ASSEMBLIES AND METHODS FOR ERECTING STRUCTURES

Abstract

An assembly comprising a first precast concrete structure including a first rebar member and a second precast concrete structure including a second rebar member. The second rebar member is aligned with the first rebar member along an axis. The assembly further includes a sleeve with an aperture. The sleeve is coupled to the first rebar member. The assembly further includes a connecting member coupled to the second rebar member, and a rebar dowel coupled to the connecting member; wherein the rebar dowel extends through the aperture in the sleeve and is at least partially received within the sleeve. The assembly further includes a grout positioned within the sleeve; a gasket positioned between the sleeve and the connecting member; a seal positioned between the first precast concrete structure and the second precast concrete structure; and a shim positioned between the first precast concrete structure and the second precast concrete structure.

Description

TECHNICAL FIELD

The present disclosure relates systems, devices, assemblies, and methods for use in erecting structures. More particularly, the present disclose relates to modular elevator shafts, stairwells, and associated assembly techniques.

BACKGROUND

Concrete structures (e.g., elevator shafts, stairwells, stair shafts, etc.) are an important part of any mid-rise multistory building project.

However, conventional elevator shafts are time consuming and expensive to build—requiring heavy labor to be repeated the entire height of the shaft. For example, reinforced Concrete Masonry Units (CMUs) are laid up to an elevation not to exceed 5′4″ above the top of the elevator pit with a conventional low-lift grout technique and 12′8″ above the top of elevator pit with inspection windows at the first course of the vertical reinforcement locations utilizing a conventional high-lift grout technique. With conventional methods, deformed billet mild steel (e.g., rebar) must then be placed in the vertical and horizontal CMU reinforcement locations, inspected, and in the case of the high-lift grout technique, the inspection windows must be cleaned of mortar droppings and debris, and formed closed prior to grouting by method of concrete pumping the reinforced cells with the project-specified cell-fill concrete mix. At the vertical elevations where elevator rail bracket receivers are located and built into the wall, CMU reinforced bond beams must be incorporated into the wall requiring reinforcement, inspection, and grouting to provide strength to resist pull out of the bracket receiver.

This conventional process repeats itself in the described sequence to the full height of the elevator shaft. The conventional process requires scaffolding around the elevator shaft to the full height of the elevator shaft to provide access for the block masons, mason tenders, and other associated trades. At the top of the elevator shaft, a hoist beam is required to be set in the grout reinforced pocket incorporating a horizontal weld plate and welded, inspected, formed, and grouted to achieve the full 2-hour CMU fire rating. The CMUs are then “topped out” at the bearing height of the elevator cap with a CMU bond beam assembly, inspected and grouted. The elevator cap, typically a 6″ cast in place concrete slab is then formed, inspected, and poured to complete the assembly. This lengthy process is the reason the erection of elevator shafts often negatively impacts a building schedule and make it difficult to meet project deadlines.

Similarly, stair shafts (e.g., stairwells) are time consuming and expensive to build, requiring a heavy laborious sequence to be repeated the entire height of the shaft. For example, reinforced Concrete Masonry Units (CMUs) are laid up to an elevation not to exceed 5′4″ above the ground floor elevation with a conventional low-lift grout technique and 12′8″ above the ground floor elevation with inspection windows at the first course of the vertical reinforcement locations utilizing a conventional high-lift grout technique. With conventional methods, deformed Billet mild steel (e.g., rebar) must then be placed in the vertical and horizontal CMU reinforcement locations, inspected, and in the case of the high-lift grout technique, the inspection windows must be cleaned of mortar droppings and debris, and formed closed prior to grouting by method of concrete pumping the reinforced cells with the project specified cell-fill concrete mix.

This conventional process repeats itself in the described sequence to the full height of the stairwell shaft. The conventional process requires scaffolding around the stairwell to the full height of the stairwell for access for the block masons, mason tenders, and other associated trades. The CMUs are then “topped out” at the bearing height of the stair cap with a CMU bond beam assembly, inspected and grouted. A stairwell cap, typically a 6″ cast in place concrete slab is then formed, inspected, and poured to complete the assembly. This lengthy process is the reason the erection of stairwells often negatively impacts a building schedule and make it difficult to meet project deadlines.

SUMMARY

The disclosure provides, in one aspect, an assembly comprising: a first precast concrete structure including a first rebar member and a second precast concrete structure including a second rebar member. The second rebar member is aligned with the first rebar member along an axis. The assembly further includes a sleeve with an aperture, the sleeve coupled to the first rebar member; a connecting member coupled to the second rebar member; and a rebar dowel coupled to the connecting member. The rebar dowel extends through the aperture in the sleeve and is at least partially received within the sleeve. The assembly further includes a grout positioned within the sleeve; a gasket positioned between the sleeve and the connecting member; a seal positioned between the first precast concrete structure and the second precast concrete structure; and a shim positioned between the first precast concrete structure and the second precast concrete structure.

In some embodiments, the first precast concrete structure includes a first surface, and the second precast concrete structure includes a second surface, and wherein the seal is positioned between the first surface and the second surface.

In some embodiments, the first precast concrete structure further includes a lifting anchor assembly with an aperture formed in the first surface.

In some embodiments, the sleeve is aligned with the axis and the axis extends through the aperture.

In some embodiments, the sleeve is coupled to the first rebar member with a threaded connection.

In some embodiments, the sleeve includes a cylindrical wall extending along the axis, a cavity, a first charge port in fluid communication with the cavity, and a second charge port in fluid communication with the cavity.

