WO2016020932A2

WO2016020932A2 - Deployable pre-fabricated reinforcement cage system

Info

Publication number: WO2016020932A2
Application number: PCT/IN2015/000308
Authority: WO
Inventors: Srinidhi Anantharaman; Akhila ANANTHARAMAN; Chiranjib MUKHERJEE; M Usha
Original assignee: Srinidhi Anantharaman
Priority date: 2014-08-04
Filing date: 2015-08-03
Publication date: 2016-02-11
Also published as: WO2016020932A3

Abstract

The present invention relates to a deployable pre-fabricated reinforcement cage system for construction of civil structures which are initially or eventually encased in concrete to help create precast or cast in-situ Reinforced Cement Concrete (RCC) construction technology within less time. The deployable pre-fabricated reinforcement cage system for use in precast concrete and cast-in-place concrete comprising of one or more pre-fabricated wall panels; one or more pre-fabricated column or pedestal panels; one or more pre-fabricated beam panels; and one or more pre-fabricated slab panels. The pre-fabricated reinforcement panels are fixed and positioned through connectors.

Description

DEPLOYABLE PRE FABRICATED REINFORCEMENT CAGE SYSTEM

FIELD OF INVENTION

The present invention generally relates to pre-fabricated reinforcement cage. Specifically, the present invention relates to deployable pre-fabricated reinforcement cage system for construction of civil structures that is robust. More specifically, the present invention relates to deployable pre-fabricated reinforcement cage system for construction of civil structures which are initially or eventually encased in concrete to help create precast or cast in-situ Reinforced Cement Concrete (RCC) construction technology within less time.

BACKGROUND OF INVENTION

Pre-fabrication is the practice of assembling components of a structure in a factory or other manufacturing site and transporting complete assemblies or sub-assemblies to the construction site where the structure is to be located.

Conventional reinforced cement concrete structures consist of steel reinforcement bars which are cut, bent (if required) and tied together in place into cages using flexible binding wires. These cages are enclosed in wooden, metal or other formwork moulds into which a mixture of water, cement, sand, stone aggregates and other admixtures in the form of a wet cement concrete mix are poured in. This mix then hardens and bonds with the reinforcement cages to form a homogenous and monolithic matrix called Reinforced Cement Concrete (RCC). In pre- stressed concrete the process is similar to the RCC process except that high tensile wires are threaded into the matrix and tensioned either prior to pouring the concrete or after the concrete is hardened. This concrete can be cast in position or precast away from the final location and placed in position after hardening. In order to reduce the labour at site, off-site cutting and bending of reinforcement bars was introduced. These cages are generally tied in place using labour for placement and binding wires for tying them together either manually or with hand tools. Off-site pre-fabrication of the cages are not yet popular as the cages get distorted during transportation due to the current method , of using binding wires to hold the bars together. Another difficulty in off-site pre- fabrication is the cost of transport due the voluminous nature of the cages. Known in prior art is use of precast RCC elements such as . walls, slabs, beams and columns. Precast elements are made from pre-fabricated cages which are placed in formwork moulds forming the finished shape and size of the element offsite either in factories or at yards. Concrete is poured into these moulds and allowed to cure normally or rapidly by using techniques such as accelerated* steam curing. However, due to the heavy weights of these elements, the manufacture, storage, transport and fixing at site are all expensive and cumbersome.

Another known in prior art is creating a mesh of reinforcement, which was originally developed for fencing and grating applications. The drawbacks associated with welded mesh include the loss of strength and ductility at the welded junctions and the need for volumes due to the high speed machines.

Another known in prior art is using reinforcement cut and bends, based on Bar Bending Schedule (BBS), where the arrangement and assembly take place at site, separate formwork for walls and slabs are aligned and concrete cast in place. This system requires a bar bending schedule or shop drawing to be generated prior to the cut and bend work and does not eliminate the excessive labour, time and supervision during assembly and fixing.

Another known in prior art is reinforcement cages for monolithic RCC elements such as beams, slabs, walls and columns in buildings which can be pre-fabricated using cut and bend equipment and also tying them into the three-dimensional cages for transport to the sites. Due to the volumes involved in the three-dimensional configurations the transportation cost can be quite prohibitive if done off site and the use of wires for tying the bars together does not lend itself to integrity.

