Reinforced concrete column integrated with a foundation footer

Abstract

A method for construction of a reinforced-concrete column having integrally fixed a column part and a foundation footer part. The method provides for clearing a column product line (CPL) stand, assembling the formwork by aligning plywood formwork elements and installing anchor fixing sleeves and installing a reinforcement structural framework of the column part and the foundation footer part employing protective layer and additional reinforcement elements. The method further provides for moulding the column by pouring a concrete mixture into the formwork to cover the reinforcement structural framework and curing the concrete mixture over the reinforcement structural framework. Finaly, the method discloses dismantling the formwork and removing the rigging elements and clearing air outlets and holes for assisting in lifting the reinforced-concrete column.

Description

TECHNICAL FIELD

[0001] The present disclosure generally relates to industrial construction. More specifically, the present invention relates to a reinforced column integrated with a foundation footer and used in a construction system for erecting multipurpose industrial buildings from large-unit blocks.BACKGROUND

[0002] As the need for warehousing and other industrial buildings continues to grow, so is the desire to increase the availability of industrial buildings. One way to increase the number of the available industrial buildings is to build them quicker and make their construction more and more cost effective.

[0003] However, erection of industrial buildings efficiently and quickly can be challenging. Labor and materials costs can vary dramatically depending on where you build and, in many instances, can be prohibitively high. Moreover, with rapidly spiked demand for industrial buildings comes tighter construction schedules.

[0004] To accommodate the demand, various solutions have been proposed. For example, the construction of a building using prefabricated building units was proposed, each having a horizontal upper exterior surface and a plurality of vertical wall surfaces, and at least some of the prefabricated building units have at least one hollow column formwork structure. Another construction system for erecting building structures was shown to have a plurality of prefabricated interconnectable modular building units, each unit comprising framing members and a plurality of nodes. However, the conventional modular manufacturing industry has not succeeded in penetrating the construction market to any significant degree because it has not solved the issues relating to labor materials and costs and access to affordable skilled labor.

[0005] Accordingly, there is a need for a system for erecting multipurpose industrial buildings from large-unit blocks that solves the forgoing shortcomings. The foundation footer of such a system and its integral components is a reinforced column integrated with a foundation footer and used to connect the walls of the industrial buildings and support, for example, its roof.SUMMARY

[0006] In one aspect, the present invention provides a reinforced-concrete column having a column part and a foundation footer part integrally and rigidly connected with the column part. The reinforced-concrete column further has a reinforcement structural framework having reinforcement rods configured to provide rigid connection between the column part and the foundation footer part and a concrete layer. In addition, the reinforced-concrete column can have a chamfer on each corner of the column part, reinforced protective corner, and embedded bars for attaching to adjacent structures.

[0007] In another aspect, the present invention provides a method for construction of a reinforced-concrete column having integrally fixed a column part and a foundation footer part. The method provides for clearing a column product line (CPL) stand, assembling the formwork by aligning plywood formwork elements and installing anchor fixing sleeves and installing a reinforcement structural framework of the column part and the foundation footer part employing protective layer and additional reinforcement elements. The method further provides for moulding the column by pouring a concrete mixture into the formwork to cover the reinforcement structural framework and curing the concrete mixture over the reinforcement structural framework. Finaly, the method discloses dismantling the formwork and removing the rigging elements and clearing air outlets and holes for assisting in lifting the reinforced-concrete column.

[0008] In yet another aspect, the present invention provides a method of installing the reinforced-concrete column by providing a pit having a floor and walls, stabilizing the ground subbase for the floor and the walls and placing the foundation footer part of the reinforced-concrete column on the floor of the pit. Then the method discloses filling the pit with concrete in liquid form through the air outlets and allowing the concrete to solidify in the pit.BRIEF DESCRIPTION OF THE DRAWINGS

[0009] In order that the invention will be readily understood, a more particular description of the invention briefly described above will be rendered by reference to specific embodiments that are illustrated in the appended drawings. Understanding that these drawings depict only typical embodiments of the invention and are not therefore to be considered to be limiting of its scope, aspects of the invention will be described and explained with additional specificity and detail through the use of the accompanying drawings.