In some embodiments, the first charge port extends along a first charge port axis and the second charge port extends along a second charge port axis, wherein the first charge port axis is perpendicular to the axis and the second charge port axis is perpendicular to the axis.

In some embodiments, the sleeve is coupled to the first rebar member at a first end of the sleeve, and the aperture is positioned at a second end of the sleeve, wherein the second end is opposite the first end.

In some embodiments, the connecting member has a first end coupled to the second rebar member and a second end coupled to the rebar dowel, where the first end is opposite the second end.

In some embodiments, the rebar dowel has a threaded end coupled to the connecting member.

In some embodiments, the gasket includes a gasket aperture, and the rebar dowel extends through the gasket aperture.

In some embodiments, the seal is a polyurethane foam.

In some embodiments, the seal includes a first ridge, a second ridge, and a portion extending between the first ridge and the second ridge.

In some embodiments, the shim is positioned between the first ridge and the second ridge.

In some embodiments, the shim has a thickness within a range of 0.25 inches to 0.75 inches.

In some embodiments, the seal and the shim are part of a joint assembly with at least a 2-hour fire-rating.

In some embodiments, the first precast concrete structure includes an opening and a plurality of rebar members extending through the opening.

In some embodiments, the first precast concrete structure or the second precast concrete structure includes a first notch, a second notch, and a hoist beam at least partially positioned with the first notch and the second notch.

In some embodiments, the second precast concrete structure is a cap.

In some embodiments, the first precast concrete structure and the second precast concrete structure at least partially form an elevator shaft or a stairwell.

The disclosure provides, in one aspect, a method of erecting a structure, the method comprising: positioning a seal on a first precast concrete structure; raising a second precast concrete structure; coupling a rebar dowel to the second precast concrete structure; aligning the second precast concrete structure with the first precast concrete structure; and lowering the second precast concrete structure onto the first precast concrete structure. The seal is positioned between the first precast concrete structure and the second precast concrete structure.

In some embodiments, the method further includes positioning a plurality of shims on the seal.

In some embodiments, raising the second precast concrete structure includes attaching a crane to a plurality of lifting anchors in the second precast concrete structure.

In some embodiments, coupling the rebar dowel to the second precast concrete structure includes threading the rebar dowel into a connecting member in the second precast concrete structure.

In some embodiments, aligning the second precast concrete structure with the first precast concrete structure includes aligning the rebar dowel with a sleeve formed in the first precast concrete structure.

In some embodiments, lowering the second precast concrete structure onto the first precast concrete structure includes lowering the rebar dowel into a sleeve formed in the first precast concrete structure.

In some embodiments, the method further includes injecting a grout into a sleeve formed in the first precast concrete structure prior to lowering the second precast concrete structure onto the first precast concrete structure.

In some embodiments, the method further includes forming the first precast concrete structure and the second precast concrete structure at an offsite facility and transporting the first precast concrete structure and the second precast concrete structure to a jobsite.

In some embodiments, the first precast concrete structure and the second precast concrete structure form one story of a building when joined together.

In some embodiments, the method further includes positioning a second seal on the second precast concrete structure; raising a third precast concrete structure; coupling a second rebar dowel to the third precast concrete structure; aligning the third precast concrete structure with the second precast concrete structure; and lowering the third precast concrete structure onto the second precast concrete structure. The second seal is positioned between the second precast concrete structure and the third precast concrete structure.

In some embodiments, the method further includes cutting a plurality of rebar from an opening formed in the first precast concrete structure.

In some embodiments, the method further includes adding masonry to the opening.

In some embodiments, no scaffolding is required for the method.

In some embodiments, no backer-rod and fire caulk joint assembly are positioned between the first precast concrete structure and the second precast concrete structure.

Other aspects of the disclosure will become apparent by consideration of the detailed description and accompanying drawings.

Definitions

As used herein, “about” and “approximately” are used to provide flexibility to a numerical range endpoint by providing that a given value may be “slightly above” or “slightly below” the endpoint without affecting the desired result.

The term “coupled,” as used herein, is defined as “connected,” although not necessarily directly, and not necessarily mechanically. The term coupled is to be understood to mean physically, magnetically, chemically, fluidly, electrically, or otherwise coupled, connected or linked and does not exclude the presence of intermediate elements between the coupled elements absent specific contrary language.

The terms “comprise(s),” “include(s),” “having,” “has,” “can,” “contain(s),” and variants thereof, as used herein, are intended to be open-ended transitional phrases, terms, or words that do not preclude the possibility of additional acts or structures. The singular forms “a,” “an” and “the” include plural references unless the context clearly dictates otherwise. The present disclosure also contemplates other embodiments “comprising,” “consisting of” and “consisting essentially of,” the embodiments or elements presented herein, whether explicitly set forth or not.

For the recitation of numeric ranges herein, each intervening number there between with the same degree of precision is explicitly contemplated. For example, for the range of 6-9, the numbers 7 and 8 are contemplated in addition to 6 and 9, and for the range 6.0-7.0, the number 6.0, 6.1, 6.2, 6.3, 6.4, 6.5, 6.6, 6.7, 6.8, 6.9, and 7.0 are explicitly contemplated.

In the foregoing description of preferred embodiments, specific terminology has been resorted to for the sake of clarity. However, the invention is not intended to be limited to the specific terms so selected, and it is to be understood that each specific term includes all technical equivalents which operate in a similar manner to accomplish a similar technical purpose. Terms such as “top” and “bottom”, “front” and “rear”, “inner” and “outer”, “above”, “below”, “upper”, “lower”, “vertical”, “horizontal”, “upright” and the like are used as words of convenience to provide reference points.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of an elevator shaft structure.

