Floor Plate Fabrication with Camber Control for Vertical Lifting
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Solution Overview
Problem
Traditional methods for constructing high-rise buildings are inefficient and costly due to the need for extensive crane operations and sequential assembly of structural elements, which require specialized equipment and time-consuming processes.
Innovation Solution
A vertical slip form construction system where floor plates are fabricated at ground level, lifted, and attached to a vertical support core, with cambers imparted into framing members to ensure flatness, using a system of girders, cantilevered beams, and hydraulic pedestals to control deflections and support points for precise assembly and hardenable material placement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If structural elements are assembled one member at a time above ground level using tower cranes, then the building frame can be constructed vertically, but the construction process becomes time-consuming and costly due to extensive crane operations and sequential assembly
Solution Approach 1:
The building structure is divided into modular floor plates that can be fabricated separately at ground level and then assembled vertically. Each floor plate is a self-contained module containing multiple structural elements already connected, allowing parallel fabrication and reducing on-site assembly time.
Solution Approach 2:
Floor plates are pre-assembled and pre-connected at ground level before being lifted into position. This preliminary assembly of multiple members simultaneously at ground level eliminates the need for sequential crane-based assembly at elevation, significantly reducing construction time.
2Ease of manufacture
If concrete is pumped to the final elevation of each floor during construction, then the hardening material can be placed at height, but specialized equipment and setup logistics are required which increase cost and time
Solution Approach 1:
The building is segmented into discrete floor plate modules that are completed at ground level. This segmentation allows concrete to be placed at ground elevation where equipment is simple and access is easy, eliminating the need for complex high-elevation concrete pumping operations.
Solution Approach 2:
The floor plate acts as an intermediary structure that is fabricated complete at ground level and then transported to its final position. This intermediary approach transfers the concrete placement operation from high elevation to ground level, simplifying equipment requirements.
3Productivity
If floor plates are fabricated at ground level and lifted to final position, then construction time is reduced, but the floor plate must be designed with permanent support points for attachment to the vertical support core
Solution Approach 1:
The floor plate structure incorporates localized permanent support points at specific locations where attachment to the vertical support core is required. These support points are strategically positioned to provide structural connection while maintaining the overall simplicity of the modular floor plate design.
Data Source
AI summary
Fabrication of a multi-story building includes fabricating floor plates at or near ground level, and lifting them to a final position on a vertical support core. A method for assembling one of the floor plates assembling a floor plate frame near ground level. Cambers are imparted into framing members based upon expected deflections, and metal decking is installed onto the floor plate frame. A plurality of permanent support points for the floor plate are determined, wherein the floor plate is attachable to the vertical support core at the permanent support points. First pedestals are installed between ground level and the floor plate frame proximal to the permanent support points for the floor plate. Hardenable material is dispersed onto the metal decking of the floor plate frame while the floor plate frame is lifted at the permanent support points.