WO2022148762A1

WO2022148762A1 - A precast concrete structure and method of forming a precast concrete structure

Info

Publication number: WO2022148762A1
Application number: PCT/EP2022/050119
Authority: WO
Inventors: Donal O'FLYNN; David Smith
Original assignee: Oflynn Donal; David Smith
Priority date: 2021-01-05
Filing date: 2022-01-05
Publication date: 2022-07-14
Also published as: GB202100077D0; GB2602503A

Abstract

A precast concrete building structure (10) comprising a plurality of modular precast concrete components (11). The modular precast concrete components (11) each comprise a plurality of load bearing members (12) arranged such that gaps (13) are defined between the plurality of load bearing members (12). The modular precast concrete components (11) are configured for assembly to form said building structure. Advantageously, the building structure (10) is formed from modular precast concrete components (11) which comprise gaps (13) making said components (11), and the overall building structure (10), lighter, more cost effective to produce, and more sustainable, all without sacrificing structural strength and stability.

Description

A PRECAST CONCRETE STRUCTURE AND METHOD OF FORMING A PRECAST CONCRETE

STRUCTURE

Field of the Invention

This invention relates to a precast concrete structure and in particular to a modular precast concrete building structure.

Background of the invention

Any instance where it is advantageous to elevate or suspend equipment or cabling can benefit from utilisation of a building structure to facilitate such suspension of elevation, and in particular tower structures may be useful for this purpose. Common examples are the installation of wind turbines and suspension of electrical or communications cabling. Existing tower designs typically utilise large reinforced concrete wall sections or comprise an all steel construction. In both cases, the constituent components which are utilised to form the tower structure are large and of significant weight, and are thus typically difficult and expensive to transport and provide access issues when installation sites are remote or otherwise difficult to reach. Moreover, given that existing designs comprise solid reinforced concrete or substantial steel beam components, they are expensive to manufacture from a material usage standpoint and are not sustainable in nature. In addition, most existing tower structures are constructed from basic constituent parts on site; therefore most of the construction is required to be completed at the installation site, which again can be difficult depending on the location and layout of the site.

It is desirable to provide a building structure and a method of manufacturing a building structure that allows for flexibility of design, is more easily constructed at the site of installation, and is more easily transported to a site of installation.

Summary of the Invention

According to the invention there is provided a precast concrete building structure comprising a plurality of modular precast concrete components, the modular precast concrete components each comprising a plurality of load bearing members arranged such that gaps are defined between the plurality of load bearing members, wherein the modular precast concrete components are configured for assembly to form said building structure.

Advantageously, the building structure is formed from modular precast concrete components which comprise gaps making said components , and the overall building structure, lighter, more cost effective to produce, and more sustainable, all without sacrificing structural strength and stability. Further advantageously, the modular precast concrete components may be manufactured offsite and due to their reduced size and/or weight be transported more easily to a desired site for assembly when compared to more traditional building materials such as concrete solid wall components or steel tubular/beam components.

Ideally, the building structure is a tower structure.

Preferably, the plurality of load bearing members are structural load bearing members,

Ideally, the plurality of load bearing members arranged in an intersecting arrangement wherein all or some of the load bearing members may intersect with each other.

Ideally, the modular precast concrete components comprise mechanical interconnection features therebetween.

Preferably, the mechanical interconnection features facilitate joining of adjacent modular precast concrete components to form the precast concrete building structure.

Advantageously, the mechanical interconnection features provide increased structural stability and/or may aid to guide correct assembly of the building structure.

Ideally, the mechanical interconnection features comprise complimentary male and female interconnection features which engage to retain adjacent modular precast concrete components together to form the precast concrete building structure.

Preferably, the joints between modular precast concrete components comprise grout or a seal element to create a solid connection. Advantageously this ensures good bonding between the adjoined modular precast components and avoids abrasion between the concrete surfaces of adjoined modular precast components.

Preferably, the modular precast concrete components are pre-stressed modular precast concrete components.

Ideally, the modular precast concrete components are diagrid components such as X-grid components.

Preferably, the modular precast concrete components comprise an upper beam and a lower beam arranged in a horizontal spaced apart arrangement, the upper beam and lower beam having a plurality of load bearing members arranged in an intersecting arrangement therebetween. Ideally, the building structure comprises means for post tensioning the building structure once assembled.

Alternatively, or in combination, the building structure comprises means for post tensioning sections of the building structure at intermediate points throughout the assembly.

Ideally, the means for post tensioning comprises cable elements which extend through a plurality of the modular precast concrete components between a first anchored end and a second end in operable engagement with a cable tensioning mechanism.

Preferably, the modular precast concrete components through which the cable elements extend comprise through bores therein sized and dimensioned to permit passage of the cable elements therethrough.

Ideally, at least some of the modular precast concrete components may comprise cable access features.

Preferably, the cable access features carry the cable elements and extend internally of the building structure such that access can be gained to the cable element for tensioning and/or anchoring thereof.

Alternatively, or in combination, the means for post tensioning comprises cable members which extend from a first end locatable at a base of a fully assembled precast concrete building structure to a second end locatable at a top thereof.