FIG. 2 is a perspective view of the elevator shaft structure of FIG. 1, shown prior to installation of door assemblies.

FIG. 3 is a perspective exploded view of the elevator shaft structure of FIG. 2.

FIG. 4 is a perspective exploded view of an elevator shaft structure.

FIG. 5A is a perspective exploded view of a lowest segment of an elevator shaft structure.

FIG. 5B is a cross-sectional exploded view of the lowest segment of FIG. 5A.

FIG. 6 is a perspective exploded view of a first concrete structure, a second concrete structure, and a joint assembly positioned between the first concrete structure and the second concrete structure.

FIG. 7 is an enlarged partial view of the joint assembly of FIG. 6.

FIG. 8 is an exploded view of a tension connection assembly.

FIG. 9 is a cross-sectional view of a sleeve of the tension connection assembly of FIG. 8.

FIG. 10A is a cross-sectional view of a rebar dowel being coupled to an upper concrete structure.

FIG. 10B is a cross-sectional view of an upper concrete structure aligned with a lower concrete structure.

FIG. 10C is a cross-sectional view of the upper concrete structure of FIG. 10B lowered onto the lower concrete structure, illustrating a joint assembly and a tension connection assembly.

FIG. 11 is an exploded perspective view of a top portion of an elevator shaft structure, illustrating a hoist beam.

FIG. 12 is a partial cross-sectional view of the hoist beam of FIG. 11.

FIG. 13 is a cross-sectional view of the hoist beam of FIG. 11.

FIG. 14 is a flowchart of a method of erecting a structure.

FIG. 15 is a perspective view of a stairwell structure.

FIG. 16 is a perspective exploded view of the stairwell structure of FIG. 15.

FIG. 17 is a perspective exploded view of a stairwell structure.

FIG. 18 is a perspective exploded view of a lowest segment of a stairwell structure.

FIG. 19 is an exploded perspective view of a top portion of a stairwell structure.

FIG. 20 is a perspective view of a top cap of a stairwell structure.

FIG. 21 is a partial cross-sectional view of the top cap of FIG. 20.

FIG. 22 is a perspective view of a stairwell structure.

Before any embodiments are explained in detail, it is to be understood that the invention is not limited in its application to the details of construction and the arrangement of components set forth in the following description or illustrated in the following drawings. The invention is capable of other embodiments and of being practiced or of being carried out in various ways.

DETAILED DESCRIPTION

Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art. In case of conflict, the present document, including definitions, will control. Preferred methods and materials are described below, although methods and materials similar or equivalent to those described herein can be used in practice or testing of the present disclosure. All publications, patent applications, patents and other references mentioned herein are incorporated by reference in their entirety. The materials, methods, and examples disclosed herein are illustrative only and not intended to be limiting.

Disclosed herein are constructions techniques for use in erecting mid-rise multi-story wood framed or steel stud framed buildings. In one aspect, the present disclosure relates to a modular elevator shaft structure with a 2-hour fire rated assembly and associated assembly techniques. In another aspect, the present disclosure relates to a modular stairwell (e.g., stair shaft) with a 2-hour fire rated assembly and associated assembly techniques. The disclosed assemblies and methods achieve the technical aspects and dimensional requirements of elevator or manufacturer and building codes, while resulting in a significantly reduced erection duration (e.g., days) when compared to the typical time required to complete a conventional reinforced CMU 2-hour fire rated stairwell or elevator shaft (e.g., weeks).

With reference to FIG. 1, an elevator shaft structure 10 is illustrated with door assemblies 14 installed. In some embodiments, each door assembly 14 includes an elevator door 18 and a masonry assembly 22 positioned at least partially around the elevator door 18.

With reference to FIG. 2, the elevator shaft structure 10 is shown erected but prior to installation of the door assemblies 14. The elevator shaft structure 10 is made up of a plurality of segments (e.g., precast concrete segments, precast concrete structures). In some embodiments, the plurality of segments are precast concrete structures. In the illustrated embodiment, the elevator shaft structure 10 includes a lowest segment 26 (e.g., a bottom-most segment, a first-installed segment), a plurality of lower segments 30, a plurality of upper segments 34, a riser segment 38, and a cap segment 42. As detailed further herein, the riser segment 38 is also known as the head room for the elevator and hoist beam (FIGS. 11-13).

As detailed further herein, segments (e.g., segments 26, 30, 34, 38, 42) of the elevator shaft structure 10 are precast segments that are formed and produced at an offsite facility. These segments are transported to a jobsite and erected to full height by joining upper and lower segments together. In the illustrated embodiment, each lower and upper segment, when joined together, are equivalent to one story of the building. Using precast concrete monolithic elevator segments simplifies and expedites the construction process exponentially. In some embodiments, the entire elevator shaft structure is erected in less than a single day each. As a result, the disclosed assemblies and methods result in substantial time savings over traditional methods employing reinforced concrete masonry, which requires days and weeks to construct a single shaft.

With reference to FIG. 2, the modular precast elevator shaft structure 10 is fully assembled. In the illustrated embodiment, the elevator shaft structure 10 is for a four-story building. In other embodiments, the elevator shaft structure 10 is any number of floors. In some embodiments, the elevator shaft structure 10 is within a range from two to seven stories.

With continued reference to FIG. 2, the elevator shaft structure 10 includes a plurality of openings 46 that receive corresponding door assemblies 14. In the illustrated embodiment, each of the plurality of openings 46 is partially formed by a lower segment 30 and an upper segment 34. For example, the opening 46 includes a first portion 50 formed in the lower segment 30 and a second portion 54 formed in the upper segment 34. Together, the first portion 50 and the second portion 54 form a larger rough opening to receive elevator door assemblies, for example.

