PRECAST STRUCTURE AND CONSTRUCTION METHOD THEREOF

Description

BACKGROUND

1. Field of the Disclosure

The subject disclosure relates to a construction structure and the method thereof, in particular, a precast structure and the construction method thereof.

2. Description of Related Art

Traditional methods of building reinforced concrete (RC) structures involve constructing floor by floor from the bottom up, which can be time-consuming. This approach also requires numerous processes such as tying reinforced steel, molding, grouting, and more, which necessitates a large workforce on the construction site. The quality of the construction is heavily reliant on the skill and experience of the workers and is also susceptible to weather conditions, making it difficult to control. In contrast, using steel reinforced concrete (SRC) for load-bearing beams and columns can speed up the construction process, but it also requires a significant amount of steel, leading to higher construction costs. To address these challenges, the precast construction method was developed.

The precast construction method involves producing concrete structures in a factory by pouring concrete into reusable molds, allowing it to harden in a controlled environment, and then transporting it to the construction site for installation. This method offers several advantages, including environmental stability, immunity to weather conditions, reduced reliance on skilled labor, and standardized operating procedures. On the construction site, mechanical equipment can be used to assemble and lift the precast structures without the need for external scaffolding. This allows for simultaneous installation of exterior walls and interior decorations, effectively shortening construction time. Additionally, precast construction methods help preserve forest resources, are environmentally friendly, and keep construction sites neat and clean. These methods are particularly suitable for building structures that need to bear heavy loads, such as precast columns or beams.

In traditional building construction, the process typically involves constructing one story at a time, starting from the lowest level and working upwards to complete the entire building. This method can be complex and time-consuming, especially when it comes to coordinating the various tasks involved in the construction process, such as hoisting structures, transporting materials, and providing access for workers. As the building gets taller, these logistical challenges only become more difficult to manage. As a result, traditional construction methods may not be the most efficient way to complete a building project.

Given the significant investment in the high-tech industry and the rapid pace of change in the market for high-tech goods, there is a need for quick construction of high-tech plants in order to expedite the construction of interior clean rooms and the arrangement of manufacturing machines. This is necessary to meet or exceed production timelines for the fabrication of high-tech products such as chips. For instance, on precast construction sites, precast columns and beams are placed in predetermined locations by tower cranes or mobile cranes. However, these cranes have their own limitations in terms of loading capacity and distance, making it more costly and challenging to lift heavier precast columns and beams. As a result, the conventional construction method is unable to meet the requirements for rapid construction and shortened construction periods.

Based on the information provided, we are seeking a solution to expedite the construction process for high-tech plants.

SUMMARY

An embodiment of the present disclosure provides a construction method. The method comprises: providing a first precast column, a second precast column and a third column arranged at sequential intervals; providing a first precast beam, the first precast beam comprises a first section, a second section spaced apart from the first section, and a first rebar penetrating through the first section and the second section; lifting the first precast beam, so that the first precast beam bridges the first precast column and the second precast column, wherein two end portions of the first section are respectively arranged on a first end of the first precast column and a second end of the second precast column, the first end of the first precast column facing the second end of the second precast column, the second section is arranged on a third end, opposite to the second end, of the second precast column; providing a second precast beam, the second precast beam comprises a first end portion and a second end portion opposite to the first end portion; lifting the second precast beam, so that the first end portion of the second precast beam is arranged on a temporary supporting frame, and the second end portion of the second precast beam is arranged on a fourth end of the third precast column; and moving the second precast beam, and coupling the first end portion of the second precast to a connecting end of the first rebar in the first precast beam, the connecting end extending beyond an end of the second section of the first precast beam.

An embodiment of the present disclosure provides a precast structure precast structure, comprising: a first precast beam and a second precast beam. The first precast beam comprises a first section, a second section and a first rebar. The second section is spaced part from the first section and a gap is formed therebetween. The first rebar connects and penetrates through the first section and the second section along a length direction of the precast beam structure. The second precast beam is substantially aligned with the first precast beam along the length direction thereof and is adjacent to the second section of the first precast beam. The second precast beam is coupled to the first bar of the first precast beam.