[0010] FIG. 1 depict a diagram of a fully assembled reinforced column according to embodiments of the present invention;

[0011] FIG. 2 depicts a diagram of an another view of the reinforced column according to embodiments of the present invention;

[0012] FIG. 3 depicts a diagram of a method for formation of the reinforced column according to embodiments of the present invention; and

[0013] FIG. 4 depicts a diagram of a method for installation of the reinforced column using a foundation footer pit.DETAILED DESCRIPTION

[0014] Reference to “a specific embodiment” or a similar expression in the specification means that specific features, structures, or characteristics described in the specific embodiments are included in at least one specific embodiment of the present invention. Hence, the wording “in a specific embodiment” or a similar expression in this specification does not necessarily refer to the same specific embodiment.

[0015] Hereinafter, various embodiments of the present invention will be described in more detail with reference to the accompanying drawings. Nevertheless, it should be understood that the present invention could be modified by those skilled in the art in accordance with the following description to achieve the excellent results of the present invention. Therefore, the following description shall be considered as a pervasive and explanatory description related to the present invention for those skilled in the art, not intended to limit the claims of the present invention.

[0016] Reference to “an embodiment,”“a certain embodiment” or a similar expression in the specification means that related features, structures, or characteristics described in the embodiment are included in at least one embodiment of the present invention. Hence, the wording “in an embodiment,”“in a certain embodiment” or a similar expression in this specification does not necessarily refer to the same specific embodiment.

[0017] Embodiments of a reinforced column integrated with a footer and method to manufacture the same are described herein. In particular, the present disclosure is directed to a method for manufacturing a monolithic weight-bearing column that includes a vertical reinforced concrete part fully integrated with a foundation footer part. The construct and method of the monolithic weight-bearing column allows its application with various part of an industrial building and its adaptation to various parameters and requirements of the different installation positions of the industrial building.

[0018] Generally, the construction material of choice for modern industrial structures is concrete. Concrete is a durable material, and readily available around the world. It can be used to form walls and columns of the industrial building. Conventional cast-in-place concrete construction relies on the use of labor-intensive, time-consuming, built-in-place formwork that must be erected for each column. The formwork takes up space that could be used for moving around the site and is a time-consuming process.

[0019] Given the time-consuming nature of cast-in-place concrete, the concept of casting off-site arose, with the pre-cast concrete pieces then being assembled on-site. While moving the slow and time-consuming process of pouring concrete and waiting for cure, to an off-site location, does speed up the process of construction, the resulting structure lacks the strength of a cast-in-place building due to weak connectivity.

[0020] The present invention solves the foregoing issues of constructing the monolithic weight-bearing column that is manufactured using the continuous moulding method. The column can have internal connections and reinforcements of various sized and diameters depending on the size and purpose of the column. Additionally, as further descried in this disclosure, for installation at the foundation footer of the column, holes are formed using embedded bars for alignment into the installation position with an accuracy of about to 3 / 16 of an inch and subsequent fixation with specialized non-shrinking concrete mixture through the holes. Embodiments of the present invention illustrated by FIGS. 1-4 disclose a reinforced column integrated with a foundation footer by a single piece reinforcement structural frame.

[0021] FIG. 1 shows a diagram of the fully assembled reinforced column 100. The column 100 has a vertical column part 20 fully integrated with a foundation footer part 40. The column part 20 can be provide with a chamfer 11 on each corner of the column part 20 to create a transitional edge, for example, a 45 degree angle. A stainless still protective corner 12 can also be provided (shown on FIGS. 1 and 2). The protective corner 12 prevents concrete chipping and provides an aesthetically pleasing design for the lower portion of the reinforced column 100.