In the illustrated embodiment, the first portion 50 of the opening 46 formed in each of the lower segments 30 is pre-formed from reinforced concrete and includes rebar 58 (e.g., #6 rebar) positioned within the opening 46. In other words, the lower segment 30 includes an opening 46 and a plurality of rebar members 58 extend through the opening 46. The rebar 58 position within the opening 58 advantageously provides fall protection for workers working near the elevator shaft structure 10. In some embodiments, a grout recess 62 is formed in each upper segment 34 to accommodate installation of an elevator door sill, for example.

With reference to FIG. 3, each upper segment 34 is formed to match the dimensions of the lower segment 30. In the illustrated embodiment, the lower segment 30 includes four walls 66A-66D, an upper surface 70, and a lower surface 74. Similarly, the upper segment 34 includes four walls 78A-78D, an upper surface 82, and a lower surface 86. Although the illustrated elevator shaft structure has a rectangular-shaped cross-section, the use of other shaped cross-sections is within the scope of the present disclosure.

With continued reference to FIG. 3, the elevator shaft structure 10 includes seal assemblies 90 positioned between two adjacent concrete segments. In the illustrated embodiment, each of the seal assemblies 90 include a seal 94 and at least one shim 98. In the illustrated embodiment, the seal 94 is positioned between a first surface of a first precast concrete structure and a second surface of a second precast concrete structure. For example, the seal 94 is positioned between an upper surface 70 of a lower segment 30 and a lower surface 86 of an upper segment 34. As explained in greater detail herein, the seal assemblies 90 provide at least a 2-hour rated assemblies, based on UL certification. The seal assemblies 90 advantageously replace conventional backer-rod and fire caulk joint assemblies, which are time consuming to install and can only be installed as a separate step after the elevator shaft is erected.

With reference to FIG. 7, the seal 94 includes a first ridge 102, a second ridge 106, and a portion 110 (e.g., an intermediate portion) extending between the first ridge 102 and the second ridge 106. In some embodiments, the seal 94 is a polyurethane foam sealant (e.g., CFS-TTS 600 available from Hilti).

In the illustrated embodiments, the shims 98 are positioned between the first ridge 102 and the second ridge 106 of the seal 94. In other words, the shims 98 are positioned on top of the portion 110 of the seal 94. In some embodiments, the shims 98 are multipolymer bearing pads available from Korolath. In some embodiments, the shims 98 are 4-inch×4 inch squares that are 0.5 inches thick. In some embodiments, the shims 98 have a thickness within a range of approximately 0.25 inches to approximately 0.75 inches. In some embodiments, the shims 98 maintain a spacing between opposing surfaces of adjacent concrete segments. In other words, the shims 98 are positioned between a first precast concrete structure and a second, adjacent, precast concrete structure. In some embodiments, the shims 98 maintain a half inch space between adjacent segments. In other words, the shims 98 control the amount of compression on the seal 94 positioned between adjacent concrete segments (e.g., lower segment 30 and upper segment 34).

In some embodiments, the seal assembly 90 further includes a gasket 114. In some embodiments, the gasket 114 is a compressible gasket available from Dayton Superior. In the illustrated embodiment, the gasket 114 includes a gasket aperture 118 configured to receive a rebar portion (e.g., the rebar dowel 134).

With continued reference to FIG. 3, the elevator shaft structure 10 further includes a plurality of tension connection assemblies 122 that interconnect adjacent concrete structures. For example, FIG. 6 illustrates four tension connection assemblies 122 coupling the lower segment 30 to the upper segment 34. As explained in greater detail herein, the tension connection assemblies 122 provide an efficient manner in which to couple rebar members of a first precast concrete structure to rebar members of a second precast concrete structure.

With reference to FIG. 8, the tension connection assembly 122 includes a sleeve 126, a connecting member 130, a rebar dowel 134, and the gasket 114. As explained further herein, the tension connection assembly 122 further includes a grout 138 positioned within the sleeve 126. The rebar dowel 134 is coupled to the connecting member 130. When assembled, the rebar dowel 130 extends through an aperture 142 in the sleeve 126 and is at least partially received within the sleeve 126. In some embodiments, the gasket 114 of the tension connection assembly 122 is the same as the gasket 114 of the seal assembly 90. In the illustrated embodiment, the gasket 114 is positioned between the sleeve 126 and the connecting member 130. In the illustrated embodiment, the rebar dowel 134 extends through the gasket aperture 118.

The sleeve 126 is coupled at a first end 150 of the sleeve 126 to a rebar member 146 positioned within the concrete structure. In some embodiments, the sleeve 126 is coupled to the rebar member 146 with a threaded connection. The connecting member 130 is coupled to a rebar member 146 positioned within the concrete structure. In some embodiments, rebar members 146 includes a sleeve 126 at one end of the rebar member 146 and a connecting member 130 at the opposite end of the rebar member 146. In some embodiments, the rebar members 146 includes a sleeve 126 at both end of the rebar member 146 (e.g., lowest segment 26).