BRIEF DESCRIPTION OF THE DRAWINGS

Aspects of some embodiments of the present disclosure are readily understood from the following detailed description when read with the accompanying figures. It should be noted that various structures may not be drawn to scale, and dimensions of the various structures may be arbitrarily increased or reduced for clarity of discussion.

FIG. 1 is a schematic view showing a construction process in accordance with one embodiment of the present disclosure;

FIG. 2 is a schematic view showing another construction process in accordance with the above embodiment of the present disclosure;

FIG. 3 is a schematic view showing another construction process in accordance with the above embodiment of the present disclosure;

FIG. 4 is a schematic view showing another construction process in accordance with the above embodiment of the present disclosure;

FIG. 5 is a schematic view showing another construction process in accordance with the above embodiment of the present disclosure;

FIG. 6 is a schematic view showing another construction process in accordance with the above embodiment of the present disclosure;

FIG. 7 is a schematic view showing another construction process in accordance with the above embodiment of the present disclosure;

FIG. 8 is a cross sectional view along line 8-8 shown in FIG. 7;

FIG. 9A is a schematic view showing a conventional construction method with a stair-type lifting sequence; and

FIG. 9B is a schematic view showing a construction method with a vertical lifting sequence in accordance with the above embodiment of the present disclosure.

DETAILED DESCRIPTION

The following disclosure provides many different embodiments, or examples, for implementing different features of the provided subject matter. Specific examples of components and arrangements are described below to simplify the present disclosure. These are, of course, merely examples and are not intended to be limiting. For example, the formation of a first feature over or on a second feature in the description that follows may include embodiments in which the first and second features are formed in direct contact, and may also include embodiments in which additional features may be formed between the first and second features, such that the first and second features may not be in direct contact. In addition, the present disclosure may repeat reference numerals and/or letters in the various examples. This repetition is for the purpose of simplicity and clarity and does not in itself dictate a relationship between the various embodiments and/or configurations discussed.

Further, spatially relative terms, such as “beneath,” “below,” “lower,” “above,” “upper” and the like, may be used herein for ease of description to describe one element or feature's relationship to another element(s) or feature(s) as illustrated in the figures. The spatially relative terms are intended to encompass different orientations of the device in use or operation in addition to the orientation depicted in the figures. The apparatus may be otherwise oriented (rotated 90 degrees or at other orientations) and the spatially relative descriptors used herein may likewise be interpreted accordingly.

It should be understood that, although the terms first, second, etc., may be used herein to describe various elements, these elements should not be limited by these terms. Unless indicated otherwise, these terms are only used to distinguish one element from another element.

As used herein, the terms “approximately,” “substantially,” “substantial” and “about” are used to describe and account for small variations. When used in conjunction with an event or circumstance, the terms can refer to instances in which the event or circumstance occurs precisely as well as instances in which the event or circumstance occurs to a close approximation. For example, when used in conjunction with a numerical value, the terms can refer to a range of variation less than or equal to ±10% of that numerical value, such as less than or equal to ±5%, less than or equal to ±4%, less than or equal to ±3%, less than or equal to ±2%, less than or equal to ±1% less than or equal to ±0.5%, less than or equal to ±0.1%, or less than or equal to ±0.05%. For example, two numerical values can be deemed to be “substantially” the same as or equal if a difference between the values is less than or equal to ±10% of an average of the values, such as less than or equal to ±5%, less than or equal to ±4%, less than or equal to ±3%, less than or equal to ±2%, less than or equal to ±1%, less than or equal to ±0.5%, less than or equal to ±0.1%, or less than or equal to ±0.05%

As shown in the figures of the instant application, and in the following description of the embodiments, to facilitate explanation of the disclosure, xyz-coordinates will be used. The xyz-coordinates include an X-axis and a Y-axis and a Z-axis. FIG. 1 is a schematic view showing a construction process in accordance with one embodiment of the present disclosure. A first precast column 600, a second precast column 700 and a third precast column 800 are arranged at sequential intervals along the direction of the X-axis.

As shown in FIG. 1, the first precast column 600 includes a first body 610 and a first rebar set 620. The first body 610 contains concrete encased stirrups (not shown). The first rebar set 620 includes a set of vertical column rebars, in which the rebars are spaced apart within the first body 610 in the direction of the X-axis, and extend upwardly (along the direction of the Y-axis) from the inside of the first body 610 and to beyond a top surface 615 of the first body 610. In the present embodiment, the first rebar set 620 is exemplified by only two rebars, while in some embodiments of the present disclosure, the first rebar set 620 may comprise a plurality of rebars, such as twelve or more rebars. In addition, the first precast column 600 has a first end 630 that faces the second precast column 700.