Some of the other known prior arts are:

US7895794 discloses a pre-fabricated structure comprising a plate or shell including a plate or shell frame and an extension including an extension frame deployable from the plate or shell. The plate or shell frame comprises a floor support, a roof support and a plurality of columns which extends between the floor support and the roof support, the plurality of column including a "C" channel. The components of the inner portion and the outer portion can be welded, riveted, bonded or otherwise fixedly connected. However, individual units should be shipped individually because of greater widths where the total width is only slidable inside. Damages in the either floor or wall or roof need to be repaired at workshop and cannot be fixed onsite.

CN101139849 discloses an assembled building elements, consisting essentially of erected wall panels supported through adjusting bracing rod assembly; partition wall panels and external wall panels are embedded with hooked nuts on side walls; the hooked nuts are connected with externally-arranged hoops; studs for fixed construction columns are put through upper rings and lower rings of the hoops, so that structural column bodies can be formed through pea gravel concrete casting and ramming. The assembled building elements as disclosed in the prior art is limited to single storey cannot be used / implemented for residential, commercial and multi- storey's.

US8769906 discloses a reinforcement system for concrete structures, comprising a first set of reinforcement elements configured to be connected to and co-functioning with a second set of reinforcement elements. At least the first set of reinforcement elements, comprising several looped, winded or coiled units, interconnected by means of at least one interconnecting band, is delivered to a construction site in a reduced volume, flat packed condition and is then stretched out to its full length in the form work in situ whereupon the second set of the reinforcement elements bars are placed in intended position with respect to said first set of stretched out reinforcement elements and then tied together. However, second set of the reinforcement elements bars are fixed at site and the number of second set of the reinforcement elements bars are more, and fixing longitudinal and transverse bars of the second set first and later fixing to the first set of bars is time consuming and cumbersome process.

US20120233936 discloses a monolithic reinforced concrete (RC) dense column structure that includes RC dense columns along a structure perimeter, RC window structures along the structure perimeter, and a RC beam over the dense columns and the window structures around the structure perimeter. Each window structure includes RC window columns, a RC short window column between the window columns, and a RC window beam between the window columns and over the short window column. Disadvantages of the monolithic RC dense column structure is, installation is step by step process where the next level operations cannot be started till the completion of installation of wall panels, concreting of columns and beams and installation of slab panels for lower floor. Requires rebar operation at onsite for columns and beams with panel wise fixing / installation of non load bearing prefabricated wall. Accordingly, there is a need for improvement in the design and construction practices of reinforcement in concrete reducing labour and time.

OBJECTS OF INVENTION

One or more problems present of the prior art may be overcome by various embodiment of the present invention.

Accordingly it is the primary object of the present invention to provide a deployable prefabricated reinforcement cage system with or without edge frame for construction of civil structures, said civil structures includes pre-fabricated wall panel, pre-fabricated column or pedestal panels, beam panel and slab panel for raft foundation, floor or roof slab.

Another object of the present invention is to provide deployable pre-fabricated reinforcement cage system for construction of civil structures which are eventually encased in concrete to help create precast or cast in-situ RCC construction technology within shortest possible time.

It is another object of the present invention, wherein the deployable pre-fabricated reinforcement cage system for construction of civil structures can further be used for multi storey buildings. It is another object of the present invention to simplify fixing arrangement of reinforcement bars at shop by clamping each other during process of manufacturing of the pre-fabricated cages.

It is another object of the present invention to simplify transportation and handling of the pre- fabricated reinforcement cage system used in precast concrete and cast-in-place concrete.

It is another object of the present invention to simplify fixing of the pre-fabricated reinforcement cages system through connectors in place as required in the case of precast concrete and cast-in-place concrete.

It is another object of the present invention to provide collapsed pre-fabricated reinforcement system during transportation and deployable pre-fabricated reinforcement cage system comprising stay-in-situation wall/column/beam proprietary formworks and concrete with/without hollow cored wall segments.

It is . another object of the present invention to provide pre-fabricated reinforcement cage system with partial pre-cast ribbed floor slab system which further comprises cast-in-situ concrete which helps to create a lightweight monolithic RCC civil structure within shortest possible time.

It is another object of the present invention to simplify manufacturing process with the help of simple manual techniques with flat bed formers or advanced automatic linear machines with two-dimensional control of bar diameter, spacing and shapes within the shortest possible time.

