threaded connector 206 through the threaded cavity at a base of the hollow box section member 202 at the time of installation.

At a step 410, the method 400 may include coupling the hollow box section member 202 and the threaded connector 206 using a connection mechanism, thereby coupling the vertical precast structure, i.e., the first wall structure 104, with the foundation structure 102. In some embodiments, the hollow box section member 202 and the threaded connector 206 may be mechanically coupled using the mechanical fastener 210 for coupling the first wall structure 104 with the foundation structure 102 at the construction site.

At a step 412, the method 400 may include sealing a gap between the hollow box section member 202 flush-mounted with the internal bottom edge of the first wall structure 104 and the top surface of the foundation structure 102 with the sealant 226.

Advantageously, by using the connection assembly mechanism 114 as disclosed herein, construction of the enclosure structure 100 is rapid, with the desired structural integrity and strength. Further, as described above, this process of construction provides stability for the enclosure structure 100, making it durable and weatherproof, among other such advantages mentioned in detail above.

The terms “comprising,” “including,” and “having,” as used in the specification herein, shall be considered as indicating an open group that may include other elements not specified. The terms “a,” “an,” and the singular forms of words shall be taken to include the plural form of the same words, such that the terms mean that one or more of something is provided. The term “one” or “single” may be used to indicate that one and only one of something is intended. Similarly, other specific integer values, such as “two,” may be used when a specific number of things is intended. The terms “preferably,” “preferred,” “prefer,” “optionally,” “may,” and similar terms are used to indicate that an item, condition, or step being referred to is an optional (not required) feature of the disclosure. The term “connecting” includes connecting, either directly or indirectly, and “coupling,” including through intermediate elements.

The disclosure has been described with reference to various specific and preferred embodiments and techniques. However, it should be understood that many variations and modifications may be made while remaining within the spirit and scope of the disclosure. It will be apparent to one of ordinary skill in the art that methods, devices, device elements, materials, procedures, and techniques other than those specifically described herein may be applied to the practice of the disclosure as broadly disclosed herein without resort to undue experimentation. All art-known functional equivalents of methods, devices, device elements, materials, procedures, and techniques described herein are intended to be encompassed by this disclosure. Whenever a range is disclosed, all subranges and individual values are intended to be encompassed. This disclosure is not to be limited by the embodiments disclosed, including any shown in the drawings or exemplified in the specification, which are given by way of example and not of limitation. Additionally, it should be understood that the various embodiments of the building blocks described herein contain optional features that may be individually or together applied to any other embodiment shown or contemplated here to be mixed and matched with the features of that building block.

While the disclosure has been described with respect to a limited number of embodiments, those skilled in the art, having benefit of this disclosure, will appreciate that other embodiments may be devised which do not depart from the spirit and scope of the disclosure as disclosed herein.