The second precast column 700 includes a second body 710 and a second rebar set 720. The second body 710 contains concrete encased stirrups (not shown). The second rebar set 720 includes a set of rebars, in which the rebars are spaced apart within the second body 710 in the direction of the X-axis, and extend upwardly (along the direction of the Y-axis) from the inside of the second body 710 and to beyond a top surface 715 of the second body 710. In the present embodiment, the second rebar set 720 has structures similar to those of the first body 610. The second precast column 700 has a second end 730 and a third end 740 opposite to the second end 730 along the direction of the X-axis. The second end 730 of the second precast column 700 faces the first end 630 of the first precast column 600, and the third end 740 of the second precast column 700 faces the third precast column 800. The method of constructing the present embodiment comprises the step of providing a corner bracket 790 at an outer side of the third end 740 of the second precast column 700, wherein the corner bracket 790 faces the third precast column 800, and a top surface 795 of the corner bracket 790 is substantially flush with the top surface 715 of the second body 710 of the second precast column 700. In the present embodiment, a plurality of triangular corner brackets 790 are disposed on the side of the third end 740 of the second precast column 700 and are arranged in parallel along the direction of the Z-axis.

The third precast column 800 includes a third body 810 and a third rebar set 830. Similarly, the third body 810 contains concrete encased stirrups (not shown). The third precast column 800 has a fourth end 840 and a fifth end 850 opposite to the fourth end 840 along the direction of the X-axis. The fourth end 840 faces the third end 740 of the second precast column 700. The third rebar set 830 includes a set of rebars, in which the rebars are spaced apart within the third body 810 in the direction of the X-axis. The third rebar set 830 comprises a first main bar 860 and a second main bar 870. In the present embodiment, the first main bar 860 of the third precast column 800 is adjacent to the fifth end 850 of the third precast column 800 and extends from the inside of the third precast column 800 and beyond a top surface 815 of the third body 810 of the third precast column 800. The second main bar 870 of the third precast column 800 is adjacent to the fourth end 840 of the third precast column 800, and a top end of the second main bar 870 is entirely embedded in the third precast column 800 in the direction of the Y-axis. In the present embodiment, the top end of the second main bar 870 adjacent to the fourth end 840 is further provided therein with a second coupler 820 exposed to the surface 815 of the third precast column 800. In the figures of the present embodiment, the first main bar 860 and the second main bar 870 are exemplified by a single bar respectively, while in some other embodiments of the present disclosure, the first main bar 860 and the second main bar 870 may be plural, such as six or more for each.

FIG. 2 is a schematic view showing another construction process in accordance with the above embodiment of the present disclosure. As shown in FIG. 2, a first precast beam 100 includes a first section 110, a second section 120 and a first rebar 130. The first section 110 and the second section 120 are spaced apart by a gap G. The first rebar 130 penetrates through and connects the first section 110 and the second section 120 along a length direction of the first precast beam 100 (i.e., the direction of the X-axis shown in FIG. 2). A free end 134 of the first rebar 130 distant from the second precast column 700 extends beyond an end surface of the first section 110 and further extends upwardly from a side of the first precast column 600 in an upward direction (i.e., the direction of Y-axis). A connecting end 132 of the first rebar 130 opposite to the free end 134 extends beyond an end surface of the second section 120 of the first precast beam 100 by a predetermined distance. The figures of the present embodiment are illustrated with a single first rebar 130 as examples, while in practice, the first rebars 130 generally include a plurality of rebars spaced apart along the direction of the Z-axis.