SUMMARY OF INVENTION

Thus according to the basic aspect of the present invention there is provided a deployable prefabricated reinforcement cage system for use in precast concrete and cast-in-place concrete comprising:

one or more pre-fabricated wall panels;

one or more pre-fabricated column or pedestal panels;

one or more pre-fabricated beam panels; and

one or more pre-fabricated slab panels,

wherein each of the pre-fabricated wall panel comprising:

one or more horizontal reinforcement bars;

one or more vertical reinforcement bars;

one or more U-bent bars;

one or more zigzag spacer reinforcement bars;

one or more locks; and

one or more clamps,

wherein the horizontal reinforcement bar and vertical reinforcement bar are connected with each other through the clamp, and

wherein the U-bent bars are the continuation of the vertical reinforcement bars and zigzag reinforcement bars to maintain continuity of the structural system from bottom to top,

wherein each of the pre-fabricated column or pedestal and beam panel comprising: one or more longitudinal/vertical reinforcement bars; one or more horizontal swivel link bars;

one or more fixed horizontal linked bars; and

one or more clamps,

wherein the longitudinal reinforcement bars and horizontal swivel link bar are connected to each other through the clamp, and

wherein the horizontal swivel link bar provides the collapse mechanism through pivot action and helps to form the pre-fabricated cage in deployed condition, wherein each of the pre-fabricated slab panel for raft foundation, floor or roof comprising:

one or more shorter span reinforcement bars;

one or more longitudinal reinforcement bars;

one or more zigzag spacer reinforcement bars; and

one or more clamps,

wherein the shorter span reinforcement bar and longitudinal reinforcement bar are connected with the zigzag spacer reinforcement bar) through the clamp, and wherein the pre-fabricated reinforcement panels are fixed and positioned through connectors.

It is another aspect of the present invention, wherein the pre-fabricated wall panel includes openings with extra reinforcement at the corners for fixation of door and/or window frames. It is another aspect of the present invention, wherein the door and/or window frames are attached with the pre-fabricated wall panels to have a metal plane surface to fix further customized frames or door/window panels.

It is another aspect of the present invention, wherein the locks include horizontal swivel lock and diagonal swivel lock, said horizontal swivel lock is connected through the clamp through which it can rotate to lock the vertical reinforcement bar and zigzag spacer reinforcement bar in deployed position.

It is another aspect of the present invention, wherein the diagonal swivel lock connects in between the vertical reinforcement bars and maintains the deployed cage system in position.

It is another aspect of the present invention, wherein the pre-fabricated column or pedestal and beam panel further includes diagonal swivel link bar, which takes place after deployment of the pre-fabricated column or pedestal and beam panel to hold the pre-fabricated cage system in deployed position.

It is another aspect of the present invention, wherein in deployed position, the pre-fabricated beam panel consists of partial pre-cast at bottom level to avoid on-site bottom formwork.

It is another aspect of the present invention, wherein the pre-fabricated wall panel further includes conduits of pre-defined diameter in between the wall reinforcement.

BRIEF DESCRIPTION OF DRAWINGS

Figure 1A and IB: illustrates perspective view of a pre-fabricated reinforcement system in deployed form for wall panel according to the present invention.

Figure 2A and 2B: illustrates perspective view of a pre-fabricated reinforcement system in collapsed form for wall panel according to the present invention.

Figure 3: illustrates stacking system of a pre-fabricated reinforcement panel according to the present invention.

Figure 4 A and 4B: illustrates deployment and fixing arrangement of a pre-fabricated reinforcement panel according to the present invention

Figure 5 A and 5B: illustrates deployed and fixed pre-fabricated reinforcement system for column and pedestals according to the present invention. Figure 6 A and 6B: illustrates collapsed and deployed pre-fabricated reinforcement system for beams according to the present invention.

Figure 6C: illustrates the pre-fabricated beam panel with partial pre-cast according to the present invention.

Figure 7 A and 7B: illustrates collapsed and deployed pre-fabricated reinforcement system for slabs according to the present invention.

Figure 8: illustrates clamp used for pre-fabricated reinforcement system according to the present invention.

Figure 9: illustrates pivot action through clamp according to the present invention.