Ideally, one of the first or second ends of the cable members is anchored by an anchoring component and the opposing end is in operable engagement with a cable tensioning mechanism.

Most ideally, the first end is anchored by the anchoring component and the second end is in operable engagement with the cable tensioning mechanism.

Preferably, cable guide elements are provided internally of the precast concrete building structure to guide the cable members during post tensioning.

Most preferably, the guide elements are guide rails.

Ideally, the cable elements and/or cable members may be steel cables or basalt cables. Advantageously, where basalt cables are utilized reduced environmental degradation may be experienced.

Ideally, the building structure comprises stacked layers of modular precast concrete components. Preferably, the modular precast concrete components comprise a semi-circular cross sectional shape such that joining of two complimentary modular precast concrete components forms a layer comprising a circular outer cross section defining a circular void therein.

Alternatively, each layer of the modular precast concrete components comprise more than two modular precast concrete components which when combined forms a layer comprising a circular outer cross section defining a circular void therein.

Further alternatively, each layer comprises a unitary layer comprising a circular outer cross section defining a circular inner void.

Ideally, each layer of the building structure is connected to an adjacent layer above and/or below in an offset manner such that the joints between the modular precast concrete components which form the connected layers are offset and not vertically aligned.

Preferably, the layers of the modular precast concrete components which form the precast concrete building structure are mechanically coupled to adjacent layers located above and/or below via mechanical coupling features.

Ideally, the mechanical coupling features are complimentary male and female coupling features.

Preferably, one or more reinforcing cable is provided internally of the building structure.

Ideally, the one or more reinforcing cables spans across an internal diameter of the building structure between opposing sides of said building structure.

Preferably, the one or more reinforcing cable is attachable to the opposing sides of the building structure and prevents movement of said opposing sides in a direction away from each other.

Ideally, a plurality of reinforcing cables are provided at one or more horizontal locations within the tower structure.

Preferably, the plurality of reinforcing cables form a spoke arrangement within the tower structure at a desired horizontal location.

Optionally, each layer of modular precast concrete components is sized and dimensioned such that the diameter at a lower end thereof is larger than the diameter at an upper end thereof.

Advantageously when the layers of modular precast concrete components are stacked the resulting building structure has a tapered shape from a lower end thereof to an upper end thereof. Preferably, the building structure is a wind turbine tower sized and dimensioned to support a wind turbine, an electrical transmission tower, or any such tower.

According to a second aspect of the invention there is provided a modular precast concrete component for use in a precast concrete building structure, the modular precast concrete component comprising a plurality of load bearing members arranged such that gaps are defined between the plurality of load bearing members.

Preferably, the modular precast concrete component is a pre-stressed modular precast concrete component and the mould comprises means for applying pre-stress.

According to a third aspect of the invention there is provided a method of manufacturing a modular precast concrete component for use in a precast concrete building structure, the modular precast concrete component comprising a plurality of load bearing members arranged such that gaps are defined between the plurality of load bearing members, the method comprising forming a mould and casting the modular precast concrete component.

Ideally, the method comprising the step of, during the casting process, pre-stressing the modular precast concrete component.

According to a fourth aspect of the invention there is provided a mould shaped and dimensioned for forming a modular precast concrete component for use in a precast concrete building structure, the modular precast concrete component comprising a plurality of load bearing members arranged such that gaps are defined between the plurality of load bearing members.

According to a fifth aspect of the invention there is provided a method of manufacturing a precast concrete building structure comprising the steps of: providing a mould and forming a plurality of modular precast concrete components by casting said components in said mould, each modular precast concrete component comprising a plurality of load bearing members arranged such that gaps are defined between the plurality of load bearing members, and assembling the modular precast concrete components into a building structure.

Preferably the method comprises pre-stressing the plurality of modular precast concrete components during the casting process.

Ideally, the modular precast concrete components comprise mechanical interconnection features therebetween and the step of assembling the modular precast concrete components into a building structure comprises joining the modular precast concrete components about the mechanical interconnection features. Ideally, the method comprises shaping the mould such that the mechanical interconnection features are formed during casting in the mould.

Preferably, the method comprises joining the modular precast concrete components to form layers.

Ideally, the layers are circular layers comprising a circular outer cross section defining a circular void therein, the layers being joined to adjacent layers located above and/or below by mechanical coupling features.

Preferably, the method comprises connecting each layer of the building structure to an adjacent layer above and/or below in an offset manner.

Ideally, each layer of the building structure is joined to an adjacent layer above and/or below in an offset manner such that the joints between the modular precast concrete components which form the connected layers are offset and not vertically aligned.

Advantageously, as the joints of each layer are offset, subsequent layers act to reinforce vertical joints in the layer below as they extend over the joint of the layer below bridging said joints.

Preferably, the method comprises offsetting the modular precast concrete components of each layer relative to an adjacent layer below and about a central axis of the building structure before they are placed on the adjacent layer below.

Ideally, the method comprising offsetting each layer by up to approximately 90 degrees relative to an adjacent layer below.

