SYSTEMS AND METHODS FOR BUILDING ELEVATED STRUCTURES

Abstract

Self-supporting concrete slabs can eliminate the need for temporary backshoring, streamlining the building process and enhancing productivity. These slabs are engineered to support their own weight and additional loads without relying on external supports, reducing labor and material costs while accelerating construction schedules. The process incorporates advanced reinforcement techniques, including post-tensioning and code-compliant splicing methods, to ensure structural integrity, continuity, and compliance with building codes. By simplifying forming processes and enabling early access for other trades, self-supporting slabs offer significant economic and operational advantages, making them a superior alternative to traditional slab designs.

Claims

1. A self-supporting concrete slab, comprising: a concrete body having a thickness, a length, and a width; and a plurality of reinforcing steel bars at least partly embedded within the concrete body, wherein the concrete slab is configured to support its own weight and additional loads without requiring temporary backshoring during construction.

2. The self-supporting concrete slab of claim 1, wherein the reinforcing steel bars are arranged to span substantially the entire length and/or width of the concrete slab.

3. The self-supporting concrete slab of claim 1, wherein at least two of the reinforcing steel bars are connected via a splicing device.

4. The self-supporting concrete slab of claim 1, wherein the reinforcing steel bars are arranged to not span substantially the entire length and/or width of the concrete slab.

5. The self-supporting concrete slab of claim 1, wherein the reinforcing steel bars are also at least partly embedded within a second concrete body and arranged to be movable relative to the second concrete body.

6. A multi-floor building, comprising: the self-supporting concrete slab of claim 1.

7. The multi-floor building of claim 6, further comprising: at least five floors stacked vertically, wherein the at least five floors are configured such that, during the construction of a top-most floor, four floors below the top-most floor does not include any shoring.

8. The multi-floor building of claim 6, further comprising: at least five floors stacked vertically, wherein the at least five floors are configured such that, during the construction of a top-most floor, four floors below the top-most floor does not include any backshoring.

9. The multi-floor building of claim 6, further comprising: at least five floors stacked vertically, wherein the at least five floors are configured such that, during the construction of a top-most floor, four floors below the top-most floor does not include any reshoring.

10. The multi-floor building of claim 6, further comprising: at least five floors stacked vertically, wherein the at least five floors are configured such that, during the construction of a top-most floor, a bottom-most floor does not include any shoring.

11. The multi-floor building of claim 6, further comprising: at least five floors stacked vertically, wherein the at least five floors are configured such that, during the construction of a top-most floor, a bottom-most floor does not include any backshoring.

12. The multi-floor building of claim 6, further comprising: at least five floors stacked vertically, wherein the at least five floors are configured such that, during the construction of a top-most floor, a bottom-most floor does not include any reshoring.

13. A method of constructing a multi-floor building, wherein the multi-floor building includes at least four floors stacked vertically, the method comprising: forming a concrete floor slab at a top-most floor that includes reinforcing steel rebars arranged to span the concrete floor slab, wherein the concrete floor slab is configured to support its own weight without requiring any temporary backshoring during the forming of the concrete floor slab.

14. The method of claim 13, wherein the method does not include any shoring four floors below the top-most floor during the forming step.

15. The method of claim 13, wherein the method does not include any backshoring four floors below the top-most floor during the forming step.

16. The method of claim 13, wherein the method does not include any reshoring four floors below the top-most floor during the forming step.

17. The method of claim 13, wherein the method does not include any shoring at a bottom-most floor during the forming step.

18. The method of claim 13, wherein the method does not include any backshoring at a bottom-most floor during the forming step.

19. The method of claim 13, wherein the method does not include any reshoring at a bottom-most floor during the forming step.

20. A building construction, comprising: a plurality of floors stacked vertically, each of the plurality of floors including a self-supporting concrete slab, wherein the self-supporting concrete slab includes: a concrete body having a thickness, a length, and a width, and a plurality of reinforcing steel bars at least partly embedded within the concrete body, wherein the concrete slab is configured to support its own weight and additional loads without requiring temporary backshoring during construction.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0029] References are made to the accompanying drawings that form a part of this disclosure and that illustrate embodiments in which the systems and methods described in this Specification can be practiced. Like reference numbers represent the same or similar parts throughout.