With reference to FIG. 9, the aperture 142 is positioned at a second end 154 of the sleeve 126, opposite the first end 150. In the illustrated embodiment, the sleeve 126 is aligned with an axis 158 and the axis 158 extends through the aperture 142. The sleeve 126 includes a cylindrical wall 162 extending along the axis 158, a cavity 166, a first charge port 170 in fluid communication with the cavity 166, and a second charge port 174 in fluid communication with the cavity 166. The first charge port 170 extends along a first charge port axis 172 and the second charge port 174 extends along a second charge port axis 176. In the illustrated embodiment, the first charge port axis 172 is perpendicular to the axis 158 and the second charge port axis 174 is perpendicular to the axis 158. In the illustrated embodiment, the first charge port axis 170 is spaced from and parallel to the second charge port axis 174. In some embodiments, the sleeve 126 is a D420 Single-Ended Sleeve-Lock® Grout Sleeve available from Dayton Superior. In some embodiments, the sleeve 126 is pre-filled with grout 138 before receiving the rebar dowel 134. In some embodiments, the charge ports 170, 174 are used to fill the sleeve 126 with grout 138 after receiving a rebar (e.g., FIGS. 5A and 5B).

With reference to FIG. 8, the connecting member 130 has a first end 180 coupled to a rebar member 146 and a second end 184 coupled to the rebar dowel 134. In the illustrated embodiment, the first end 180 is opposite the second end 184. The rebar dowel 134 has a threaded end 188 coupled to the connecting member 130. In other words, the rebar dowel 134 is removably coupled to the connecting member 130 via a threaded connection. In some embodiments, the connecting member 130 is D340 Taper-Lock® Flange Coupler available from Dayton Superior.

In some embodiments, the grout 138 is a non-shrink grout. In some embodiments, the grout 138 is a non-shrink, non-corrosive, and non-metallic cementitious grout. In some embodiments, the grout 138 is high strength grout that develops at least 12,000 PSI. In some embodiments, the grout 138 is Turbo Grout HP 12® available from Dayton Superior.

In one embodiment, #5 taper-threaded rebar (e.g., rebar 146) is mechanically connected to the sleeve 126 with the sleeve uniquely inverted to allow the insertion of the gasket 114 and for pre-filling the sleeve 126 with grout 1380. A 6-inch length #5 threaded rebar dowel 134 is mechanically connected to a connecting member 130. The tension connection assembly 122 is fixed in the form system and cast in precise vertical alignment with the concrete elements, except for the gasket 114, grout 138, and rebar dowel 134 that are installed during the erection process.

With reference to FIGS. 5A and 5B, the lowest segment 26 is shown attaching to an elevator pit 192 (e.g., a cast-in-place elevator pit). A seal assembly 90 is positioned between the elevator pit 192 and the lowest segment 26. Specifically, a seal 94 (e.g., a firestop polyurethane foam joint sealant) is positioned on a top surface 196 of the elevator pit 192 and a plurality of shims 98 (e.g., multipolymer bearing pads) are positioned on the seal 94.

To begin assembly (e.g., erection) of the elevator shaft structure 10, the lowest segment 26 is aligned with the elevator pit 192. The elevator pit 192 includes rebar portions 200 extending from the top surface 196. Sleeves 126 in the lowest segment 26 are aligned with the rebar portions 200. In the illustrated embodiment, the lowest segment 26 has sleeves 126 at both ends of the rebar 146. After the lowest segment 26 is lowered onto the elevator pit 192, the rebar portion 200 is received within the sleeve 126 (e.g., the lower sleeves) and the grout 138 is injected into the sleeve 126 via the charge ports 170, 174. In other words, in the lowest segment 26, the sleeve 126 is filed with grout 138 via the charge ports 170, 174 after the lowest segment 26 has been positioned on top of the elevator pit 192.

With reference to FIG. 6, the assembly of the upper segment 34 to the lower segment 30 is illustrated. In this example, the lower segment 30 is a first precast concrete structure including a first rebar member 146A, and the upper segment 34 is a second precast concrete structure including a second rebar member 146B. The second rebar member 146B is aligned with the first rebar member 146A along an axis 148. The sleeve 126 is coupled to the first rebar member 146A. In the illustrated embodiment, the axis 158 of the sleeve 126 is aligned with the axis 148. The connecting member 130 is coupled to the second rebar member 146B.

The segments 26, 3034, 38, 42 includes lifting anchor assemblies 204 located at the top surface of each segment for handling and erection purposes. For example, the lower segment 30 includes a lifting anchor assembly 204 with an aperture 206 formed in the upper surface 70.

With reference to FIGS. 10A-10C, the joining of two precast concrete structures (e.g., lower segment 30 and upper segment 34) is shown with a tension connecting assembly 122 and a seal assembly 90. The two precast concrete structures 30, 34 are pre-formed at a location remote from the jobsite. The connecting member 130 and the sleeve 126 are interconnected by a threaded connection, for example, to the rebar 146 within the concrete casting to maintain the continuity of the tension tie.

With reference to FIG. 14 and FIGS. 10A-C, a method 300 of erecting a structure is shown. The method 300 includes (STEP 301) positioning a seal (e.g., the seal 94) on a first precast concrete structure (e.g., a lower concrete structure 30). In some embodiments, the method 300 further includes positioning a plurality of shims (e.g., shims 94) on the seal. The method 300 further includes (STEP 302) raising a second precast concrete structure (e.g., an upper concrete structure 34). In other words, (STEP 302) includes lifting the second concrete structure into the air with a crane. In some embodiments, (STEP 302) raising the second precast concrete structure includes attaching a crane to a plurality of lifting anchors (e.g., lifting anchor assemblies 204) in the second precast concrete structure. In some embodiments, the method 300 further includes forming the first precast concrete structure and the second precast concrete structure at an offsite facility and transporting the first precast concrete structure and the second precast concrete structure to a jobsite (e.g., the location at which the structure is erected).