Alternatively, the method comprising offsetting each layer by approximately 90 degrees relative to an adjacent layer below.

Alternatively, the method comprising offsetting each layer by approximately 30 degrees or approximately 60 degrees relative to an adjacent layer below.

Preferably, the method comprises forming each layer such that the diameter at a lower end thereof is larger than the diameter at an upper end thereof.

Ideally, the method further comprising the step of post tensioning the building structure once assembled.

Alternatively, or additionally, the method comprises the step of post tensioning sections of the building structure at intermediate points throughout the assembly. Preferably, the method comprising the step of attaching one or more reinforcing cable internally of the building structure.

Ideally, the at least one reinforcing cable spans across the internal diameter of said building structure between opposing sides of said building structure to prevent movement of said opposing sides in a direction away from each other.

Preferably, the at least one reinforcing cable is a steel tension restraining cable.

According to a sixth aspect of the invention there is provided a kit of parts for assembly into a building structure, the kit of parts comprising a plurality of modular precast concrete components, the modular precast concrete components each comprising a plurality of load bearing members arranged such that gaps are defined between the plurality of load bearing members, wherein the modular precast concrete components are configured for assembly to form said building structure.

Ideally, the kit of parts also comprising means for post tensioning the building structure once assembled and/or post tensioning sections of the building structure at intermediate points thought the assembly.

Brief description of the drawings

Embodiments of the invention are now described by way of example and with reference to the accompanying drawings in which:

Figure 1 is a side elevation of a precast concrete building structure;

Figure 2 is a detail view of feature A of Figure 1 ;

Figure 3 is a plan view of the building structure of Figure 1 ;

Figure 4 is a detail view of an interconnection between a plurality of modular precast concrete components;

Figure 5 is a detail view of a joint between four modular precast concrete components;

Figure 6 is a side view of a joint between two modular precast concrete components showing mechanical interconnection features therebetween;

Figure 7 is a side view of an alternative joint between two modular precast concrete components showing mechanical interconnection features therebetween and an additional seating feature; Figure 8 is a view of a portion of a modular precast concrete component comprising a rectangular bar form;

Figure 9 is a view of a portion of an alternative modular precast concrete component comprising a cylindrical form;

Figure 10 is a view of a sectional view of a portion of a precast concrete building structure showing a cable extending through two connected modular precast concrete components;

Figure 11 is a cross sectional view of a joint between two modular precast concrete components showing one of said components having a cable access feature;

Figure 12 is a conceptual plan view of a section of a precast concrete building structure showing a tendon extending through the modular precast concrete components thereof and showing a cable access feature;

Figure 13 is a plan view of a layer of a precast concrete building structure showing mechanical coupling features;

Figure 14 is an isometric view of a semi-circular modular precast concrete component;

Figure 15 is a perspective view of a portion of two layers of a precast concrete building structure, the two layers each comprising two semi-circular modular precast concrete components and mechanical coupling features therebetween;

Figure 16 is a conceptual plan view of a section of a precast concrete building structure showing reinforcing steel tension restraint cables;

Figure 17 is a conceptual plan view of a section of a precast concrete building structure showing a tendon extending through the modular precast concrete components thereof;

Figure 18 is a side view of an embodiment of two connected modular precast concrete components;

Figure 19 is a side view of an embodiment of a modular precast concrete component;

Figure 20 is a side view of a further embodiment of a modular precast concrete component;

Figure 21 is a isometric view of a further embodiment of a modular precast concrete component; and Figure 22 is a further view of the modular precast concrete component of Figure 21 , showing cable elements extending through cable guide elements locatable on said modular precast concrete component.

Detailed Description of the drawings

The present teaching will now be described with reference to an exemplary precast concrete building structure. It will be understood that the exemplary precast concrete building structure is provided to assist in an understanding of the present teaching and are not to be construed as limiting in any fashion. Furthermore, elements or components that are described with reference to any one Figure may be interchanged with those of other Figures or other equivalent elements without departing from the spirit of the present teaching.

Referring now to the Figures there is illustrated a precast concrete building structurelO. In the embodiment of the drawings, the concrete building structure 10 is a tower structure 10. It should be understood that, whilst the description will hereinafter refer to a tower or tower structure, the structure and method of manufacturing the same as disclosed herein are applicable to building structures in general. The tower structure 10 comprises a plurality of modular precast concrete components 11 . The modular precast concrete components 11 each comprise a plurality of load bearing members 12 arranged in an intersecting arrangement such that gaps 13 are defined between the plurality of load bearing members 12. The intersecting arrangement is such that all or some of the load bearing members 12 may intersect with each other. The modular precast concrete components 11 are configured for assembly to form said tower structure 10. Advantageously, the tower structure 10 is formed from modular precast concrete components 11 which comprise gaps 13 making said components 11 , and the overall tower structure 10, lighter, more cost effective to produce, and more sustainable, all without sacrificing structural strength and stability. Further advantageously, the modular precast concrete components 11 may be manufactured offsite and due to their reduced size and/or weight be transported more easily to a desired site for assembly when compared to more traditional tower building materials such as concrete solid wall components or steel tubular/beam components. The modular precast concrete components 11 are assembled to form a tower structure 10 having a diagrid type arrangement. This arrangement may be in the form of X-shaped grid sections, or any other such arrangement of intersecting load bearing members 12 interspersed with gaps 13. Various embodiments of modular precast concrete components 11 are envisaged as shown in Figures 5, 10, 14, and 18-20, and it should be understood that the invention is not limited to a particular arrangement of load bearing members 12 but lies in the provision of an arrangement which provides sufficient rigidity and structural strength yet acts to reduce cost and weight when compared to solid wall sections.