Figure 10: illustrates perspective view of a pre-fabricated reinforcement system in deployed form for wall panel with cutouts for opening according to the present invention. Figure 1 1A and 1 IB: illustrates wall to wall connectivity according to the present invention.

Figure 12: illustrates partial pre-cast in slab according to the present invention.

Figure 13A and 13B: illustrates perspective view of a pre-fabricated reinforcement system in deployed form for wall panel with provision for window frames (13 A) , safety grills, window sills, cable, conduit (13B) etc. according to the present invention. Figure 14A and 14B: illustrates method of manufacturing of pre-fabricated reinforcement system according to the present invention.

Figure 15A and 15B: illustrates horizontal swivel lock in pre-fabricated reinforcement system according to the present invention.

Figure 16: illustrates diagonal swivel lock in pre-fabricated reinforcement system according to the present invention.

Figure 17: illustrates clamp in slab pre-fabricated reinforcement system according to the present invention.

DETAILED DESCRIPTION OF THE INVENTION WITH REFERENCE TO THE ACCOMPANYING DRAWINGS

The present invention as discussed hereinbefore relates to deployable pre-fabricated reinforcement cage system with or without edge frame for construction of civil structures that is robust. More specifically, relates to deployable pre-fabricated reinforcement cage system for construction of civil structures which are eventually encased in concrete to help create precast or cast in-situ Reinforced Cement Concrete (RCC) construction technology within less time.

The deployable pre-fabricated reinforcement cage system for use in precast concrete and cast- in-place concrete comprises of one or more pre-fabricated wall panels; one or more prefabricated column or pedestal panels; one or more pre-fabricated beam panels; and one or more pre-fabricated slab panels.

Referring to Figures 1 A and IB, each of the pre-fabricated wall panel comprises of one or more horizontal reinforcement bar (1), one or more vertical reinforcement bars (2), one or more zigzag spacer reinforcement bars (3 and 9), one or more clamps (4), one or more U-bent bars (5), one or more locks (6) and (7). The locks include horizontal swivel lock (6) and diagonal swivel lock (7). The horizontal reinforcement bar (1) and vertical reinforcement bar (2) are connected with each other through the clamp (4) prepared from thin MS plate. Few of the rebar has transformed as zigzag spacer reinforcement bar (3) to provide the rigidity and space between the two layers of reinforcement bars which contributes in steel requirement as well. The clamp (4) includes two parts having vertical and horizontal plate bent to accommodate the reinforcement bars. These two parts of the clamp (4) can be tightened to each other either through self piercing rivet or by corner fold as shown in Figure 8. The U-bent (5) bars are the continuation of the vertical reinforcement bars (2) and zigzag reinforcement bars (3) to maintain the continuity of the structural system from bottom to top. The deployed form of the pre-fabricated wall panel is assured through the pivot action as shown in Figure 9 in reinforcement bars (1), (2), (3) or (9) through the clamp (4).

The system is adapted for creating hinge-like mechanisms consisting of thin metal flat plates with embossed grooves in the clamps (4) through which the reinforcement bars (1), (2), (3) or (9) are connected, having the provision of holding the bars in place while permitting pivoting action of the bars in desired direction. The horizontal swivel lock (6) is a single bent bar as shown in Figure 15A which provides the locking system for the vertical reinforcement bars (2) and (3) to assure the lateral stiffness once the pre-fabricated wall panel gets deployed shape. The clamps (4) with self locking arrangements ensures the flexibility of movement for collapse and deployment of the reinforcement bars (1), (2), (3) or (9) without dislocation of joint. The horizontal swivel lock (6) is connected through another clamp (4) through which it can rotate and takes place as shown in Figure 15B to lock the vertical bar (2) and (3) in deployed situation. The diagonal swivel lock (7) is another arrangement as shown in Figure 16 to maintain the deployed cage in position. It is the diagonal connection in between the two vertical reinforcement bars (2) which takes place in position once the cage becomes deployed. Figures 2 A and 2B represents the collapsed form of pre-fabricated reinforcement panels where the horizontal swivel lock (6) and diagonal swivel lock (7) takes place after the deployment.

Figure 3 illustrates the stacking of the collapsed pre-fabricated wall panels with the help of suitable packing materials. The pre-fabricated wall panels can be stacked with an ease on top of another with the help of packing materials.