The method 300 further includes (STEP 303) coupling a rebar dowel (e.g., rebar dowel 134) to the second precast concrete structure (e.g., FIG. 10A). In some embodiments, (STEP 303) coupling the rebar dowel to the second precast concrete structure includes threading the rebar dowel into a connecting member (e.g., connecting member 130) in the second precast concrete structure.

The method 300 further includes (STEP 304) aligning the second precast concreate structure with the first precast concrete structure (e.g., FIG. 10B). In some embodiments, (STEP 304) aligning the second precast concrete structure with the first precast concrete structure includes aligning the rebar dowel with a sleeve (e.g., sleeve 126) formed in the first precast concrete structure.

After (STEP 304), the method 300 includes (STEP 305) lowering the second precast concrete structure onto the first precast concrete structure. In some embodiments, (STEP 305) lowering the second precast concrete structure onto the first precast concrete structure includes lowering the rebar dowel into a sleeve (e.g., sleeve 98) formed in the first precast concrete structure. In some embodiments, the method 300 includes injecting a grout (e.g., grout 138) into a sleeve (e.g., sleeve 126) formed in the first precast concrete structure prior to (STEP 305) lowering the second precast concrete structure onto the first precast concrete structure. With the second precast concrete structure lowered, the seal is positioned between the first precast concrete structure and the second precast concrete structure. In some embodiments, the shim maintains at least an approximately 0.5-inch distance between the adjacent concrete structures. In some embodiments, the first precast concrete structure and the second precast concrete structure form one story of a building when joined together.

Steps of the method 300 may be repeated to erect additional stories of the structure. For example, in some embodiments, the method 300 further includes positioning a second seal on the second precast concrete structure; raising a third precast concrete structure; coupling a second rebar dowel to the third precast concrete structure; aligning the third precast concrete structure with the second precast concrete structure; and lowering the third precast concrete structure on the second precast concrete structure. With the third precast concrete structure lowered, the second seal is positioned between the second precast concrete structure and the third precast concrete structure. In other words, first the second precast concrete structure is lowered onto and secured to the first precast concrete structure and then the third precast concrete structure is lowered onto and secured to the second precast concrete structure.

In some embodiments, the method 300 further includes cutting a plurality of rebar (e.g., rebar 58) from an opening formed in the first precast concrete structure. In other words, the method 300 includes cutting out the rebar from the opening when the door assemblies, for example, are ready to be installed. In some embodiments, the method 300 further includes adding masonry (e.g., door assemblies 14, masonry assembly 22) to the opening. In other words, after completion of installing the elevator car, the rebar is removed to accommodate the elevator door installation. The void between the rough openings and the finished door frame are then infilled with the masonry assembly (e.g., a 2-hour rated reinforced CMU). Advantageously, no scaffolding is required for the method 300. Advantageously, no conventional backer-rod and fire caulk joint assembly is positioned between the first precast concrete structure and the second precast concrete structure.

The method 300 is repeated until the last upper segment is installed at which point the riser segment 38 is installed next.

With reference to FIGS. 11-13, the riser segment 38 includes a first notch 210 and a second notch 214 formed on an opposite wall as the first notch 210. A hoist beam 218 is at least partially positioned within the first notch 210 and the second notch 218. A weld plate 222 is cast in the notches 210, 214, and the hoist beam 218 is welded to the weld plate 222 offsite. A grout pocket 226 around the hoist beam 218 is grouted solid, offsite. The riser segment 38 is then connected to the upper surface 82 of the upper segment 34 with a seal assembly 90 positioned between the riser segment 38 and the upper segment 34. Similar to the other tension connection assemblies 122, reinforcing dowels 134 extend from a connecting member 130 in the riser segment 38 and are positioned into the sleeve 126 of the upper segment 34 that is pre-filled with grout 138.

With continued reference to FIG. 11, one of the final steps is installing the reinforced concrete cap segment 42, which includes rebar positioned within its interior. The cap segment 42 is connected to an upper surface 230 of the riser segment 38 with a seal assembly 90 positioned between the riser segment 38 and the cap segment 42. Similar to the other tension connection assemblies 122, reinforcing dowels 134 extend from a connecting member 130 in the cap segment 42 and are positioned into the sleeve 126 of the riser segment 38 that is pre-filled with grout 130.

With reference to FIG. 4, an elevator shaft structure 410 is illustrated for a two-story building. The elevator shaft structure 410 includes a lowest segment 426 (e.g., a bottom-most segment), a lower segment 430, a plurality of upper segments 440, a riser segment 438, and a cap segment 442. The elevator shaft structure 410 further includes seal assemblies 446 and tension connection assemblies 450 positioned between adjacent concrete segments.

