Patent Application
20160116112
The present invention relates to prefabricated modules for assembly into partially or fully enclosed hollow structures such as passageways, culverts or other roadway components as well as other uses such as parking garages and water holding tanks. More particularly, the invention relates to prefabricated modules which are assembled from separate segments.
Prefabricated structural modules, which may be fabricated from concrete or other moldable material, can be configured to provide a wide variety of assembled structures. For example, prefabricated modules can be assembled into culverts, pipes or passageways for diverting water or other applications, as well as water retention systems for homes, businesses communities and other applications. As well, prefabricated modules can be used to assemble structures that serve other functions, such as storage or other utility structures, parking facilities, bridges or over/underpasses and a wide variety of other uses. Structural modules or components thereof may be prefabricated from concrete and transported to a remote location for assembly. Modules or their components should be of a size and weight that permits them to be transported and assembled using generally conventional equipment and facilities. Modules should be capable of being assembled into a wide variety of modules and structures that preferably have a high degree of durability and strength, ease of installation and if required, water tightness.
Conventional modules and modular systems typically are designed for specific end uses, such as storm water retention, subsurface culverts and the like. However, it can be desirable to provide structural modules that may be assembled into a relatively wide variety of structures with little or no modification to the basic module design. Furthermore, it is desirable to provide modules that are relatively compact and lightweight that can be easily transported and assembled using conventional equipment, while still being capable of assembly into relatively large structures that have a relatively high weight-bearing capacity. Furthermore, it is desirable to provide modules that when assembled can be sealed against water leakage, in particular at the joints between modules. This is particularly desirable for modules used for water retention or derivation, such as water retention tanks, culverts and the like.
Modular assemblies must often be capable of a high degree of load bearing, for example when used as underpasses, bridges or culverts for roadways or other applications in which significant weight-bearing is required.
A modular assembly is disclosed, for example, in U.S. Pat. No. 8,770,890 to May et al.
The present invention relates to improved segments, modules and modular assemblies that may be fabricated from precast concrete, which have at least the potential to address the requirements and needs discussed herein.
According to one broad aspect, the invention relates to a modular system for assembling a hollow structure. Modules are assembled from first and second segments each being defined by opposing ends with an elongate axis between said ends. The assembled module has opposing upper and lower decks, each of which has opposing sides and opposing ends. The respective surfaces of deck consist of opposing upper and lower surfaces, opposing side edges and opposing end edges. The first and second segments are configured for assembly in inverted, vertically aligned relation to each other to form a hollow module comprising the opposed upper and lower decks. The first and second segments are configured to engage each other when assembled in vertically and/or axially aligned relationship with mutually engaging three-dimensional structures that restrict lateral and/or vertical slippage between the segments.
According to a further general aspect, the system comprises multiple segments that may be assembled into vertical aligned modules, which in turn can be axially aligned with similar modules to form elongate structures such as culverts and water-retention systems.
The segments may, in one aspect, each comprise opposing sidewalls at their sides with the deck spanning the sidewalls. The first and second segments are configured for assembly in axially and vertically aligned relation to each other to form a hollow module wherein the respective sidewalls when assembled form essentially continuous outer walls of said structure and the respective decks oppose each other. The first and second segments are configured to engage each other when assembled in vertically aligned and/or end to end relationship with mutually engaging structures. The mutual engagement is provided by interlocking or mutually engaging three dimensional structural elements that restrict lateral slippage between segments and/or lateral/vertical slippage between adjacent modules. The vertical alignment between the segments comprises vertical alignment of the sidewalls. The ends of the respective segments may also be vertically aligned or may be out of alignment to form a staggered vertical joint structure.