[0030] FIG. 1 is an exemplary schematic side view of a traditional multi-floor building being constructed using a traditional method of backshoring during construction of the floors.

[0031] FIG. 2 is an exemplary schematic side view of a multi-floor building being constructed using some embodiments of a method disclosed herein.

[0032] FIG. 3 is a flowchart according to embodiments of a method disclosed herein.

[0033] FIG. 4 is a schematic top plan view of a floor construction according to some embodiments.

[0034] FIG. 5 is a schematic elevation view of the floor construction shown in FIG. 4.

[0035] FIG. 6 is a schematic top plan view of a floor construction according to some embodiments.

[0036] FIG. 7 is a schematic top plan view of a floor construction according to some embodiments.

DETAILED DESCRIPTION

[0037] Shoring is generally necessary in multi-floor building construction that has concrete floors. Generally, shoring is necessary for the concrete floor slabs because the construction methods must include a building design which is code compliant. Traditional methods generally requires a leave-outs (gaps) for the concrete floor slabs during construction to allow for the concrete floor slabs to shorten. Because of the leave-outs (gaps) form disconnecting regions between the floor slabs, the floor slabs, generally, cannot be self-supporting. Thus, backshoring is necessary during the construction of the floor slabs.

[0038] FIG. 1 shows a schematic diagram of a traditional building 100 construction at a time when nine floors 102, 104, 106, 108, 110, 112, 114, 116, 118 are built vertically. The top floor 102, which is the floor being formed, includes concrete floor slabs separated (i.e., disconnected) by a leave-out 122. Each of the other floors 104, 106, 108, 110, 112, 114, 116 below the top floor 102 also include similar leave-outs.

[0039] The leave-out 122 can be 3 feet to 8 feet in distance, or greater distances. The leave-out 122 have been incorporated in traditional concrete slab (e.g., post-tensioned concrete slabs) as being necessary to minimize cracking caused by concrete shrinkage restrained by vertical elements of the lateral system. Accordingly, the floor 102 (and each of the slabs separated by the leave-out 122) are not self-supporting. Likewise, all of the lower floors 104-116 that have leave-outs 122 are not self-supporting. Additionally, they cannot support the load from the floors above them.

[0040] The leave-outs 122 are filled at a later time, after the concrete slabs are fully formed (no longer shrinking). Only then is the entire concrete floor slab connected together forming a one contiguous floor of the building. At this time, the floor may become self-supporting, and the reshoring 134 systems can be removed.

[0041] Generally, leave-out 122 is located at an inflection point of the span. Accordingly, a very careful design and execution of the design is necessary to ensure the location of the leave-out 122. Backshoring 132 is thus necessary to support the concrete floor slabs 102, especially near the leave-out 122.

[0042] Further, as the multi-floor building 100 is constructed, each additional floor adds additional load to the lower (already completed) floors. Accordingly, it can become necessary to add reshoring 134 to all or nearly all of the lower floors. For example, while the top floor 102 is being formed, backshoring 132 is provided to support that floor 102 at the immediate floor below 104. The floors 106-118 below these upper floors 102, 104 can require substantial reshoring 134 to support the load of the upper floors. As such, at the lower floors, e.g., floors 116, 118, an increased number of reshoring 134 may be necessary, in particular near the areas where the leave-out 122 still exist and have not been filled in yet. When the number of reshoring 134 are extensive, that floor or areas near the leave-out 122 may not be reasonably accessible to other workers. Thus, there can be significant delay in the project's completion due to the required backshoring 132 and reshoring 134.

[0043] FIG. 2 shows a schematic diagram of a multi-floor building 200 construction according to exemplary embodiments. FIG. 2 shows its construction, at a time when nine floors 202, 204, 206, 208, 210, 212, 214, 216, 218 are built vertically. The top floor 202, which is the floor being formed, includes concrete floor slabs that is not by a traditional leave-out (see FIG. 1 in comparison). Each of the other floors 204, 206, 208, 210, 212, 214, 216, 218 below the top floor 202 also do not include traditional leave-outs.

[0044] The concrete slabs at each of the floors 202-216 are connected mechanically to be fully self-supporting. Accordingly, when the top-most floor 202 is being constructed, the floor 202 is configured to be self-supporting. Thus, backshoring is not necessary. That is, according to some embodiments, the system and methods do not include backshoring.