The pre-cast concrete elevator structure and erection method disclosed herein include at least the following advantages. The disclosed construction method 300 provides an advantage by allowing elevator shafts to be rapidly assembled at a jobsite prior to the first-floor slab being poured, finished, and cured by erecting the shaft directly on the elevator pit walls or prior to the start of framing the walls and elevated floors after the first level slab is poured, finished, and cured. No scaffolding is required for access as would be required with CMU construction, allowing immediate access of following trades to the area upon completion of the erection of the shaft. Temporary bracing, which is disruptive to following trades, is not required, as the precast concrete structures disclosed herein are monolithic “boxes” which will withstand construction wind loads due to geometry, self-weight, and the fact that the permanent connections are made at the elevator pit walls and segment-to-segment during the sequential erection process. The 2-hour UL rated joint assembly 90 is installed between the segments during the erection of the segments and cap, contributing to the short time duration by eliminating the common backer-rod and fire caulk joint assembly installed in joints after the wall completion. The wide flange hoist beam 218, required by all elevator manufacturers to be installed at the top of the shaft for the purpose of building the elevator and later servicing the elevator is installed in the precast element offsite, eliminating the onsite activities of setting, welding, inspecting, and grouting around the beam within the thickness of the wall. The concrete cap segment 42 is produced offsite and installed during the final step of the precast erection. In some embodiments, the erection method 300 requires 4 workers for a much shorter duration, (a CMU shaft requires double the manpower for a much longer duration), reducing overall risks and hazards associated with working on scaffolding at significant heights. Rebar 58 is installed in the lower segment door openings offsite to ensure fall protection per OSHA guardrail guidelines for following trades working near the elevator shafts. The inspection process for the elevator shaft 10 is reduced to minimal requirements, which will save additional time over the reinforced CMU method which requires multiple inspections.

With reference to FIGS. 15-22, similar assemblies and methods are shown applied to a stairwell structure 510 (e.g., a stair shaft). Unless stated otherwise, descriptions above with respect to the elevator shaft structure 10 apply equally to similar components of the stairwell structure 510. Similar to the elevator shaft 10, the precast concrete segments of the stairwell 510 are formed at an offsite facility and transported to a jobsite to be erected into the stairwell 510.

With reference to FIG. 15, the stairwell 510 includes a plurality of segments (e.g., precast concrete segments, precast concrete structures). In the illustrated embodiment, the stairwell structure 510 includes a lowest segment 514 (e.g., a bottom-most segment, a segment that is installed first), a plurality of lower segments 518, a plurality of upper segments 522, a first cap segment 526, and a second cap segment 530. In the illustrated embodiment, the stairwell structure 510 is for a four-story building. In other embodiments, the stairwell structure 510 is any number of floors. In some embodiments, the stairwell structure 510 is within a range from two to seven stories.

With reference to FIG. 16, a seal assembly 534 is positioned between adjacent precast concrete structures. In some embodiments, the seal assembly 534 is similar or identical to the seal assemblies 90 discussed herein with respect to the elevator shaft structure 10. A tension connection assembly 538 interconnects adjacent precast concrete structures. In some embodiments, the tension connection assembly 538 is similar or identical to the tension connection assemblies 122 discussed herein with respect to the elevator shaft structure 10.

With reference to FIG. 18, the lowest segment 514 is connected to the ground floor elevation concrete slab 542 with a seal assembly 534 positioned on top of the ground floor elevation concrete slab 542. The lowest segment 514 is then set in alignment with the ground floor elevation concrete slab 542, centering the tension connection assembly 538 with rebar 546 projecting from the ground floor elevation concrete slab 542.

With reference to FIGS. 19 and 20, the final segments of the stairwell 510 are the first cap segment 526 and the second cap segment 530. Each concrete cap segment 526, 530 includes rebar positioned within its interior. Lifting anchors 550 are located at a top surface 554 of each cap segment 526, 530 for handling and erection purposes. One of the final steps of the assembly is installing the first reinforced concrete cap segment 526. Cap segment 526 is connected to the upper surface of the upper segment 522 with a seal assembly 534 positioned between the upper segment 522 and the cap segment 526. Reinforcing dowels 554 extend from a connecting member 558 in the concrete cap 526 and extend into a sleeve 562 pre-filled with grout. The same process is then completed for the second concrete cap 530. With reference to FIG. 21, the first concrete cap segment 526 and the second concrete cap segment 530 are then fire caulked with silicone fire caulk 566 at the top of a shiplap joint 570 and with an acrylic fire caulk 574 at the bottom of the shiplap joint 570.

With reference to FIG. 17, a stairwell structure 710 is illustrated for a two-story building. The stairway structure 710 includes a lowest segment 714 (e.g., a bottom-most segment), a lower segment 718, a plurality of upper segments 722, a first cap segment 726, and a second cap segment 730. As another example, with reference to FIG. 22, a stairwell structure 810 is illustrated with a plurality of interconnected precast concrete segments 814.

The pre-cast concrete stairwell structure and erection method disclosed herein include at least the following advantages. The erection method 300 provides an advantage by allowing stairwell structure to be rapidly assembled at a jobsite prior to the first-floor slab being poured, finished, and cured by erecting the shaft directly on the foundation or—prior to the start of framing the walls and elevated floors after the first level slab is poured, finished, and cured. No scaffolding is required for access as would be required with CMU construction, allowing immediate access of following trades to the area upon completion of the erection of the shaft. The stairs can be immediately installed offering safe first responder and gurney access to all floors as they progress vertically. A fire protection standpipe can be immediately installed allowing access to pressurized water in the event of a fire during the construction process. The permanent stairs installed immediately allows vertical access to all tradesman, inspectors and supervisors, eliminating the need for vertical access by ladder, which is a risk hazard. Temporary bracing (which is disruptive to following trades) is not required, as the precast elements are monolithic “boxes” which will withstand construction wind loads due to geometry, self-weight, and the fact that the permanent connections are made at the ground floor slab and segment-to-segment during the sequential erection process. The 2-hour UL rated joint assembly 534 is installed between the segments during the erection of the segments and cap, contributing to the short time duration by eliminating the common backer-rod and fire caulk joint assembly installed in joints after the wall completion. The concrete caps 526, 530 are also produced offsite and installed during the final step of the precast erection. The erection process requires 4 men for a much shorter duration, (a CMU shaft requires double the manpower for a much longer duration), reducing overall risks and hazards associated with working on scaffolding at significant heights. The inspection process is reduced to minimal requirements, which will save additional time over the reinforced CMU method which requires multiple inspections.