In one aspect, the deck may have a cantilever member protruding from a lateral edge of a deck for interlocking with a corresponding cantilever member in an abutting, axially aligned deck of a second segment. The cantilever joint member comprises a shelf protruding from an edge surface of the deck which is configured to bear upon or be borne upon a similar shelf protruding from a corresponding edge of the deck of a corresponding one of the segments when assembled in axial alignment. The deck may comprise opposing end edge surfaces and respective ones of the shelves of said deck are configured to engage and bear upon or be borne upon shelves of corresponding ones of said segments when assembled in axial alignment. A deck may have two exposed end edge surfaces, one exposed end edge surface or no exposed end edge surface depending on whether the segment includes no end walls, one end wall or two opposing end walls; it will be seen that the number of walls in the module relates to the number of exposed edge surfaces that are present at the wall-free edges of the decks.
In one aspect, the cantilever joint members consist of four different cross sectional profiles that may be repeated in a multi-module structure. The four profiles consist of a first configuration for a first end surface of an upper deck, a second configuration for an opposed second surface of a second upper deck, a third configuration for a third end surface of a lower deck and a fourth configuration of an opposed lower deck. The opposing decks interlock in a load-bearing cantilever joint configuration when brought into end to and abutting relationship.
In another aspect, vertical edge surfaces of the respective sidewalls may comprise vertically oriented protrusions which are continuous with the shelf structures of the decks. The protrusion interlocks with a similar protrusion in an adjacent segment when the respective modules are assembled in end-to-end axially aligned relationship.
The segments and modules may be open at both ends for assembly into an open-ended four-sided hollow structure. Others of the segments may have a single end wall for assembly into a five-sided hollow structure having one closed end or two end walls at opposing ends for assembly into a fully enclosed, six-sided structure.
According to another aspect, the segments may, (depending on span and loading) further comprise at least one half-column protruding from a surface of said deck towards an opposing one of said segments whereby when said first and second segments are assembled in vertically aligned relationship, the half-columns abut each other to form load-bearing continuous columns extending between opposing ones of said decks. A “half-column” is a vertically-oriented member having a length which is half the length of a full-height column, and which is configured to be vertically aligned with and abut a similar half column to form a full-height column that for structural purposes is equivalent to a monolithic weight-bearing column. The exposed ends of the half-columns may comprise interlocking projections and recesses, such as a mortice and tenon configuration. The columns may be configured such that a pair of the half columns is aligned along an axis transverse to the elongate axis of each module.
According to another aspect, the sidewalls of the first segment may have axially-aligned lower edges comprising a tongue and groove structure configured to interlock with similar structures in the upper edges of sidewalls of the second segment when assembled in vertical alignment.
In this patent specification, the terms defined below shall have the meanings set forth herein, unless otherwise stated or the context clearly requires otherwise.
“Module” refers to a structural member that can be assembled with other like modules in an interchangeable fashion into a structure. A given assembled structure may be composed of multiple identical modules or a plurality of module types. A module may be composed of multiple segments, or it may be a monolithic member.
“Segment” refers to a structural member that forms part of a module. Multiple segments having the same or different configurations may be assembled into a module.
The terms “slab” and “deck” are generally used interchangeably and refer to an essentially continuous plate-like member.
“Cantilever” refers to a structure having a member projecting horizontally outwardly from a surface, supported only at one end of the member other than when bearing on another member. A cantilever member is normally capable of load bearing in either of a downwards or upwards direction when opposing ones of the cantilever members engage each other.
“Column” is a vertically-oriented structure that is normally load-bearing when located in an assembled structure. A column may have any suitable cross-sectional configuration. A “half column” is an upper or lower half of a column that may be mated with a similar opposing half column to form a column.
Directional references herein are used purely for convenience and are not intended to limit the scope of the invention in any respect. For example, directional references such as vertical, upwardly, horizontal and like, are intended purely for ease of description. Furthermore, it will be understood that embodiments of the invention may be produced on essentially any scale. Accordingly, references to specific dimensions are, unless otherwise expressly stated, not intended to limit the scope of the invention in any respect. The embodiments described herein are intended purely for illustration purposes, to provide teachings that describe certain aspects of the invention. The specific embodiments described herein are purely by way of example and illustration and are not intended to limit the scope of the invention in any respect.