In the present embodiment, a crane (not shown) lifts the first precast beam 100 with a hook 1000, so that the first precast beam 100 bridges the first precast column 600 and the second precast column 700 with its two end portions (i.e., the first end portion 111 and the second end portion 112). In the present embodiment, cables 400 of the crane are bundled with stirrup hooks 114 extending from the inside of and to beyond a top surface of the first section 110 of the first precast beam 100, so as to lift the first precast beam 100. In other embodiments, cables 400 of the crane are wrapped around and secured to the first section 110 for lifting the first precast beam 100. The two opposite end portions (i.e., the first end portion 111 and the second end portion 112) are arranged respectively on the first end 630 of the first precast column 600 and the second end 730 of the second precast column 700, wherein the first end 630 of the first precast column 600 faces the second end 730 of the second precast column 700. The second section 120 is arranged on the third end 740 of the second precast column 700 opposite to the second end 730. In such a case, the gap G is formed on top of the second body 710 of the second precast column 700 and is configured to receive the second rebar set 720 protruding from a top surface 715 of the second precast column 700, and the rebars in gap G do not interfere with each other. In the present embodiment, the step of lifting the first precast beam 100 further comprises causing at least a portion of the second section 120 of the first precast beam 100 to be placed on a top surface 795 of the corner bracket 790 secured to the side surface of the second precast column 700. In other words, a portion of the second section 120 of the first precast beam 100 is arranged on the top of the second body 710, and another portion thereof is arranged on the corner bracket 790. With the corner bracket 790, the landing area of the second section 120 of the first precast beam 100 is increased, enhancing the stability of the first precast beam 100. In other embodiments, other corner brackets (not shown) are arranged both on the first end 630 of the first column 600 and the second end 730 of the second precast column 700.

FIG. 3 is a schematic view showing another construction process in accordance with the above embodiment of the present disclosure. In the present embodiment, a temporary supporting frame 900 is provided on the ground between the second precast column 700 and the third precast column 800, and a top surface 910 of the temporary supporting frame 900 is substantially aligned with the top surface 715 of the second precast column 700 and the top surface 795 of the corner bracket 790.

FIG. 4 is a schematic view showing another construction process in accordance with the above embodiment of the present disclosure. As shown in FIG. 4, a second precast beam 200 comprises a body 210, a second rebar 230 and a first coupler 240. The body 210 of the second precast beam 200 has a channel 214 extending along a length direction of the second precast beam 200 (i.e., the direction of the X-axis shown in FIG. 4) therein, and comprises a first end portion 211 and a second end portion 212 opposite to the first end portion 211. The first coupler 240 is embedded in the channel 241 of the first end portion 211. The second rebar 230 is inserted from the second end portion 212 into the channel 214 of the body 210, so that the first end 231 of the second rebar 230 is placed in the first end portion 211 of the body 210. In addition, the first end 231 of the second rebar 230 is fixed to the first coupler 240 in the body 210. The opposing second end 232 of the second rebar 230 extends beyond an end surface of the second end portion 212 by a distance and is then bent upward in the direction of the Y-axis.

As shown in FIG. 4. the second precast beam 200 is lifted so that the first end portion 211 of the second precast beam 200 is arranged on the top surface 910 of the temporary supporting frame 900, and the second end portion 212 of the second precast beam 200 is arranged on the fourth end 840 of the third precast column 800 and covers the top end of the second main bar 870 in the third precast column 800. In such a case, the second precast beam 200 is substantially aligned with the first precast beam 100 in the length direction thereof (i.e., in the direction of the X-axis), and the first end portion 211 of the second precast beam 200 is adjacent to the second section 120 of the first precast beam 100. As shown in FIG. 4, cables 400 of the crane (not shown) are bundled with stirrup hooks 216 extending from inside of and to beyond a top surface of the body 210 of the second precast beam 200 for lifting the second precast beam 200. It should be noted that although the second end portion 212 of the second precast beam 200 is arranged on the fourth end 840 of the third precast column 800 and above the top end of the second main bar 870 in the third precast column 800, the lifting of the second beam 200 would not interfere with the third precast column 800 because the second main bar 870 and the second coupler 820 are embedded in the third body 810.

