Hybrid Precast Concrete System for Rapid Assembly and Structural Continuity
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Solution Overview
Problem
Conventional building construction methods, such as cast-in-place concrete and precast concrete, face challenges in speed and strength, with cast-in-place being labor-intensive and time-consuming, and precast lacking structural continuity and load transfer between bays.
Innovation Solution
A hybrid system combining precast vertical components and cast-in-place horizontal components, where precast elements are used for rapid construction and cast-in-place elements are supported temporarily during curing, allowing for quicker assembly and improved structural strength by redistributing stresses across greater lengths.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If precast concrete panels are used for rapid assembly, then construction speed is improved, but structural continuity and load transfer between bays deteriorate
Solution Approach 1:
The structure is divided into precast vertical columns and horizontal beams, with cast-in-place concrete infill panels. This segmentation allows rapid assembly of structural elements while the infill panels provide continuity. The vertical columns are precast for speed, while horizontal beams connect them, and cast-in-place infill panels fill the spaces between, creating a hybrid system that combines the advantages of both precast and cast-in-place construction.
2Strength
If cast-in-place concrete construction is used, then structural strength and continuity are improved, but construction time and labor intensity increase
Solution Approach 1:
The construction process is segmented into phases where precast elements (columns, beams) are installed first to provide immediate structural framework and load-bearing capacity. Then cast-in-place concrete infill panels are added to provide continuity and complete the structural system. This segmentation allows the time-consuming cast-in-place work to be done in smaller, parallel sections rather than requiring entire structures to be poured and cured sequentially.
Solution Approach 2:
Precast concrete columns and beams are manufactured off-site in advance and delivered to the construction site ready for installation. This preliminary action removes the time-consuming formwork, pouring, and curing processes from the critical construction path, allowing the structural framework to be assembled rapidly while cast-in-place infill panels are added subsequently to provide continuity without delaying the overall construction schedule.
3Productivity
If precast panels are transported to site, then construction speed is improved, but panel size is limited and structural span capability deteriorates
Solution Approach 1:
The structural system is segmented into smaller, transportable precast columns and beams that can be delivered by standard equipment, and cast-in-place infill panels that are poured on-site. This segmentation bypasses the transportation size limitation by using smaller modular precast elements that assemble into larger structural configurations, with the infill panels providing the necessary span coverage between structural members.
Data Source
AI summary
The disclosed system divides the precast and cast-in-place construction into vertical and horizonal components. The vertical components are precast, permitting rapid vertical building construction without a delay for concrete to set. The two primary precast components are a column that includes a horizontal inflexible slab portion, and a central panel placed diagonally between columns. Each precast component is a weight and size that is readily manageable using a standard construction crane.The horizontal components are a combination of cast-in-place, and precast components. The result creates a continuous unitary floor structure that carries larger loads with less thickness that purely simple span pre-cast construction.