Upper and lower segments 10 and 12 are similar (but not identical nor mirror image) in configuration to each other and are configured to be assembled in vertical alignment with each other to form module 1.
Segments 10 and 12 (and the similar segments described herein) are fabricated from a moldable material such as concrete and are typically pre-cast at a concrete plant and transported to a remote assembly. Preferably, the concrete is reinforced and may be pre-stressed. The materials used for reinforcing and pre-stressing comprise any suitable reinforcing materials known to art and may be ferrous and/or non ferrous.
As seen in more detail in
Upper segment 10 further comprises half-columns 32a and 32b which extend downwardly from the underside of slab 24 towards the interior space of segment 10. Lower segment 12 has similar half-columns 66a and b, described below, that extend upwardly to join with half-columns 32 to form structurally continuous weight-bearing columns extending between slabs 24 and 64. The number and dimensions of half columns 32 may vary depending on the structural requirements of the assembled structure. Furthermore, in some cases interior columns 32 and 66 may not be required in the structure, for example if the structure is expected to experience reduced load-bearing requirements and/or reduced unsupported span distances relative to structures that normally require interior columns. Half-columns 32 may have a square or rectangular cross-sectional configuration, as illustrated, or any other suitable cross-sectional configuration. In the present example, two half-columns 32 are provided in side by side relation along an axis which is transverse to the longitudinal axis A. Half-columns 32 may taper inwardly from slab 24 to their exposed end surfaces 34 (see
Sidewalls and end walls 20, 22 and 30, as well as half columns 32, all extend downwardly to the same extent wherein the lower surfaces thereof are co-planar and comprise a plane of engagement with the corresponding upper surfaces of lower segment 12.
In one embodiment, half-columns 32 may range from 0.5 m to 2.0 m in height. Their width can range from 0.15 m to 0.5 m at the lower surface at the plane of engagement and from 0.15 to 0.6 m where column 32 meets neck 38. Tenon 36 has an overall height of between 25 mm to 75 mm.
Slab 24 comprises opposing end surfaces 40 and 41 at the respective ends thereof. A first end surface 40 is adjacent to open end 28 of segment 10 and normally faces an adjacent modular segment when module 1 is assembled end to end with similar modules to form an elongate segmented structure with a hollow interior. An opposing end 41 of slab 24 meets end wall 30. End surface 40 has a stepped configuration which will be described in more detail below, which cooperates with a similar structure an adjoining segment to interlock in a cantilever-type joint.
Side walls 20 and 22 have horizontally-disposed lower edges 48 that are aligned with axis A and vertically disposed end edges 50. End edges 50 are exposed at the open end 28 of segment 10 (see
The lower edges 48 of sidewalls 20 and 22 are configured to rest upon and engage corresponding upper edges of lower segment 12 with an interlocking engagement, such that the respective sidewalls are vertically aligned to form an essentially continuous wall of the assembled structure. The exposed lower edges of walls 20 and 22 each comprise a central downwardly projecting tongue 51 flanked by recessed portions 52a and 52b (see
Turning now to the opposed lower segment 12, as seen in
Half-columns 66a and b each have a flat upper surface 70, having a mortice 72 recessed therein. Mortice 72 is configured to snuggly receive tenon 36 therein to interlock the respective exposed end surfaces of half-columns 32 and 66 when assembled. An adhesive such as grout may be applied between the contacting mortice and tenon members. After the grout or other adhesive hardens, the respective half-columns effectively form a continuous, monolithic structural member. Half-columns 32 and 66 are configured and located within segments 10 and 12 such that when assembled in vertical alignment, the respective half-columns are vertically aligned and their exposed surfaces meet whereby tenon 36 fits within mortice 72 and columns 32 and 66 form an essentially continuous load-bearing column spanning the full height of the assembled module. The dimensions of half-columns 66 match those of half-columns 32 whereby when module 1 is assembled and columns 32 and 66 meet at their plane of engagement, the respective half-columns define mirror images with the respective mortice and tenons thereof interlocking.