Various features and advantages are set forth in the following claims.

Claims

1. An assembly comprising: a first precast concrete structure including a first rebar member;a second precast concrete structure including a second rebar member; wherein the second rebar member is aligned with the first rebar member along an axis;a sleeve with an aperture, the sleeve coupled to the first rebar member;a connecting member coupled to the second rebar member;a rebar dowel coupled to the connecting member; wherein the rebar dowel extends through the aperture in the sleeve and is at least partially received within the sleeve;a grout positioned within the sleeve;a gasket positioned between the sleeve and the connecting member;a seal positioned between the first precast concrete structure and the second precast concrete structure; anda shim positioned between the first precast concrete structure and the second precast concrete structure.

2. The assembly of claim 1, wherein the first precast concrete structure includes a first surface, and the second precast concrete structure includes a second surface, and wherein the seal is positioned between the first surface and the second surface.

3. The assembly of claim 2, wherein the first precast concrete structure further includes a lifting anchor assembly with an aperture formed in the first surface.

4. The assembly of claim 1, wherein the sleeve is aligned with the axis and the axis extends through the aperture.

5. The assembly of claim 1, wherein the sleeve is coupled to the first rebar member with a threaded connection.

6. The assembly of claim 1, wherein the sleeve includes a cylindrical wall extending along the axis, a cavity, a first charge port in fluid communication with the cavity, and a second charge port in fluid communication with the cavity.

7. The assembly of claim 1, wherein the first charge port extends along a first charge port axis and the second charge port extends along a second charge port axis, wherein the first charge port axis is perpendicular to the axis and the second charge port axis is perpendicular to the axis.

8. The assembly of claim 1, wherein the sleeve is coupled to the first rebar member at a first end of the sleeve, and the aperture is positioned at a second end of the sleeve, wherein the second end is opposite the first end.

9. The assembly of claim 1, wherein the connecting member has a first end coupled to the second rebar member and a second end coupled to the rebar dowel, where the first end is opposite the second end.

10. The assembly of claim 1, wherein the rebar dowel has a threaded end coupled to the connecting member.

11. The assembly of claim 1, wherein the gasket includes a gasket aperture and the rebar dowel extends through the gasket aperture.

12. The assembly of claim 1, wherein the seal is a polyurethane foam.

13. The assembly of claim 1, wherein the seal includes a first ridge, a second ridge, and a portion extending between the first ridge and the second ridge.

14. The assembly of claim 13, wherein the shim is positioned between the first ridge and the second ridge.

15. The assembly of claim 14, wherein the shim has a thickness within a range of 0.25 inches to 0.75 inches.

16. The assembly of claim 1, wherein the seal and the shim are part of a joint assembly with at least a 2-hour fire-rating.

17. The assembly of claim 1, wherein the first precast concrete structure includes an opening and a plurality of rebar members extending through the opening.

18. The assembly of claim 1, wherein the first precast concrete structure or the second precast concrete structure includes a first notch, a second notch, and a hoist beam at least partially positioned with the first notch and the second notch.

19. The assembly of claim 1, wherein the second precast concrete structure is a cap.

20. The assembly of claim 1, wherein the first precast concrete structure and the second precast concrete structure at least partially form an elevator shaft or a stairwell.

21. A method of erecting a structure, the method comprising: positioning a seal on a first precast concrete structure;raising a second precast concrete structure;coupling a rebar dowel to the second precast concrete structure;aligning the second precast concrete structure with the first precast concrete structure; andlowering the second precast concrete structure onto the first precast concrete structure, wherein the seal is positioned between the first precast concrete structure and the second precast concrete structure.

22. The method of claim 21, further comprising positioning a plurality of shims on the seal.

23. The method of claim 21, wherein raising the second precast concrete structure includes attaching a crane to a plurality of lifting anchors in the second precast concrete structure.

24. The method of claim 21, wherein coupling the rebar dowel to the second precast concrete structure includes threading the rebar dowel into a connecting member in the second precast concrete structure.

25. The method of claim 21, wherein aligning the second precast concrete structure with the first precast concrete structure includes aligning the rebar dowel with a sleeve formed in the first precast concrete structure.

26. The method of claim 21, wherein lowering the second precast concrete structure onto the first precast concrete structure includes lowering the rebar dowel into a sleeve formed in the first precast concrete structure.

27. The method of claim 21, further including injecting a grout into a sleeve formed in the first precast concrete structure prior to lowering the second precast concrete structure onto the first precast concrete structure.

28. The method of claim 21, further including forming the first precast concrete structure and the second precast concrete structure at an offsite facility and transporting the first precast concrete structure and the second precast concrete structure to a jobsite.

29. The method of claim 21, wherein the first precast concrete structure and the second precast concrete structure form one story of a building when joined together.

30. The method of claim 21, further including positioning a second seal on the second precast concrete structure;raising a third precast concrete structure;coupling a second rebar dowel to the third precast concrete structure;aligning the third precast concrete structure with the second precast concrete structure; andlowering the third precast concrete structure onto the second precast concrete structure;

31. The method of claim 21, further including cutting a plurality of rebar from an opening formed in the first precast concrete structure.

32. The method of claim 31, further including adding masonry to the opening.

33. The method of claim 21, wherein no scaffolding is required.

34. The method of claim 21, wherein no backer-rod and fire caulk joint assembly is positioned between the first precast concrete structure and the second precast concrete structure.