As can be best viewed in Figures 4 to 7, the modular precast concrete components 11 comprise mechanical interconnection features 14, 15 therebetween which permit joining of adjacent modular precast concrete components 11 to form the precast concrete tower structure. The mechanical interconnection features 14, 15 provide increased structural stability and/or may aid to guide correct assembly of the tower structure. In the preferred embodiment, the mechanical interconnection features 14, 15 comprise complimentary male 14 and female 15 interconnection features which engage to retain adjacent modular precast concrete components 11 together to form the precast concrete tower structure 10. The mechanical interconnection features may be of any suitable form as would be envisaged and known to the skilled person. Therefore the invention encompasses the many forms of such mechanical connections that the skilled person would be well aware of. The joints between adjacent modular precast concrete components 11 may take any suitable form as would be known by the skilled person. For example, as shown in Figure 6, the joint may be a lap type joint and the male and female mechanical interconnection features 14, 15 may be correspondingly located on abutting ends 18, 19 of the lap joint portions 16, 17 to form the desired mechanical engagement. As is best seen in Figure 7, the joints 21 may also comprise a seating feature 20 which acts to aid in seating a portion of a one modular precast concrete component 11 relative to an adjacent modular precast concrete component 11 to which it is to be joined. The seating feature 20 also acts to reinforce the joint as it extends thereacross. In some embodiments, the joints and/or the male and female mechanical interconnection features 14, 15 may be reinforced by the application of an adhesive or the like. As can be seen in Figures 8 and 9, the modular precast concrete components 11 may comprise load carrying members 12 which have a rectangular cross section (see Figure 8) a rounded/cylindrical cross section (see Figure 9), or any other such suitable cross section such as hexagonal, octagonal, etc.

The modular precast concrete components 11 are cast in a mould and pre-stressed. The moulding and pre-stressing techniques would be well known to the person skilled in the art and as such will not be described in detail herein for brevity. However, the standard technique of tensioning high strength tendons 22 distributed within the concrete components 11 as they are cast before releasing said tension upon setting of the components 11 to place the components 11 in compression is broadly employed. As can be seen in Figures 12 and 17, the tendons 22 are preferably distributed generally radially with respect to the tower structure 10, and extend generally horizontally when the modular precast concrete components 11 are in use. However, it would be understood that the tendons 22 may be orientated in any reasonable direction as would be considered by the skilled person. The modular precast concrete components 11 are manufactured from a form of cement that exhibits high strength and also aids in preventing degradation of tendons and other such metalwork that may be embedded in or pass through the concrete structure. In preferred embodiments the cement may be Portland cement, geopolymer cement, a nano-particle reinforced cement, or a fibre reinforced cement. In preferred embodiments, the concrete, once cast, should exhibit a compressive strength of at least between 40 and 140N/mm².

In some embodiments, as can be seen in particular in Figures 14, 19, and 20, the modular precast concrete components 11 comprise an upper beam 23 and a lower beam 24 arranged, in use, in a horizontal spaced apart arrangement, the upper beam 23 and a lower beam 24 having a plurality of load bearing members 12 arranged in an intersecting arrangement therebetween. The modular precast concrete components 11 may also comprise side beams 25, 26 which extend along the opposing vertical sides of the modular precast concrete components 11 between the upper and lower beams 23, 24. The side beams 25, 26 and the upper and lower beams 23, 24 may intersect with some or all of the load bearing members 11 .

The tower structure 10 comprises a system for post tensioning the tower structure 10. The post tensioning may be carried out once the tower structure 10 is fully assembled. Alternatively, or in combination, the system for post tensioning the tower structure 10 may post tension sections of the tower structure 10 at intermediate points throughout the assembly process. As can be seen for example in Figure 10, the system for post tensioning comprises cable elements 27 which extend through a plurality of the modular precast concrete components 11 between a first anchored end in operable engagement with an anchor point (not shown) and a second end in operable engagement with a cable tensioning mechanism (not shown). The anchor point and tensioning mechanism may be any suitable as would be used by the skilled person in a post tensioning process. Post tensioning of the tower structure 10 places the connected arrangement of modular precast concrete components 11 in compression increasing the overall structural properties of the tower structure 10. Moreover, the ability to post tension at intermediate points provides greater flexibility in relation to the creation of towers of greater height whilst still suitably placing the entirety of the tower structure 10 in compression. The modular precast concrete components 11 through which the cable elements 27 extend comprise throughbores therein sized and dimensioned to permit passage of the cable elements 27 therethrough. The method of manufacturing the tower structure 10 may comprise forming these throughbores as part of the casting process or they may be drilled or the like once the modular precast concrete components 11 have been cast.

