Segmented Precast Beam Assembly for Crane-Limited Construction
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Solution Overview
Problem
Traditional construction methods for high-tech plants are time-consuming and inefficient, particularly in constructing high-tech buildings that require rapid assembly and heavy load-bearing structures, due to limitations in lifting capacity and distance of cranes, leading to increased costs and logistical challenges.
Innovation Solution
A construction method involving precast columns and beams with integrated rebars, allowing for vertical lifting and assembly of beams without interference, using temporary supporting frames and corner brackets to enhance stability and efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If traditional construction methods are used to construct floor by floor from bottom up, then the construction process can be completed with conventional equipment, but the construction time is excessive and the process is time-consuming
Solution Approach 1:
The construction process is segmented into precast manufacturing (factory) and on-site assembly (construction site). Precast columns and beams are manufactured separately in a factory with reusable molds, then transported and assembled on-site using mechanical equipment. This segmentation enables parallel processing and eliminates sequential dependencies, dramatically reducing construction time.
Solution Approach 2:
Precast structural components (columns and beams) are manufactured in advance in a factory environment before being transported to the construction site. This preliminary action allows construction activities to proceed simultaneously with component fabrication, eliminating the sequential wait time inherent in traditional on-site construction methods.
2Productivity
If precast construction method is used with tower cranes or mobile cranes to place precast columns and beams, then the construction process is accelerated, but the loading capacity and distance limitations of cranes increase costs and challenges
Solution Approach 1:
The precast beam is segmented into multiple sections (first section, second section, etc.) that can be lifted and positioned separately. This segmentation reduces the weight and dimensions of individual components, allowing standard cranes with limited capacity and reach to handle them effectively, thereby reducing crane-related costs and logistical challenges.
Solution Approach 2:
Corner brackets are introduced as intermediary components to facilitate the connection between precast beams and columns. These brackets enable efficient load transfer and structural assembly without requiring oversized lifting equipment, as the connection mechanism is simplified and optimized for standard crane capabilities.
3Reliability
If traditional construction methods are used with numerous processes such as tying reinforced steel, molding, grouting, then the construction quality relies on worker skill and experience, but the construction process becomes complex and difficult to control
Solution Approach 1:
The construction process is divided into distinct phases: precast manufacturing (with controlled quality processes) and on-site assembly (with simplified connection processes). This segmentation transfers complex quality-critical processes to the factory environment where they can be standardized and controlled, while on-site work focuses on straightforward assembly operations.
Solution Approach 2:
The construction approach transitions from cast-in-place concrete (requiring formwork, reinforcement tying, and curing) to precast assembly (using pre-manufactured components with standardized connection details). This parameter change fundamentally reduces the number of on-site processes from multiple complex steps to primarily lifting, positioning, and connecting operations.
Data Source
AI summary
A precast structure and a method of constructing the precast structure. The precast structure includes a first precast beam and a second precast beam. The first precast beam includes a first section, a second section and a first rebar. The second section is separate from the first section and a gap is formed therebetween. The first rebar penetrates through and connects the first section and the second section along a length direction. The second precast beam aligns with the first precast beam and being adjacent to the second section of the first precast beam. The second precast beam is coupled to the first rebar of the first precast beam.