[0045] FIG. 2 shows that the floor 202 is supported by reshoring 234 from floor 204 (immediately beneath floor 202) to support the load on the floor 202 while the floor 202 is being constructed. Some of the load can be further supported by additional reshoring 234 at floor 206. Some of the load can also be further supported by additional reshoring 234 at floor 208.

[0046] According to some embodiments, at four floors below floor 202 (e.g., 210), reshoring is not necessary, as that floor 210 can fully support itself and the load above it. According to some embodiments, at five floors below floor 202 (e.g., 212), reshoring is not necessary, as that floor 212 can fully support itself and the load above it. According to some embodiments, at six floors below floor 202 (e.g., 214), reshoring is not necessary, as that floor 214 can fully support itself and the load above it. According to some embodiments, at seven floors below floor 202 (e.g., 216), reshoring is not necessary, as that floor 216 can fully support itself and the load above it. According to some embodiments, at the lower-most floor below floor 202 (e.g., 218), reshoring is not necessary, as that floor 218 can fully support itself and the load above it. According to some embodiments, at four or more floors below floor 202 (e.g., 210-218), reshoring is not necessary, as the lower floors 210-218 can each fully support itself and the load above it. According to some embodiments, at five or more floors below floor 202 (e.g., 212-218), reshoring is not necessary, as the lower floors 212-218 can each fully support itself and the load above it. According to some embodiments, at six or more floors below floor 202 (e.g., 214-218), reshoring is not necessary, as the lower floors 214-218 can each fully support itself and the load above it. According to some embodiments, at seven or more floors below floor 202 (e.g., 216-218), reshoring is not necessary, as the lower floors 216-218 can each fully support itself and the load above it. According to some embodiments, at eight or more floors below floor 202 (e.g., 218), reshoring is not necessary, as the lower floors 218 can each fully support itself and the load above it.

[0047] Yet, the concrete slabs at each of the floors 202-218 can be post-tensioned or otherwise to minimize cracking caused by concrete shrinkage restrained by vertical elements of the lateral system. Additionally, as the floors are completed, they can fully support the load from the floors above them. That is, as the multi-floor building 200 is constructed, each additional floor adds additional load to the lower (already completed) floors. However, because the floors do not have traditional leave-outs, and further can be mechanically self-supporting, it can be unnecessary to add reshoring to the lower floors. And the shoring (e.g., reshoring) can be removed from the lower floors as the upper floors are being constructed.

[0048] For example, while the top floor 202 is being formed, backshoring is not provided to support that floor 202 at the immediate floor below 204. Instead, some reshoring 234 can be provided to support the load on the top floor 202. The floors 206-208 below these upper floors 202, 204 can require some reshoring 234 to support the load of the upper floors 202, 204. However, at the lower floors, e.g., floors 210-218, reshoring is not necessary. Thus, any reshoring equipment can be removed from these floors 210-218, allowing for other equipment and workers to have access to the entire floor. This can significantly speed up the project's completion.

[0049] FIG. 3 shows an exemplary flowchart for a method of constructing a multi-floor building. The multi-floor building includes at least four floors stacked vertically. The method includes, at least, forming 300 a concrete floor slab at a top-most floor that includes reinforcing steel rebars arranged to span the concrete floor slab, wherein the concrete floor slab is configured to support its own weight without requiring any temporary backshoring during the forming of the concrete floor slab.

[0050] As an example, the following construction productivity comparison can be expected between a traditional method (e.g., FIG. 1) versus the embodiments disclosed herein (e.g., FIG. 2). The TABLE below only considers the pour strip bay/span. Construction assumed to progress 1 level per week. Slabs are expected to be 8 inches (100 psf). Pour back time is assumed 28 days. The table below is a snapshot just before level 7 is cast.