To provide access to the cable elements 27 at intermediate points for tensioning by a tensioning mechanism or for connection to an anchor point, at least some of the modular precast concrete components 11 may comprise cable access features 28. The cable access features 28 carry the cable elements 27 and extend internally of the tower structure 10 such that access can be gained to the cable element 27 for tensioning and/or anchoring thereof. This can be best viewed in Figures 11 and 12, wherein the cable access element 28 projects inwardly to expose an end 29 of the cable element 27 internally of the tower structure 10. The exposed end may then be anchored at this point or engaged by a tensioning mechanism to tension the cable element 27 and resultantly apply a compression force to at least the portion of the tower structure 10 through which the cable element 27 travels. It should be understood that the cable access features 28 may also be configured to project outwardly of the tower structure 10 and thus access to the cable elements 27 is provided externally of the tower structure 10. Alternatively, or in combination, the means for post tensioning comprises cable members 33 which extend from a first end locatable at the a base 30 of a fully assembled precast concrete tower structure 10 to a second end locatable at a top 30 thereof. The cable members 33 extend internally of the tower structure 10 generally proximal inner walls 32 of the tower structure. One of the first or second ends of the cable members 33 is anchored by an anchoring component and the opposing end is in operable engagement with a cable tensioning mechanism. In a preferred embodiment, the first end of the cable members 33, locatable at the base 30 of a fully assembled precast concrete tower structure 10, is anchored and the second end of said cable members 33 is operably engagable with a cable tensioning mechanism to tension the cable members 33. Cable guide elements 34 in the form of guide rails 34 are provided internally of the precast concrete tower structure 10 to guide the cable members 33 during post tensioning.

The tower comprises stacked layers 35, 36 of modular precast concrete components 11 . In a preferable embodiment, the modular precast concrete components 11 comprise a semi-circular cross sectional shape (as can be seen in Figure 14 for example) such that joining of two complimentary modular precast concrete components 11 forms a layer comprising a circular outer cross section, defining a circular outer wall 37, a circular inner wall 38, and a circular void 39 therein. This can be best viewed in Figure 15. In an alternative embodiment, each layer 35, 36 of the modular precast concrete components 11 comprise more than two modular precast concrete components 11 which when assembled form a layer comprising the aforementioned circular outer wall 37, inner wall 38, and void 39. Further embodiments are envisioned wherein each layer comprises a unitary layer wherein a modular precast concrete component 11 comprises a unitary circular layer having the aforementioned circular outer wall 37, inner wall 38, and void 39. Moreover, it should be understood that, whilst a tower having a generally circular cross sectional shape is described herein as preferable, the tower structure and method of manufacturing the same as described herein may equally be utilized to create tower structures comprising any reasonable cross sectional shape, such as but not limited to quadrangular shaped towers, hexagonal shaped towers, etc. In addition, a tower having an outer surface exhibiting a first cross sectional shape and an inner surface defining a second cross sectional shape would be possible, for example a tower having a cross sectional shape comprised of a outer circular shape and an inner hexagonal shape. For avoidance of doubt, cross sectional shape in this regard is referring to a cross section taken perpendicular to the axial direction of the tower. The modular nature of the modular precast concrete components 11 is such that moulds can be created to form a variety of configurations of modular precast concrete components 11 which when joined form circular layers. Each layer of the tower structure 10 is connected to an adjacent layer above and/or below in an offset manner such that the joints 40, 41 between the modular precast concrete components 11 which form the connected layers 35, 36 are offset and not vertically aligned. This can be best viewed in Figure 15 which shows an upper layer 35 ready for placement upon and joining to a lower layer 36. The joints 40 of the upper layer are aligned such that they do not align with the joints 41 of the lower layer 36. In a preferable embodiment, as again shown in Figure 15, the joints 40 of a layer 35 which is to be placed on a layer 36 below are offset approximately 90 degrees relative to the joints 41 of said lower layer 36. This offset may be any reasonable value up to 90 degrees. The offsetting of the joints 40, 41 is carried out as each layer placed and acts to reinforce the structural stability of the tower 10 as aligned joints would result in a source of structural weakness. The layers 35, 36 of the modular precast concrete components 11 which form the precast concrete tower 10 are mechanically coupled to adjacent layers located above and/or below via mechanical coupling features 42, 43. The mechanical coupling features may be complimentary male and female coupling features 42, 43 similar to the mechanical interconnection features 14, 15 used to join adjacent modular precast concrete components 11 as discussed above.

One or more reinforcing cable 44 is provided internally of the tower structure 10. The one or more reinforcing cable 44 spans across the internal diameter of the tower structure between opposing sides of said tower, or more specifically between opposing points 45 on the circular inner wall 38. As can be best viewed in Figure 13, in a preferable embodiment three reinforcing cables 44 are provided which are positioned to generally segment the circular inner void 39 into generally equal segments when viewed in plan view. The three reinforcing cables 44 intersect at approximately the center point 46 of the circular inner void 39. Each of the reinforcing cables generally traverses the diameter of the inner void 39. The reinforcing cables 44 are attached to the opposing sides of the tower structure 10 and prevent movement of said opposing sides in a direction away from each other. A plurality of reinforcing cables, for example the arrangement as shown in Figure 13, are preferably provided at multiple horizontal locations within the tower structure 10. The reinforcing cables 44 preferably form a spoke type arrangement within the tower structure 10 at desired horizontal locations.