[0022] As illustrated in FIG. 1, the column part 20 can be provided with various holes, embedded bars and hinges to assist in construction of the industrial building (not shown). In particular, according to embodiments of the present invention, the column part 20 can be provided with holes 7 to assist in lifting the reinforced column 100 during the construction of the industrial building. Additionally, embedded bars 9 can be provided for attaching adjacent structures. The embedded bars can be manufactured from steel and have movable bracing (not shown). To assist with lifting the reinforced column 100, the column part can have lifting hinges 10, preferably in the form of a rod with a flattened base.

[0023] As shown on FIG. 1, the column part 20 can be provided with pins 8 bolted into the top portion of the column part 20 and, preferably, made from steel. The pins 8 can be used to connect to adjacent structures, for example, a ceiling and / or roof of the industrial building.

[0024] The foundation footer part 40 can be provided with air outlets 6 (shown on FIGS. 1 and 2). The air outlets 6 are provided to supply concrete in liquid form to level the reinforced column 100 during construction process and eliminate any voids under the reinforced column 100 after installation.

[0025] Both the column part 20 and the foundation footer part 40 can be made from high strength concrete, preferably, about 8000 pound per square inch (psi).

[0026] FIG. 2 further illustrates the reinforced column 100. The reinforcement for the reinforced column 100 can be provided by a reinforcement structural framework 15 that can include a rebar 2 with grooved profile. The rebar 2 can be made from steel or other suitable metal alloy. Additionally, reinforcements 5 can be provided over the rebar 2. The reinforcements 5 can be manufactured from steel or another flexible and strong alloy.

[0027] The foundation footer part 40 can be provided with a mesh 3 for the additional reinforcement of the foundation footer part 40. The mesh 3 can be made from welded mesh of corrugated rebar. Additionally, reinforcement rods 4 can be provided. The rods 4 are bent and have a grooved profile for anchoring into the foundation footer part 40. The rods 4 allow rigidly connecting the foundation footer part 40 to the column part 20.

[0028] FIG. 3 illustrates a method 300 according to embodiments of the present invention for formation of the reinforced column 100 off-site to be transformed to the construction site and be implemented during the construction of the industrial building. As shown in FIG. 3, first a cleaning step 310 is carried out by clearing the column product line (CPL) stand (not shown), removing bulky waste, removing traces of hot-melt adhesive, silicone sealant and tape from the CPL stand with a spatula. When cleaning the CPL stand it is especially important to cleaning the stationary board and the metal chamfer maker without striking the flatbed with metal objects so as not to damage the flatbed and create irregularities. In this step 310, cleaning of formwork is also carried out.

[0029] Next, a step of formwork assembly 315 is carried out. During the formwork assembly, polystyrene foam inserts can be installed by fixing the polystyrene foam inserts for the grooves with double-sided adhesive tape in 2 or 3 rows, depending on the width of the insert and sealing the upper and lower joints with silicone sealant. The metal sides of the formwork and the laminated plywood floor can also be sealed with silicone sealant. Then, plywood formwork elements and additional elements can be installed, as needed. This can be carried out according to the design drawings, using a tape measure, and installing the plywood formwork elements and aligning the bottom edge to the designated position. In the case of columns with cantilevers, installing additional plywood formwork and fixing it using magnets, clamps, and spacers can be necessary. Other methods of fastening additional elements can be used based on the conditions of production technology, providing the required geometric characteristics of the finished product are met. Wiping off excess sealant and hot-melt adhesive from the surface of the sides using a rag is usually also necessary.

[0030] After the installation of the plywood formwork, sleeves for anchor fixing can be installed using nailing the plastic bushing to the plywood. Then, using a spray gun, grease is applied to the surface of the boards, liners and additional formwork elements.

[0031] The next step of reinforcement installation 320 is carried out by installing protective layer retainers to ensure the required protective layer and correct spatial arrangement of the reinforcement cage, installing the reinforcement structural framework 15 and installing additional reinforcement cage elements 5.

