Precast Wall Assembly With Integrated Foundations for Fast Erection
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Solution Overview
Problem
Conventional precast concrete structures are time-consuming and expensive to build, requiring heavy labor and equipment for on-site foundation preparation, curing, and assembly, which is complicated by volatile site conditions and lengthy validation processes.
Innovation Solution
A unified precast concrete assembly comprising a foundation and column, pre-assembled off-site with a beam integrated within, allowing for rapid installation on-site without in-situ concrete pouring, and including pre-painted components for a turnkey finished wall system.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional on-site foundation preparation and concrete pouring is used, then structural stability is achieved, but construction time and labor requirements increase significantly
Solution Approach 1:
The foundation and column are pre-assembled into a unified precast concrete assembly at a manufacturing facility before delivery to the construction site. This preliminary action includes casting the foundation, positioning the beam, and securing the column in a controlled environment, eliminating the need for time-consuming on-site concrete pouring and curing operations while maintaining structural integrity
Solution Approach 2:
The patent combines the foundation, beam, and column into a single unified precast concrete assembly. This merging of previously separate components into one integrated unit allows for simultaneous installation of all three elements during a single placement operation, dramatically reducing construction time and labor requirements while ensuring proper alignment and structural connection
2Reliability
If on-site concrete pouring and curing validation is performed, then code compliance is achieved, but project schedule is extended
Solution Approach 1:
All code compliance requirements for concrete pouring, curing, and strength validation are satisfied in advance during the manufacturing process at the fabrication facility. The unified assembly is produced under controlled conditions with proper curing and testing completed before shipment, transferring the compliance validation from the construction site to the manufacturing environment and eliminating time-consuming on-site waiting periods
Solution Approach 2:
The construction process replicates the manufacturing process by simply installing pre-validates assemblies rather than repeating the concrete pouring and curing cycle on-site. The manufacturing facility serves as a template for producing code-compliant units that can be deployed anywhere, transferring the compliance achievement from one location to many without repeating the time-consuming validation steps
3Productivity
If precast components are assembled off-site, then installation speed increases, but integration precision must be maintained
Solution Approach 1:
By merging the foundation, beam, and column into a single unified precast assembly, the patent eliminates interface alignment issues between separate components. The integration precision is built-in during manufacturing when all elements are permanently connected in the correct positions, rather than requiring precise field alignment during installation. This approach transfers the precision requirement from the installation phase to the manufacturing phase, where it can be more easily controlled
Solution Approach 2:
All alignment and positioning adjustments are made in advance during the manufacturing process before the assembly is shipped to the construction site. The foundation, beam, and column are pre-positioned and permanently connected with the correct geometry and tolerances established during fabrication, eliminating the need for complex field alignment operations and ensuring integration precision is achieved without compromising installation speed
Data Source
AI summary
A precast concrete wall system comprising a first precast assembly including a first foundation and a first column positioned offset from a center of the first foundation; a second precast assembly including a second foundation and a second column positioned offset from a center of the second foundation; and a wall extending between the first precast assembly and the second precast assembly. At least a portion of the wall is received within a first channel formed in the first column, and at least a portion of the wall is received within a second channel formed in the second column. The first precast assembly, the second precast assembly, and the wall are configured to be installed at a site without the use of in-situ concrete.