In some embodiments, each layer of modular precast concrete components 11 is sized and dimensioned such that the diameter at a lower end thereof 47 is larger than the diameter at an upper end thereof 48. The diameter of any given layer 35 at its lower end is also matched to the diameter of the upper end of a layer 36 which is directly below. Advantageously when the layers 35, 36 of modular precast concrete components 11 are stacked the resulting tower 10 has a tapered shape from a lower end thereof 49 to an upper end 31 thereof. However, it should be understood that straight towers would also be easily manufactured simply by maintaining the diameter at the upper 48 and lower 47 ends of each layer 35 approximately consistent.

The tower structure 10 may be utilised for any suitable purpose as would require a tower structure.

In general by tower structure it is meant an elongate narrow structure. In a preferred embodiment, the tower structure 10 is a wind turbine tower 10 sized and dimensioned to support a wind turbine. Alternatively, the tower structure 10 may be an electrical transmission tower 10, or any such tower which acts to suspend or elevate equipment of some sort. The tower structure would require minimal adaptation to be fit for many uses which require suspension or retention at an elevated height.

Where the tower is a wind turbine tower, the wind turbine, when placed on the tower structure 10 will act to further compress the tower structure 10 further reinforcing the structural stability of the tower. The tower structure 10 is suitable for both on-shore and off-shore use. The tower structure 10 may be integrally formed with a floating platform for off-shore construction. Due to the construction and modular nature of the tower structure 10 it has no height restrictions beyond those which exceed the structural limits of the design. In an exemplary embodiment, the tower structure 10 is approximately 12 meters in height comprising of 10 layers each of 12 meters height. The exemplary tower structure 10, as shown in Figures 1 to 3, has a diameter at its base 49 of 8.5 meters, and a diameter at its top of 4.5 meters. The load bearing members 12 are square cross-section load bearing members 12 measuring 0.5 meters square and comprise two intersecting members 51 , 52 which extend from their ends 53 towards each other at an angle of approximately 70 degrees to the horizontal, intersecting at their midpoint 54 and forming an X-shape.

A method of manufacturing the precast concrete tower structure 10 is herein disclosed and any features, options, preferences described above in relation to the tower structure 10 apparatus are also applicable to the method of manufacturing the same, and it should be assumed that the method comprises creating or providing such features, options and preferences in various embodiments of said method. The method broadly comprises the steps of forming a plurality of moulds and subsequently forming a plurality of modular precast concrete components 11 by casting said components 11 in the moulds. Each modular precast concrete component 11 comprises a plurality of load bearing members 12 arranged in an intersecting arrangement such that gaps 13 are defined between the plurality of load bearing members 12. The method comprising assembling the modular precast concrete components into a tower structure 10. The plurality of modular precast concrete components 11 are pre-stressed during the casting process. The modular precast concrete components 11 comprise corresponding male and female mechanical interconnection features 14,

15 therebetween, the method comprising forming these features during the casting process by shaping the mould to comprise these features. The method further comprises the step of assembling the modular precast concrete components into a tower structure comprises joining the modular precast concrete components 11 about the mechanical interconnection features 14, 15 to form layers 35, 36 comprising a circular outer cross section defining a circular outer wall 37, a circular inner wall, 38, and a circular void 39 therein, the layers being joined to adjacent layers located above and/or below by mechanical coupling features 42, 43. In a preferable embodiment, the method comprises forming layers from modular precast concrete components 11 comprising a semi-circular cross sectional shape (as can be seen in Figure 14 for example) such that joining of two complimentary modular precast concrete components 11 forms a layer comprising a circular outer cross section, defining a circular outer wall 37, a circular inner wall 38, and a circular void 39 therein. This can be best viewed in Figure 15. The method comprises connecting each layer 35, 36 of the tower to an adjacent layer above and/or below in an offset manner such that the joints 40, 41 between the modular precast concrete components 11 which form the connected layers 35, 36 are offset and not vertically aligned as discussed above. The tower structure 10 may comprise any reasonable number of layers depending on the desired height. Specifically, the method comprises offsetting the modular precast concrete components 11 of each layer 35 relative to an adjacent layer 36 below by rotating about a central axis 50 of the tower structure 10 before they are placed on the adjacent layer 36 below. In a preferable embodiment the method comprises offsetting each layer 35 by 90 degrees relative to an adjacent layer 36 below, as can be seen in Figure 15. In some embodiments, the method comprises forming each layer 35, 36 such that the diameter at a lower end 47 thereof is larger than the diameter at an upper end 48 thereof. In this manner the tower structure 10 may adopt a tapered form as described above. However it should be noted that the aforementioned diameters may be maintained uniform such that a vertical non-tapered tower structure is created. The method may further comprise post tensioning the tower structure 10 once assembled and, alternatively or additionally, post tensioning sections of the tower structure 10 at intermediate points thought the assembly. This port tensioning is carried out as described above herein. As part of the method, throughbores may be formed in the modular precast concrete components 11 to facilitate passage of cables 27 associated with post tensioning, and cable access features 28 as discussed above may also be formed to permit tensioning and/or anchoring of the cable for post tensioning. Preferably, the method comprises shaping the mould to comprise the throughbores and cable access features 28. As part of the method, cable elements 33 and guide rails 34 may also be installed internally of the tower structure to facilitate post tensioning. Also, as described above, the method may comprise the step of attaching one or more reinforcing cables 44 internally of the tower structure 10.