The pre-fabricated wall panels get swiveled either in horizontal direction as shown in Figure 4A or in vertical direction as shown in Figure 4B through the pivot action in the clamp as shown in Figure 9 to get the deployed form of the pre-fabricated cage. The horizontal swivel lock (6) rotates through pivot action in the clamp (4) to lock the vertical bars in its position after the pre-fabricated wall panels get their deployed form.

Referring to Figure 5 A, each of the pre-fabricated column or pedestal and beam panel comprises of one or more longitudinal/vertical reinforcement bars (2), one or more horizontal swivel link bars (8), one or more fixed horizontal linked bars (10), one or more clamps (4) and one or more diagonal swivel link bar (1 1). The longitudinal reinforcement bars (2) and horizontal swivel link bars (8) are connected to each other through the clamp (4). The horizontal swivel link bar (8) provide the collapse mechanism through pivot action and the diagonal swivel link bar (11) take place after deployment of the pre-fabricated column panels to hold the pre-fabricated cage in deployed position as shown in Figure 5B.

Referring to Figure 6A, the pre-fabricated beam panel comprises of one or more longitudinal reinforcement bars (2), one or more horizontal swivel link bars (8), one or more fixed horizontal linked bars (10), and one or more clamps (4). The longitudinal reinforcement bars (2) and horizontal swivel link bar (8) are connected to each other through the clamp (4). The horizontal swivel link bar (8) provides the collapse mechanism through pivot action and helps to form the pre-fabricated cage in deployed position as shown in Figure 6B. In deployed position, the pre-fabricated beam panel consists of partial pre-cast (12) at bottom level to avoid bottom formwork at site as shown in Figure 6C. The pre-fabricated beams include plinth beam, floor beam, roof beam, etc.

Referring to Figure 7 A, each of the pre-fabricated slab panel for raft foundation, floor or roof slab etc. in collapsed form, comprises of one or more shorter span reinforcement bars (13), one or more longitudinal reinforcement bars (2), one or more zigzag spacer reinforcement bars (3 and 9) and one or more clamps (4). The shorter span reinforcement bar (13) and longitudinal reinforcement bar (2) are connected with the zigzag spacer reinforcement bar (3 and 9) through the clamp (4). The reinforcement bars rotates through the clamp as shown in Figure 17 that bent due to pivot action.

Figure 7B illustrates the deployed form of the pre-fabricated slab panels. After the deployment, addition partial precast (12) and rib (14) take place in pre-casting yard. The partial precast (12) is the concreted part at shop or site (if casting area is available) to avoid the formwork for slab at on-site where the rib (14) which is another partial precast segment provides stiffness to the bottom precast segment by dividing the pre-fabricated slab panels in smaller spans as shown in Figure 12. The zigzag spacer reinforcement bar (3 and 9) provides the reinforcement in the rib (14). Referring to Figure 10, the pre-fabricated wall panel includes opening cutouts during primary fabrication of the pre-fabricated panels with extra reinforcement at the corners for easy fixation of the door or window frames in the pre-fabricated wall panels. The door and window frames are attached with the pre-fabricated wall panels to have a metal plane surface to fix further customized frames or door/window panels as shown in Figure 13 A, said metal plane surface is made up of steel.

Referring to Figures 11A and 1 1B, the pre-fabricated wall panel to panel connection is established through connector bar (15) at site which behaves as dowels in the structural wall system and maintains continuity in between the walls.

Referring to Figure 13B, the pre-fabricated wall panel further includes conduits in between the wall reinforcement for electrical pipes, plumbing pipes, sanitary fittings, etc as per predefined layout. The conduit has pre-defined diameter based on the requirement and wall thicknesses. Referring to Figures 14A and 14B, the reinforcement bars are been feed in the flat bed and the bar crimping tool is stationary, the tool is used to place the clamp in position and to lock the reinforcement bars altogether as shown in Figure 14 A. The longitudinal reinforcement bars are laid on the flat bed, bar crimping tool is suspended from above to move in longitudinal direction to place the secondary bars and clamp in position as shown in Figure 14B. Both the operations as shown in Figures 14 A and 14B produce higher numbers of pre-fabricated panels in short time span for faster production aspect.