TABLE-US-00001 TABLE Comparison of Traditional Pour Strip and Embodiment of Gapless Pour Strip - Snapshot at level 7 pour Level Traditional Embodiment 7 Top level ready to be cast. Top level ready to be cast. 6 All forming is custom hand framed or All forming same as all other special framed. Prepped for bays/spans no special form framing. backshoring. No prep for backshoring. No backshoring. Reshoring. Level 6 carries weight of of forming and level 7 concrete. 5 PS forming left in place. Other forming All reshored for weight of of removed and backshored and/or forming and level 7 concrete, reshored for weight of forming and concrete level 7, and concrete level 6. 4 PS forming left in place. Backshored All reshored for weight of of and/or reshored for weight of forming forming and level 7 concrete. and concrete level 7, concrete level 6, and concrete level 5. 3 PS forming left in place. PS cast. Fully open - no shores on this level Backshored and/or reshored for weight of forming and concrete level 7, concrete level 6, concrete level 5, and concrete level 4. 2 PS level 2 cast. PS forming removed. Fully open - no shores on this level Backshored and/or reshored for weight of forming and concrete level 7, concrete level 6, concrete level 5, concrete level 4, and concrete level 3. 1 Dunnage in place. Backshored and/or Fully open - no shores on this level reshored for weight of forming and concrete level 7, concrete level 6, concrete level 5, concrete level 4, concrete level 3, and concrete level 2.

[0051] As can be understood from the above TABLE, self-supporting concrete slabs can eliminate the need for temporary backshoring, streamlining the building process, and enhancing productivity. These slabs are engineered to support their own weight and additional loads without relying on external supports, reducing labor and material costs while accelerating construction schedules. The process incorporates advanced reinforcement techniques, including post-tensioning and code-compliant splicing methods, to ensure structural integrity, continuity, and compliance with building codes. By simplifying forming processes and enabling early access for other trades, self-supporting slabs offer significant economic and operational advantages, making them a superior alternative to traditional slab designs.

[0052] FIGS. 4-5 show schematic diagrams of an exemplary self-supporting concrete floor construction 400 according to some embodiments. The self-supporting concrete floor construction 400 includes a first concrete slab 402 and a second concrete slab 404. The first concrete slab 402 and the second concrete slab 404 are formed one after the other, without a traditional leave-out therebetween. The first concrete slab 402 is formed with a plurality of rebars 406 connected to a rebar splicing coupler 408. A rebar 406 can be connected to the rebar splicing coupler 408 via a threaded connection. Alternatively, the connection between the plurality of rebars 406 and the 408 can be via a weld, a mechanical connection, or other means. The rebar splicing coupler 408 includes a body defining an internal cavity through which a portion of another rebar 410 can be inserted. The rebar splicing coupler 408 has an opening for receiving the portion of the rebar 410, and the opening and/or the internal cavity is configured in such a way that the rebar 410 can move vertically and horizontally. That is, the rebar splicing coupler 408 is not configured to support rebar 410 in such a way to prevent vertical movement of the rebar 410 during the construction and forming of the second concrete slab 404. That is to say, the coupler and/or coupled connection between the plurality of rebars 406 and the rebar 410 via the rebar splicing coupler 408 is non-self-supporting. Thus, the combined system of the plurality of rebars 406, the rebar splicing coupler 408, and the rebar 410 forms a non-self-supporting connection for the floor 400. To compensate for this, a dowel 412 (e.g., a short rebar made of steel, aluminum, or other similarly hard material) that has a smooth surface that is greased and/or inserted inside a sleeve on one side 414 is provided substantially in a parallel with respect to the rebar 406 and/or the rebar 410. The dowel 412 provides sufficient supporting property for the floor 400 to be self-supporting. The smooth surface and the grease and/or the sleeve allows for the dowel 412 to move along with the shrinkage of the one or more slab(s) 402, 404. That is, the slabs 402, 404 can move away from each other, relatively speaking, during the curing of the concrete(s). Generally, the later formed concrete slab, e.g., slab 404, would shrink away from the previously poured slab, e.g., slab 402. According to this exemplary embodiment, the floor 400 is self-supporting, and there is no need for backshoring to support the floor 400 during its construction.