In a preferable case, the modular precast concrete components 11 are built in an off-site construction environment such as a factory. However, in situ construction is also possible depending on the construction requirements. For example, the moulds used to cast the modular precast concrete components 11 may be shipped to a location proximal the installation of the tower structure 10, such as a nearby concrete manufacturing facility, and the modular precast concrete components 11 may be cast at that location and thus transportation costs may be significantly reduced. The modular precast components may also be built at a deployment site by erecting a batching plant and mobilising the concrete moulds to said site. Whether transported from a central manufacturing facility or a facility proximal the installation site, the modular, light weight, and smaller components (when compared to traditional tower building components) permit transport to and installation at remote sites that may otherwise not be feasible in regards to construction of a tower. The tower exhibits a high degree of structural stability and strength and does not require a solid central support to achieve such properties, said properties being derived from the diagrid type structure and the pre and post tensioning as described above. Each modular precast concrete component 11 is designed and manufactured for a specific position in the tower structure 10 and in the sequence of construction. Therefore the tower may be supplied with a detailed and easily followed construction plan detailing placement of each modular precast concrete component 11 which limits re-work, human error, or any other factors which may delay or affect the quality of the finished product. The tower design will be dependent on key input parameters such as required height, load bearing capacity etc, and bespoke moulds may then be created to form each modular precast concrete component 11 within the tower. Each modular precast concrete component 11 must be assembled in strict sequence in line with the design and manufacturing parameters. The moulds may be re-used to create towers of the same specification. Each modular precast concrete component 11 will have a male and female interconnection features and each layer will have similar features to create mechanical interlock which will allow for safe assembly of the tower prior to post tensioning. These male and female features 14, 15, 42, 43 will also aid in the correct positioning of each modular precast concrete component 11 relative to adjacent modular precast concrete components 11 . Intermittent post tensioning, as described above, may be required depending on site conditions and the height of the tower structure 10. A dead end post tensioning anchor (not shown) may be fixed to the floating platform. While a capping ring (not shown) will be installed at the top of the tower for jacking purposes such that the cable may be tensioned between the dead end anchor and the capping ring. As discussed above, guide rails will be installed internally along the tower height for fixing of the post tensioning cable elements 33. Post tensioning will commence at predetermined tower heights until the full tower is in compression.

In relation to off-shore deployment, each modular precast concrete component 11 is loaded and transported to a dedicated dry dock. At the dry dock the first sections are fixed and installed on the floating platform. Assembly of the tower will continue as described above to a height that is deemed safe for marine transportation. In specific scenarios the full tower may be assembled in the dry dock and towed to site by tug boat. However partial assembly may only be possible. In these situations any remaining modular precast concrete components 11 will be transported to site via barge or ship and unloaded at the tower site for final assembly.

The invention is not limited to the embodiment(s) described herein but can be amended or modified without departing from the scope of the present invention.

Claims

1 . A precast concrete building structure comprising a plurality of modular precast concrete components, the modular precast concrete components each comprising a plurality of load bearing members arranged such that gaps are defined between the plurality of load bearing members, wherein the modular precast concrete components are configured for assembly to form said building structure.

2. The precast concrete building structure of claim 1 , wherein the modular precast concrete components comprise mechanical interconnection features therebetween which facilitate joining of adjacent modular precast concrete components to form the precast concrete building structure.

3. The precast concrete building structure of claim 2, wherein the mechanical interconnection features comprise complimentary male and female interconnection features which engage to retain adjacent modular precast concrete components together to form the precast concrete building structure.

4. The precast concrete building structure of any preceding claim, wherein the plurality of load bearing members arranged in an intersecting arrangement wherein all or some of the load bearing members intersect with each other.

5. The precast concrete building structure of any preceding claim, wherein the modular precast concrete components are pre-stressed modular precast concrete components and/or wherein the modular precast concrete components are diagrid components such as X-grid components.

6. The precast concrete building structure of any preceding claim, wherein the modular precast concrete components comprise an upper beam and a lower beam arranged in a horizontal spaced apart arrangement, the upper beam and a lower beam having a plurality of load bearing members arranged in an at least partially intersecting arrangement therebetween.

7. The precast concrete building structure structure of any preceding claim wherein the building structure comprises means for post tensioning the building structure once assembled and/or post tensioning sections of the building structure at intermediate points throughout assembly.