The deployable pre-fabricated reinforcement cage system according to the present invention has the following advantages:

•Low cost of manufacturing, transport and installation

· Integrated structural behavior.

•Eliminates labour intensive rebar work at site.

•Facilitates fast track construction. •Reduces site facilities and establishment.

•Favorable for diverse topographical and climatic conditions.

•Facilitates excellent surface finish.

•Promotes precision and dimensional stability.

•Eliminates brickwork and plastering.

•Reduces self weight and foundation costs.

•Unparalleled strength against earth-quakes.

•Better water resistant surface.

•Precise scheduling and quality control.

•Repetitive works require less training.

•Suitable for crane intensive erection.

• Safer construction process.

•Pre-installed service runs before concreting.

•Rhythmic work system.

Claims

1. A deployable pre-fabricated reinforcement cage system for use in precast concrete and cast- in-place concrete comprising:

one or more pre-fabricated wall panels;

one or more pre-fabricated column or pedestal panels;

one or more pre-fabricated beam panels; and

one or more pre-fabricated slab panels,

wherein each of the pre-fabricated wall panel comprising:

one or more horizontal reinforcement bars (1);

one or more vertical reinforcement bars (2);

one or more U-bent bars (5);

one or more zigzag spacer reinforcement bars (3) and (9);

one or more locks (6) and (7); and

one or more clamps (4),

wherein the horizontal reinforcement bar (1) and vertical reinforcement bar (2) are connected with each other through the clamp (4), and

wherein the U-bent (5) bars are the continuation of the vertical reinforcement bars (2) and zigzag reinforcement bars (3) to maintain continuity of the structural system from bottom to top,

wherein each of the pre-fabricated column or pedestal and beam panel comprising: one or more longitudinal/vertical reinforcement bars (2);

one or more horizontal swivel link bars (8);

one or more fixed horizontal linked bars (10); and

one or more clamps (4),

wherein the longitudinal reinforcement bars (2) and horizontal swivel link bar (8) are connected to each other through the clamp (4), and

wherein the horizontal swivel link bar (8) provides the collapse mechanism through pivot action and helps to form the pre-fabricated cage in deployed condition, wherein each of the pre-fabricated slab panel for raft foundation, floor or roof comprising: one or more shorter span reinforcement bars (13);

one or more longitudinal reinforcement bars (2);

one or more zigzag spacer reinforcement bars (3) and (9); and

one or more clamps (4), ■ wherein the shorter span reinforcement bar (13) and longitudinal reinforcement bar

(2) are connected with the zigzag spacer reinforcement bar (3) and (9) through the clamp (4), and

wherein the pre-fabricated reinforcement panels are fixed and positioned through connectors.

2. The deployable pre-fabricated reinforcement cage system as claimed in claim 1, wherein the pre-fabricated wall panel includes openings with extra reinforcement at the corners for fixation of door and/or window frames.

3. The deployable pre-fabricated reinforcement cage system as claimed in claim 2, wherein the door and/or window frames are attached with the pre-fabricated wall panels to have a metal plane surface to fix further customized frames or door/window panels.

4. The deployable pre-fabricated reinforcement cage system as claimed in claim 1, wherein the locks include horizontal swivel lock (6) and diagonal swivel lock (7), said horizontal swivel lock (6) is connected through the clamp (4) through which it can rotate to lock the vertical reinforcement bar (2) and zigzag spacer reinforcement bar (3) in deployed position.

5. The deployable pre-fabricated reinforcement cage system as claimed in claim 4, wherein the diagonal swivel lock (7) connects in between the vertical reinforcement bars (2) and maintains the deployed cage system in position.

6. The deployable pre-fabricated reinforcement cage system as claimed in claim 1, wherein the pre-fabricated column or pedestal and beam panel further includes diagonal swivel link bar (11), which takes place after deployment of the pre-fabricated column or pedestal and beam panel to hold the pre-fabricated cage system in deployed position.

7. The deployable pre-fabricated reinforcement cage system as claimed in claim 6, wherein in deployed position, the pre-fabricated beam panel consists of partial pre-cast (12) at bottom level to avoid on-site bottom formwork.

8. The deployable pre-fabricated reinforcement cage system as claimed in claims 1 and 2, wherein the pre-fabricated wall panel further includes conduits of pre-defined diameter in between the wall reinforcement.