The respective half-columns 32 and 66 thus transfer load from upper slab 24 to lower slab 64 when the respective segments 10 and 12 are assembled. In a similar fashion, side walls 20 and 22 of upper segment 10 bear upon the sidewalls 60 and 62 of lower segment 12 using grout if necessary to form essentially continuous, load-bearing sidewalls of the assembled module 1. Side walls 60 and 62 have recessed grooves 54 within their upper surfaces extending lengthwise the full length of the respective walls, configured to snuggly receive projecting tongues 51 from the sidewalls 20 and 22 of corresponding upper segment 10. In this fashion, a tongue and groove (or other suitable structural connection) interlocking structure is provided between respective side walls and a mortice and tenon (or other suitable structural connection) interlocking structure is provided between upper and lower columns so as to rigidly interlock upper and lower segments 10 and 12.
The vertical walls of the modules (e.g. sidewalls 20, 22, 60 and 62; end walls 30, and similar walls described herein) may be in the range of 100 mm to 800 mm thick, but commonly between 200 mm to 300 mm in thickness. These walls range in both width and height from 500 mm to 4 m. Slabs 24 and 64 may range in thickness between 150 mm and 600 mm thick, but commonly 200 mm to 400 mm in thickness. Slabs 24 and 64 may range in length along axis A from 500 mm to 4 m, and in width between the sidewalls from 4 m to 15 m or more.
Turning to the opposing lower segment 124, this has a complimentary structure to upper segment 122, including upwardly-projecting columns 150 and opposing side walls 152 and 154 (seen in
The upper and lower segments described herein may have equal top to bottom heights, or unequal heights.
The segments described herein have four different configurations or profiles, identified as A-D, of their respective end surfaces of the horizontal slabs which interlock to form cantilever joints when assembled in end to end axially aligned relationships. Repeating patterns of configures A-D may be provided. The term “cantilever joint” as used herein refers to an overlapping configuration wherein a cantilever member projecting from a first module rests upon and transfers load to a similar cantilever member projecting from an abutting second module. The respective cantilever members are thus configured to rest one upon the other when the respective modules are horizontally aligned.
A) First end surface: end surface 40 of slab 24 (segment 10) defines a first end surface configuration A. Surface 40 comprises an outwardly protruding shelf 42 adjacent the lower surface 43 of slab 24 and an inwardly stepped recess 44 adjacent to the upper surface of slab 24. A sloping shoulder 46 forms the transition between portions 42 and 44. As will be described below, the configuration of end 40 provides a cantilever joint between adjacent segments of the adjacent modular structure wherein shelf 42 and shoulder 46 support a corresponding shelf and shoulder of an adjacent segment.
B: Second end surface: end surface 132 of slab 130 of segment 122 defines a second end surface configuration B, which mates with first end surface 40. Surface 132 comprises an outwardly projecting cantilever (shelf) region 136, an inwardly stepped region 138 and a sloping transition zone 141. Shelf 136 is adjacent the upper surface 137 of slab 130, while recessed portion 138 is adjacent the lower surface 139 thereof.
C: Third end surface: end surface 65 of lower slab 64 (segment 12) defines a third end surface C. Surface 65 comprises a protruding shelf 67 continuous with the bottom surface of slab 64, a recess 69 adjacent to the upper surface 73 of slab 64 and a sloping shoulder 71 which forms a transition zone between shelf 67 and recess 69.
D: Fourth end surface: end surface 86 of lower slab 156 of segment 124 defines a fourth end surface D, which mates with third end surface 65. Surface 86 comprises an outwardly projecting shelf 100 which is continuous with upper surface 105 and above inwardly stepped region 102. A sloping shoulder 104 forms the transition zone between the respective regions 100 and 102.