[0053] FIG. 6 shows a schematic diagram of an exemplary self-supporting concrete floor construction 500 according to some embodiments. The self-supporting concrete floor construction 500 includes a first concrete slab 502 and a second concrete slab 504. The first concrete slab 502 and the second concrete slab 504 are formed one after the other, without a traditional leave-out therebetween. The first concrete slab 502 is formed with a plurality of rebars 506 connected to a rebar splicing coupler 508. A rebar 506 can be connected to the rebar splicing coupler 508 via a threaded connection. Alternatively, the connection between the plurality of rebars 506 and the 508 can be via a weld, a mechanical connection, or other means. The rebar splicing coupler 508 includes a body defining an internal cavity through which a portion of another rebar 510 can be inserted. The rebar splicing coupler 508 has an opening for receiving the portion of the rebar 510, and the opening and/or the internal cavity is configured in such a way that the rebar 510 cannot move vertically, but may move horizontally (relative to the floor 500). That is, the rebar splicing coupler 508 is configured to support rebar 510 in such a way to prevent vertical movement of the rebar 510 during the construction and forming of the second concrete slab 504. That is to say, the coupler and/or coupled connection between the plurality of rebars 506 and the rebar 510 via the rebar splicing coupler 508 becomes and/or is self-supporting. Thus, the combined system of the plurality of rebars 506, the rebar splicing coupler 508, and the rebar 510 forms a self-supporting connection for the floor 500. In addition, a dowel 412 that has a smooth surface that is greased and/or inserted inside a sleeve on one side 414 is provided substantially in a parallel with respect to the rebar 506 and/or the rebar 510. The dowel 412 provides additional supporting property for the floor 500 to be self-supporting. The smooth surface and the grease and/or the sleeve allows for the dowel 412 to move along with the shrinkage of the one or more slab(s) 502, 504. That is, the slabs 502, 504 can move away from each other, relatively speaking, during the curing of the concrete(s). Generally, the later formed concrete slab, e.g., slab 504, would shrink away from the previously poured slab, e.g., slab 502. According to this exemplary embodiment, the floor 500 is self-supporting, and there is no need for backshoring to support the floor 500 during its construction.

[0054] FIG. 7 shows a schematic diagram of an exemplary self-supporting concrete floor construction 600 according to some embodiments. The self-supporting concrete floor construction 600 includes a first concrete slab 602 and a second concrete slab 604. The first concrete slab 602 and the second concrete slab 604 are formed one after the other, without a traditional leave-out therebetween. Similar to the floor 500 shown in FIG. 6, first concrete slab 602 is formed with a plurality of rebars 506 connected to a rebar splicing coupler 508. A rebar 506 can be connected to the rebar splicing coupler 508 via a threaded connection. Alternatively, the connection between the plurality of rebars 506 and the 508 can be via a weld, a mechanical connection, or other means. The rebar splicing coupler 508 includes a body defining an internal cavity through which a portion of another rebar 510 can be inserted. The rebar splicing coupler 508 has an opening for receiving the portion of the rebar 510, and the opening and/or the internal cavity is configured in such a way that the rebar 510 cannot move vertically, but may move horizontally (relative to the floor 600). That is, the rebar splicing coupler 508 is configured to support rebar 510 in such a way to prevent vertical movement of the rebar 510 during the construction and forming of the second concrete slab 604. That is to say, the coupler and/or coupled connection between the plurality of rebars 506 and the rebar 510 via the rebar splicing coupler 508 becomes and/or is self-supporting. Thus, the combined system of the plurality of rebars 506, the rebar splicing coupler 508, and the rebar 510 forms a self-supporting connection for the floor 600. However, the floor 600 does not include any of the dowels as shown in FIGS. 5 and 6. That is, the rebars 506, 510 being connected via the coupler 508 is sufficient for the floor 600 to be self-supporting during construction when at least one of the slabs 602, 604 moves away from the other, relatively speaking. Generally, the later formed concrete slab, e.g., slab 604, would shrink away from the previously poured slab, e.g., slab 602. According to this exemplary embodiment, the floor 600 is self-supporting, and there is no need for backshoring to support the floor 600 during its construction.

[0055] According to some embodiments, any of the methods, systems, and components shown in FIGS. 4-7 are combined, as long as the floor itself is self-supporting during the floor's construction. Accordingly, such embodiments do not require backshoring.