FIG. 5 is a schematic view showing another construction process in accordance with the above embodiment of the present disclosure. As shown in FIG. 5, an operator by operating the crane (not shown) moves the second precast beam 200 to the left side along the X-axis after the above steps, so that the first coupler 240 within the first end portion 211 of the second precast beam 200 is coupled to the connecting end 132 of the first rebar 130, wherein the connecting end 132 extends beyond the second section 120 of the first precast beam 100. As such, the second rebar 230 of the second precast beam 200 is coupled to the first rebar 130 of the first precast beam 100 through the first coupler 240. Meanwhile, since the second precast beam 200 has been moved, the second coupler 820 is exposed to the top surface 815 of the third precast column 800. Specifically, the present embodiment further comprises: aligning the second precast beam 200 and the first precast beam 100 along their respective length directions (i.e., the direction of the X-axis shown in FIG. 5); laterally moving the second precast beam 200 to the left side shown in FIG. 5, causing the first end portion 211 of the second precast beam 200 to be arranged on the top surface 795 of the corner bracket 790, with the second portion 212 of the second precast beam 200 still on the top surface 815 of the third body 810 of the third precast column 800; and coupling the first coupler 240 in the second precast beam 200 to the connecting end 132 of the first rebar 130 of the first precast beam 100. As shown in FIG. 5, a gap G1 between the first precast beam 100 and the second precast beam 200 is provided, so that concrete or mortar can be poured into the gap G1 for connecting the first precast beam 100 to the second precast beam 200.

FIG. 6 is a schematic view showing another construction process in accordance with the above embodiment of the present disclosure. As shown in FIG. 6, the operator fixes an end of a column rebar 880 to the second coupler 820 in the top of third precast column 800 after the above steps, so that the column rebar 880 is erected on the third precast column 800 along the Y-axis. It should be noted that the column rebar 880 and the first main bar 860 are staggered with the second rebar 230 in the Z-axis direction, so as to avoid any interference with each other.

FIG. 7 is a schematic view showing another construction process in accordance with the above embodiment of the present disclosure. FIG. 8 is a cross sectional view along line 8-8 shown in FIG. 7. Referring to FIG. 7 and FIG. 8, a third precast beam 300 is provided. The operator further lifts the third precast beam 300 so that an end 310 of the third precast beam 300 is arranged in the gap G between the first section 110 and the second section 120 of the first precast beam 100, wherein the length direction of the third precast beam 300 is along the direction of the Z-axis and is substantially perpendicular to the length direction of the first precast beam 100 or the second precast beam 200 (i.e., the direction of the X-axis). The gap G between the first section 110 and the second section 120 is configured to receive the end 310 of the third precast beam 300 wherein the third precast beam 300 is substantially perpendicular to the first precast beam 100 and the second precast beam 200. Specifically, the end 310 of the third precast beam 300 is arranged on the top surface 715 of the second precast column 700, and on a sixth end 750 of the second precast column 700, which is between the second end 730 and the third end 740 of the second precast column 700 (as shown in FIG. 8). On the other hand, as shown in FIG. 8, the second precast beam 700 can be arranged on another corner bracket 760 and a temporary supporting frame 920, so as to carry the other part of the third precast beam 300. Afterward, concrete can be poured between the first section 110, the second section 120 of the first precast beam 100 and the end 310 of the third precast beam 300 to form a joint among them.

In some embodiments, the third precast beam 300 may include two spaced sections (not shown) connected by at least one rebar. The above two sections of the third precast beam 300 can be arranged respectively on the sixth end 750 and a opposite seventh end 770 of the top surface 715 of the second precast column 700

In sum, the present disclosure provides a precast structure and a construction method thereof, wherein a first precast beam has first and second sections spaced apart by a gap. The first precast beam has a first rebar therein and is connected to a second rebar in the second precast beam. With this structure, the beams are lighter in weight and can be quickly assembled on the precast columns. Such precast structure and construction method can greatly enhance the efficiency of assembling the precast beams and shorten the construction period. As described above, the precast structure and the construction method are able to spare space for lifting precast beams. Consequently, the beams at different levels need not to be lifted in a stair-type lifting procedure as shown in FIG. 9A (the precast beams “a” and “b” of the upper and lower stories should be lifted in a stair-like sequence). In contrast, the present disclosure enables vertical lifting procedure as shown in FIG. 9B (the precast beams “a” and “b” of the upper and lower stories can be lifted in a manner wherein one is on top of another). Hence, the lifting space is saved and the construction efficiency is increased.

The above embodiments merely describe the principle and effects of the present disclosure, instead of being used to limit the present disclosure. Therefore, persons skilled in the art can make modifications to and variations of the above embodiments without departing from the spirit of the present disclosure. The scope of the present disclosure should be defined by the appended claims.