[0032] The installation of reinforcement structural framework 15 is carried by installing reinforcement cage of the column shaft using an overhead travelling crane into the column production line stand, ensuring the design position of the frame, adding fixings and replacing damaged fixings if necessary. Then, installation of the required reinforcing elements is carried out to ensure the positioning by means of binding wire. And, installing and tying up the sling loops. Finally, installing the reinforcement cage of the foundation footer slab using an overhead travelling crane.

[0033] Additional reinforcement cage elements 5, for example, embedded bars, individual bars, bent bars and clamps can be secured with binding wire.

[0034] The step of final assembly of the formwork 325 is carried out by installing the end stop in the head of the column, remixing the movable side, fixing it in the designed position and installing anchors and anchor bars. A hot melt adhesive can be used for the installation.

[0035] The moulding step 330 is performed by pouring the concrete mixture into the formwork. The concrete mix container preferably is pre-treated with grease at least 30 min before the concrete mixture is delivered. The concrete mixture can be delivered following the steps of (i) filling the base slab mould; (ii) filling until the top point of the spreading concrete mix reaches ¾ of the level of the column shaft cross-section (iii) moving the concrete mix delivery chute 10 ft in the direction of the column so that the concrete mixture is poured on top of the flowing concrete mix; (iv) moving the concrete mixture through another 10 ft in accordance with the above requirements; (v) move the concrete mixture delivery chute to the final part of the stand mould near the head of the column and filling it flush with the top of the side; (vi) moving the chute in the reverse order and fill the remaining part of the column in 3 equal instalments; (vii) vibro-compacting the concrete mixture with a depth vibrator in the center of the column with a step of 2 feet and 2-3 seconds at each point, excluding cases of forming the concrete mixture with visible signs of delamination; and no earlier than 2 hours, after the concrete mixture has reached the required elastic-plastic state and no later than 4 hours, installing the base slab formwork liner and filling the remaining part of the base slab mould with concrete mixture.

[0036] The step of curing 335 the column is performed by soaking the column until the exposed surface reaches an elastic-plastic state (e.g., 3-4 hours) and then trowelling to achieve the substantial smooth surface quality. The column then is covered with the polystyrene foam boards in such a way as to ensure tight adhesion to each other and to the metal surface of the CPL stand. The polystyrene foam boards can be additionally covered with a thermal blanket. Covering of the foundation footer part 40 preferably performed not earlier than 1 hour from the completion of surface trowelling or later. Covering the column part 20 preferably performed no later than 2 hours after pouring. After the curing step 335, the column is preferably maintained in the CPL stand until it reaches a moulding strength of 6000 psi or more, but not less than 12 hours after the covering the column part 20.

[0037] The step of stripping 340 is carried out by dismantling the formwork and removal of additional equipment elements. After the formwork is dismantled and the additional equipment elements are removed, the column is transported to a “worm store” and the polystyrene foam is removed. Additionally, the polystyrene foam plugs can be inserted into the holes formed by the corrugated tubes. Concrete chips, traces of hot melt adhesive, sealant and other debris are removed from the surface of the column and embedded bars 9. Chamfers, mounting holes 7 and air outlets 6 are cleaned. Channels are installed. The embedded bars 9 are painted at least twice. The column part 20 is treated with hydrophobiser.

[0038] The final step of the reinforced column 100 production 345, is acceptance of the final column 100 by a quality control officer and dispatching the finished column 100 to the warehousing or construction site.

[0039] FIG. 4 illustrates method 400 according to embodiments of the present invention for installation of the reinforced column 100 using a foundation footer pit 410. In a step 420, the foundation footer pit's wall 404 and a floor 402 stabilized by the conventional methods known in the art, for example using polyurethane.

[0040] In a step a step 425, a support layer 405 of, for example, crushed stones can be provided. On top of the support layer, a reinforced footing layer 407 can be applied in step 430. The reinforced footing layer 407 can be made from concrete and rebar, or reinforcing bars.

[0041] In a step 435, steel leveling plates 409 can be position on top pf the reinforced footing layer 407. In a step 440, the reinforced column 100 is erected on top of the reinforced footing layer 407 and leveled using the level plates 409.