8. The precast concrete building structure of claim 7, wherein the means for post tensioning comprises cable elements which extend through a plurality of the modular precast concrete components between a first anchored end and a second end in operable engagement with a cable tensioning mechanism, and preferably wherein the modular precast concrete components through which the cable elements extend comprise throughbores therein sized and dimensioned to permit passage of the cable elements therethrough.

9. The precast concrete building structure of any of claims 6 to 8, wherein at least some of the modular precast concrete components may comprise cable access features which carry the cable elements and extend internally of the building structure such that access can be gained to the cable element for tensioning and/or anchoring thereof.

10. The precast concrete building structure of any of claims 6 to 9, wherein the means for post tensioning comprises cable members which extend from a first end locatable at a base of a fully assembled precast concrete building structure to a second end locatable at a top thereof, one of the first or second ends being anchored by an anchoring component and the opposing end being in operable engagement with a cable tensioning mechanism, and optionally wherein cable guide elements are provided internally of the precast concrete building structure to guide the cable members during post tensioning.

11. The precast concrete building structure of any preceding claim, wherein the building structure comprises stacked layers of modular precast concrete components.

12. The precast concrete building structure of claim 11 , wherein the modular precast concrete components comprise a semi-circular cross sectional shape such that joining of two complimentary modular precast concrete components forms a layer comprising a circular outer cross section defining a circular void therein, or each layer of the modular precast concrete components comprise more than two modular precast concrete components which when assembled forms a layer comprising a circular outer cross section defining a circular void therein.

13. The precast concrete building structure of claim 12, wherein each layer of the building structure is connected to an adjacent layer above and/or below in an offset manner such that the joints between the modular precast concrete components which form the connected layers are offset and not vertically aligned.

14. The precast concrete building structure of claim 12 or 13, wherein the layers of the modular precast concrete components which form the precast concrete building structure are mechanically coupled to adjacent layers located above and/or below via mechanical coupling features, preferably the mechanical coupling features being complimentary male and female coupling features.

15. The precast concrete building structure of any preceding claim, wherein one or more reinforcing cable is provided internally of the building structure and which spans across the internal diameter of said building structure between opposing sides of said building structure, is attachable to said opposing sides of said building structure, and prevents movement of said opposing sides in a direction away from each other.

16. The precast concrete building structure of any of claims 11 to 15, wherein each layer of modular precast concrete components is sized and dimensioned such that the diameter at a lower end thereof is larger than the diameter at an upper end thereof, and the resulting building structure is thus tapered from a lower end thereof to an upper end thereof.

17. The precast concrete building structure of any preceding claim wherein the building structure is a tower structure, preferably the tower structure being a wind turbine tower structure sized and dimensioned to support a wind turbine, or an electrical transmission tower structure.

18. A modular precast concrete component for use in a precast concrete building structure, the modular precast concrete component comprising a plurality of load bearing members arranged such that gaps are defined between the plurality of load bearing members.

19. A mould shaped and dimensioned for forming a modular precast concrete component for use in a precast concrete building structure, the modular precast concrete component comprising a plurality of load bearing members arranged such that gaps are defined between the plurality of load bearing members.

20. A method of manufacturing a precast concrete building structure comprising the steps of: providing a mould and forming a plurality of modular precast concrete components by casting said components in said mould, each modular precast concrete component comprising a plurality of load bearing members arranged such that gaps are defined between the plurality of load bearing members, and assembling the modular precast concrete components into a building structure, preferably the method comprising prestressing the plurality of modular precast concrete components during casting.

21. The method of claim 20, wherein the modular precast concrete components comprise mechanical interconnection features therebetween, the method comprising shaping the mould such that the mechanical interconnection features are formed during casting in the mould, and the step of assembling the modular precast concrete components into a building structure comprises joining the modular precast concrete components about the mechanical interconnection features.

22. The method of claim 20 or claim 21 , wherein the method comprises joining the modular precast concrete components to form layers, preferably the layers being circular layers comprising a circular outer cross section defining a circular void therein, the layers being joined to adjacent layers located above and/or below by mechanical coupling features.

23. The method of any of claim 22, wherein the method comprises connecting each layer of the building structure to an adjacent layer above and/or below in an offset manner such that the joints between the modular precast concrete components which form the connected layers are offset and not vertically aligned, the method comprising offsetting the modular precast concrete components of each layer relative to an adjacent layer below about a central axis of the building structure before they are placed on the adjacent layer below, and preferably, the method comprising offsetting each layer by 90 degrees relative to an adjacent layer below.

24. The method of claim 22 or 23, wherein the method comprises forming each layer such that the diameter at a lower end thereof is larger than the diameter at an upper end thereof to form a tapered building structure.

25. The method of any of claims 20 to 24, the method further comprising the step of post tensioning the building structure once assembled and/or post tensioning sections of the building structure at intermediate points throughout the assembly, and/or the method comprising attaching one or more reinforcing cable internally of the building structure which spans across the internal diameter of said building structure between opposing sides of said building structure to prevent movement of said opposing sides in a direction away from each other.