The four configurations described above are repeated within the various segments described herein to form an interlocking structure when the segments are assembled in various configurations. Accordingly, module 120 comprises upper and lower end surfaces 133 and 87 which are opposed to end surfaces 132 and 86. These in turn are identical in configuration to the first and third end surfaces (A and C). Similarly, end module 80 comprises upper and lower end surfaces 107 and 109 which are identical in configuration to the second and fourth end surfaces (B and D). In this fashion, when assembled together, the shelves of the four end surface configurations all fit within corresponding inwardly stepped regions of abutting segments whereby the respective shelves and shoulders rest one upon other. Any number of segments and modules may be combined with these four combinations of deck end surface profiles. This interlocking structure provides a cantilever joint configuration which restricts vertical slippage between the respective segments and allows vertical forces to be transmitted from one module to another via the cantilever joint configuration. It will be seen that an end module 1 or 80 that includes an end wall, wherein the upper and lower decks comprise only a single exposed end surface, comprise two distinct end surface profiles. A middle module 120 wherein the decks have both end surfaces exposed comprises all four profiles on the respective end surfaces of the upper and lower decks. The middle modules can thus join with either one of the end modules or another middle module 120.
In one aspect, the respective shelves of upper and lower decks may differ in top to bottom depth.
Turning to
In one embodiment, shown in
It will be seen that one may provide a structure wherein the above embodiments of modules and segments are combined, such that certain of the modules include multiple columns, while others include different numbers of columns or are free of columns. For example, the end segments may require a reduced number of columns, due to the additional structural support provided by the end walls.
The segments according to the present invention may be fabricated by conventional concrete casting techniques, wherein concrete is poured into a mould and allowed to harden. As discussed above, the concrete may be reinforced and/or pre-stressed. The resulting segments may be transported to a remote location for assembly into finished structures.
Assembly of the segments into a finished structure may be performed by routine construction techniques. For example, a suitable trench or other excavation may be provided, which optionally is provided with footings or the like for additional support. The lower segments are then placed into position in axial (horizontal) alignment abutting each other whereby adjacent segments interlock, using a crane or other heavy lifting equipment to place the bottom segments. Following this step, the upper segments are then positioned on top of the lower segments whereby respective pairs of upper and lower segments are vertically aligned, thereby forming modules which are incrementally installed to form the finished assembly. Alternatively, each module may be assembled and installed individually, whereby installation occurs incrementally with each module being fully assembled before installation of a subsequent module. When assembled, the segments are all interlocked vertically and horizontally (axially), by the interlocking structures described herein including the tongue and groove features of the sidewalls, mortice and tenon features of the columns and cantilever joints of the decks. Furthermore, the cantilever joints serve to transmit loads between axially aligned segments, thereby minimizing the risk of the segments being urged out of alignment by vertical forces acting unequally on the segments.
The segments may be fabricated on the basis of a design that is based on specific requirements for a given installation. The design process may begins with identifying a set of potential constraints such as the size of the required structure, which may dictate the overall number of modules and segments. This can range from a small number of segments to the many hundreds. Soil bearing capacities of the sites in question are reviewed and segment sizes and weights may be adjusted accordingly. Trucking regulations govern the weight of each load, which in turn, may affect the configuration and size of the segments. Segment sizes and weights are designed to try and minimize trucking costs. Similarly, availability of heavy and expensive lifting equipment is taken into account in the design.
The scope of the invention should not be limited by the preferred embodiments set forth in the examples but should be given the broadest interpretation consistent with the description as a whole. The claims are not to be limited to the preferred or exemplified embodiments of the invention.
This application claims the benefit of U.S. Provisional Application No. 62/067,785, filed Oct. 23, 2014, the entire disclosure of which is hereby incorporated herein by reference.
| Number | Date | Country | |
|---|---|---|---|
| 62067785 | Oct 2014 | US |