[0042] In a final step 450, the air outlets 6 are filled with concrete in liquid form to level the reinforced column 100 to eliminate any voids under the reinforced column 100 after installation.

[0043] The foregoing detailed description of the embodiments is used to further clearly describe the features and spirit of the present invention. The foregoing description for each embodiment is not intended to limit the scope of the present invention. All kinds of modifications made to the foregoing embodiments and equivalent arrangements should fall within the protected scope of the present invention. Hence, the scope of the present invention should be explained most widely according to the claims described thereafter in connection with the detailed description, and should cover all the possibly equivalent variations and equivalent arrangements.

[0044] The terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting of the present invention. As used herein, the singular forms “a”, “an” and “the” are intended to include the plural forms as well, unless the context clearly indicates otherwise. It will be further understood that the terms “comprises” and / or “comprising,” when used in this specification, specify the presence of stated features, integers, steps, operations, elements, and / or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, element components, and / or groups thereof.

[0045] The corresponding structures, materials, acts, and equivalents of all means or step plus function elements in the claims below are intended to include any structure, material, or act for performing the function in combination with other claimed elements as specifically claimed. The description of the present invention has been presented for purposes of illustration and description, but is not intended to be exhaustive or limited to the invention in the form described. Many modifications and variations will be apparent to those of ordinary skill in the art without departing from the scope and spirit of the invention. The embodiment was chosen and described in order to best explain the principles of the invention and the practical application, and to enable others of ordinary skill in the art to understand the invention for various embodiments with various modifications as are suited to the particular use contemplated.

Claims

1. A method for construction of a reinforced-concrete column having integrally fixed a column part and a foundation footer part, the method comprising:clearing a column product line (CPL) stand;assembling the formwork by aligning plywood formwork elements and installing anchor fixing sleeves;installing a reinforcement structural framework of the column part and the foundation footer part employing protective layer and additional reinforcement elements;moulding by pouring a concrete mixture into the formwork to cover the reinforcement structural framework;curing the concrete mixture over the reinforcement structural framework;dismantling the formwork and removing the rigging elements; andclearing air outlets and holes for assisting in lifting the reinforced-concrete column.

2. The method according to claim 1, wherein the column part of the reinforced-concrete column further comprises:a chamfer on each corner of the column part;reinforced protective corner; andembedded bars for attaching to adjacent structures.

3. The method according to claim 1, wherein the foundation footer part of the reinforced-concrete column further comprises:a mesh made from rebar; anda plurality of reinforcement rods.

4. The method according to claim 3, wherein the reinforcement rods are bent to provide rigid connection between the column part and the foundation footer part.

5. A method of installing the reinforced-concrete column of claim 1, the method comprising:providing a pit having a floor and walls;stabilizing the ground subbase for the floor and the walls;placing the foundation footer part of the reinforced-concrete column on the floor of the pit; filling the pit with concrete in liquid form through the air outlets; andallowing the concrete to solidify in the pit.

6. The method according to claim 5 further comprising:providing a support layer on top of the floor;providing a reinforced layer on top of the support layer; andproviding leveling plates on the reinforced layer.

7. The method according to claim 1, wherein a strength of concrete of the reinforced-concrete column is about 8000 pound per square inch (psi).

8. A reinforced-concrete column, the column comprising:a column part;a foundation footer part integrally and rigidly connected with the column part;a reinforcement structural framework having reinforcement rods configured to provide rigid connection between the column part and the foundation footer part; anda concrete layer.

9. The reinforced-concrete column according to claim 8, wherein the column part of the reinforced-concrete column further comprises:a chamfer on each corner of the column part;reinforced protective corner; andembedded bars for attaching to adjacent structures.

10. The reinforced-concrete column according to claim 8, wherein the foundation footer part of the reinforced-concrete column further comprises:a mesh made from rebar;a plurality of air outlets for stabilizing the reinforced concrete column; anda plurality of holes for assisting in lifting the reinforced-concrete column.

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