Clauses

[0056] Clause 1. A self-supporting concrete slab, comprising: a concrete body having a thickness, a length, and a width; and a plurality of reinforcing steel bars at least partly embedded within the concrete body, wherein the concrete slab is configured to support its own weight and additional loads without requiring temporary backshoring during construction. [0057] Clause 2. The self-supporting concrete slab of clause 1, wherein the reinforcing steel bars are arranged to span substantially the entire length and/or width of the concrete slab. [0058] Clause 3. The self-supporting concrete slab according to any of clauses 1-2, wherein at least two of the reinforcing steel bars are connected via a splicing device. [0059] Clause 4. The self-supporting concrete slab according to any of clauses 1-3, wherein the reinforcing steel bars are arranged to not span substantially the entire length and/or width of the concrete slab. [0060] Clause 5. The self-supporting concrete slab according to any of clauses 1-4, wherein the reinforcing steel bars are also at least partly embedded within a second concrete body and arranged to be movable relative to the second concrete body. [0061] Clause 6. A multi-floor building, comprising: the self-supporting concrete slab according to any of clauses 1-5. [0062] Clause 7. The multi-floor building of clause 6, further comprising: at least five floors stacked vertically, wherein the at least five floors are configured such that, during the construction of a top-most floor, four floors below the top-most floor does not include any shoring. [0063] Clause 8. The multi-floor building according to any of clauses 6-7, further comprising: at least five floors stacked vertically, wherein the at least five floors are configured such that, during the construction of a top-most floor, four floors below the top-most floor does not include any backshoring. [0064] Clause 9. The multi-floor building according to any of clauses 6-8, further comprising: at least five floors stacked vertically, wherein the at least five floors are configured such that, during the construction of a top-most floor, four floors below the top-most floor does not include any reshoring. [0065] Clause 10. The multi-floor building according to any of clauses 6-9, further comprising: at least five floors stacked vertically, wherein the at least five floors are configured such that, during the construction of a top-most floor, a bottom-most floor does not include any shoring. [0066] Clause 11. The multi-floor building according to any of clauses 6-10, further comprising: at least five floors stacked vertically, wherein the at least five floors are configured such that, during the construction of a top-most floor, a bottom-most floor does not include any backshoring. [0067] Clause 12. The multi-floor building according to any of clauses 6-11, further comprising: at least five floors stacked vertically, wherein the at least five floors are configured such that, during the construction of a top-most floor, a bottom-most floor does not include any reshoring. [0068] Clause 13. A method of constructing a multi-floor building, wherein the multi-floor building includes at least four floors stacked vertically, the method comprising: forming a concrete floor slab at a top-most floor that includes reinforcing steel rebars arranged to span the concrete floor slab, wherein the concrete floor slab is configured to support its own weight without requiring any temporary backshoring during the forming of the concrete floor slab. [0069] Clause 14. The method of clause 13, wherein the method does not include any shoring four floors below the top-most floor during the forming step. [0070] Clause 15. The method according to any of clauses 13-14, wherein the method does not include any backshoring four floors below the top-most floor during the forming step. [0071] Clause 16. The method according to any of clauses 13-15, wherein the method does not include any reshoring four floors below the top-most floor during the forming step. [0072] Clause 17. The method according to any of clauses 13-16, wherein the method does not include any shoring at a bottom-most floor during the forming step. [0073] Clause 18. The method according to any of clauses 13-17, wherein the method does not include any backshoring at a bottom-most floor during the forming step. [0074] Clause 19. The method according to any of clauses 13-18, wherein the method does not include any reshoring at a bottom-most floor during the forming step. [0075] Clause 20. A building construction, comprising: a plurality of floors stacked vertically, each of the plurality of floors including a self-supporting concrete slab, wherein the self-supporting concrete slab includes: a concrete body having a thickness, a length, and a width, and a plurality of reinforcing steel bars at least partly embedded within the concrete body, wherein the concrete slab is configured to support its own weight and additional loads without requiring temporary backshoring during construction.

[0076] Any or all portion(s) of any of the embodiments and/or clauses disclosed herein may be combined with any other portion(s) of any embodiment and/or clauses.

[0077] The terminology used herein is intended to describe embodiments and is not intended to be limiting. The terms a, an, and the include the plural forms as well, unless clearly indicated otherwise. The terms comprises and/or comprising, when used in this Specification, specify the presence of the stated features, integers, steps, operations, elements, and/or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, and/or components.

[0078] It is to be understood that changes may be made in detail, especially in matters of the construction materials employed and the shape, size, and arrangement of parts without departing from the scope of the present disclosure. This Specification and the embodiments described are examples, with the true scope and spirit of the disclosure being indicated by the claims that follow.