Method and apparatus for precast and framed block element construction

Abstract

Precast planar construction blocks are cast on-site or received and assembled in free-standing modules. A variety of shapes of spaced apart paired blocks form free-standing modules which apply building load over a large footprint. Biaxial sleeve connectors and threaded rods facilitate connection between blocks. The free-standing modules are connected with other structural elements to form a complete primary structure. The primary structure can then be enclosed using manufactured blocks to establish perimeter walls and roofs.

Description

[0001] This application is related to U.S. Provisional Patent Application No. 60 / 417,065 filed Oct. 8, 2002, and claims the benefit of that filing date.[0002] 1. Field of the Invention[0003] This invention is related to a building system that consists of pre-cast structural building blocks and precast or framed floor, wall and roof blocks, the combination of those blocks to create structural elements, and methods of manufacturing, assembly, disassembly and reconfiguration of those blocks.[0004] 2. Description of Related Art[0005] Various types of construction are known in the prior art including wood framed buildings, steel framed buildings, and concrete structures.[0006] The majority of structural design decisions that are made in conventional practice are driven by cost; there are enormous pressures on structural engineers of most building projects to minimize costs while upholding their first duty to ensure the safety of structures. These pressures tend to minimize the structure ...

AI Technical Summary

Benefits of technology

[0018] In various embodiments of the current invention, precast elements maybe fabricated in an efficient controlled environment such as through stack casting to provide plurality of building elements which maybe configured into a wide variety of desirable structures. The elements that can be created by combining modular blocks include walls, portions of walls, support columns, roof trusses and completed structural frames. These building blocks may be quickly assembled at a construction site and may be supported on a concrete slab, on discreet foundations, and in some cases directly on grade. By combining individual blocks or combinations of blocks with other combinations of blocks, diverse structural frames and buildings can be quickly designed and assembled. By building using large manufactured blocks with simple bolted or interlocking connections, frames and entire buildings of this construction can also be modified or dismantled without demolition.

[0018] In various embodiments of the current invention, precast elements maybe fabricated in an efficient controlled environment such as through stack casting to provide plurality of building elements which maybe configured into a wide variety of desirable structures. The elements that can be created by combining modular blocks include walls, portions of walls, support columns, roof trusses and completed structural frames. These building blocks may be quickly assembled at a construction site and may be supported on a concrete slab, on discreet foundations, and in some cases directly on grade. By combining individual blocks or combinations of blocks with other combinations of blocks, diverse structural frames and buildings can be quickly designed and assembled. By building using large manufactured blocks with simple bolted or interlocking connections, frames and entire buildings of this construction can also be modified or dismantled without demolition.

Problems solved by technology

The majority of structural design decisions that are made in conventional practice are driven by cost; there are enormous pressures on structural engineers of most building projects to minimize costs while upholding their first duty to ensure the safety of structures.

This tendency can be unfortunate when a structure is subjected to rare but extreme loads that cannot reasonably be incorporated into statistical load guidance provided by building codes.

Because much of conventional construction is inherently unstable until the construction of structural diaphragms and lateral systems are complete, structural failures during the relatively brief construction period are more common than in completed buildings that stand for years of service.

The lateral bracing and shoring that is typically required for conventional construction creates building site obstructions that contribute to many construction accidents.

Because conventional construction commonly involves the field assembly of parts that can be lifted and handled by one or two workers, the construction of exterior walls and roofs generally involves a significant amount of labor far above ground level; this creates the potential for falling hazards that generate the most lethal jobsite injuries.

Where conventional construction utilizes large parts, such as with tilt-wall construction, expensive crane time is typically consumed holding those parts in position while lateral shoring and bracing members and connections are installed; this is required to stabilize the part prior to releasing the hoisting lines.

The design of unique projects under ever-increasing time, budget, and liability pressures presents real challenges to design professionals; it also places an enormous burden on the builder that must interpret and build a unique and complex project from what will inevitably prove to be an imperfect set of drawings and specifications.

The use of on-site casting for concrete cast-in-place structures requires the expense and delay of field-fabricating the forms for pouring concrete.

Tilt wall construction provides some advantage in pre-casting wall elements, but has the disadvantage of requiring the advance construction of large areas of grade-supported slab to serve as a casting surface for the wall blocks.

Once conventional construction is complete, the modification or removal of a finished building generally involves destructive demolition.

This practice results in millions of tons of construction debris being hauled to landfills every year.

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