DESC:CROSS-REFERENCE TO RELATED APPLICATIONS AND PRIORITY
The present application does not claim priority from any application.
FIELD OF THE INVENTION
The invention relates to the field of construction technology and in particular relates to a construction system and method for precasted reinforced concrete elevated service reservoirs. Particularly, the system and the method involve rapid construction technology for the construction of reinforced concrete elevated service reservoir, mainly used for storage of a fluid. More particularly, reinforced concrete elevated service reservoir constructed by rapid construction technology is used for storage of water.
BACKGROUND
The background information herein below relates to the present disclosure but is not necessarily prior art.
Elevated service reservoirs are crucial components of water distribution systems, providing necessary water storage and pressure for delivery to consumers. Traditionally, these reservoirs are constructed using cast in-situ techniques, which are time-consuming, labor-intensive, and subject to weather conditions.
Precast structural concrete is commonly used for rapid assembling of the buildings, roads, bridges, and other structures like dams, tanks etc. Precast concrete is concrete, cast in one place to be used elsewhere and is a mobile material. Precast production is carried out under the observation of a specialist and is then transported to the actual site. Precast components and pre-fabricated structural reinforcement minimize logistical burden, cost and assembly time of construction as compared to other conventional techniques of construction by casting of concrete on-site which includes cast in situ in the field. Precast components in particular are used where a high degree of quality control, minimized assembly time on-site and highly repetitive components are necessary in the construction of a structure.
Further, precast construction offers a potential solution by allowing components to be manufactured off-site and assembled on-site, thereby reducing construction time and improving quality control.
Reference may be made to US4578921A that relates to an elevated liquid storage tank and a method of constructing same.According to one aspect of the invention, an elevated liquid storage tank comprising an upright, hollow, cylindrical shaft adapted to be anchored to a supporting base foundation. According to the another aspect of the invention, a method of constructing an elevated liquid storage tank comprising the steps of erecting an upright, hollow, cylindrical shaft including a closed upper end portion forming a partial tank support floor having a top surface. However, this method is very costly and time consuming as compared to the present invention.
Reference may be made to US8820009B2 which relates to a liquid storage tank with a capacity of at least 100,000 US gallons that has a tower section; a tank shell above the tower section; a tank volume that is encompassed by the tank shell; a reinforced ring-beam at the top of the tower section that surrounds an internal area that withstands the downward force of the liquid; at least one supporting face on the ring-beam and a dome that sits on the supporting face and is made of laterally adjacent dome segments that essentially covers the internal area. The invention also relates to a method of building a concrete dome in a composite elevated tank. The method involves casting of wedge-shaped concrete floor segments near grade (or even off-site) and lifting to the ring beam. The segments are present in curved or liner shape as per the requirement.The segments are placed side-by-side over the internal opening in the ring beam, with the outer end of each segment on a supporting face on the ring beam. The inner end of the segment is positioned higher than the outer end and when needed, can be supported by a temporary support. When they are all placed, the floor segments create the shape of the dome. The dome can be linear in both horizontal cross-section and in profile (like a pyramid), curved in profile but not in horizontal cross-section (like an umbrella), curved in horizontal cross-section but not in profile (like a cone), or curved in both horizontal cross-section and in profile (like a spherical section). This method eliminates the need for preparing and raising complicated and expensive formwork to build the dome. In addition, less labour is required at the top of the tower, reducing the risk of injury. The concrete segments can be casted directly against steel liner plates, providing further advantages of an integral or composite segment. However, this method is also very costly.
Thus, in view of the drawbacks reported in the above prior-arts, there exists a dire need to develop a system and a method for construction of precasted reinforced concrete reservoir for storage of liquids, particularly water. As the existing method for construction of RCC elevated service reservoir is time consuming, requires skilled manpower, involves high cost and requires high safety standards to minimize the risk of human life.
Therefore, the inventors of the present invention have developed a system and a method for construction of precasted reinforced concrete elevated reservoir that is used in storage of liquid, particularly water. The system comprises of the precasted reinforced components manufactured off-site and assembled on-site to form a fluid reservoir. The method involves precasting of components in a casting yard under controlled conditions and then assembling it in specially desired alignment solves the problem of requirement of skilled personnel at the construction site, reduces the time and cost requirement for the construction. The instant invention is extremely beneficial for rural areas where there is a substantial scarcity of the skilled manpower. The disclosed invention assists by easy transportation of precasted components to the rural areas. As the components required for construction of the reinforced concrete elevated reservoir are pre-casted in casting yard under controlled conditions, quality of the reinforced concrete elevated reservoir is easily maintained.
Further, the present invention provides a novel system and method for constructing elevated service reservoirs using precast reinforced concrete. The system comprises modular components, including precast columns, beams, and tank segments, designed for rapid on-site assembly. The method involves a sequential process with plurality of steps comprising site preparation, component installation, alignment, and finishing, resulting in a durable and high-quality reservoir structure.
Advantages of the Invention:
• reduced construction time due to the use of precast components and rapid assembly;
• improved Quality Control as the making of precast components in controlled factory environments, ensuring consistent quality, better curing conditions, higher precision;
• enhanced uniformity and reliability of the concrete segments due to the use of standardized molds and manufacturing processes;
• enhanced durability,longevity, structural integrity and lifespan of the reservoir due to the reinforced concrete;
• resistance to environmental factors and corrosion by the application of waterproofing and protective coatings;
• labor efficiency and simplified assembly;
• minimized weather dependency due to off-site manufacturing and quick on-site assembly;
• increased safety due to reduced scaffolding;
• environmental benefits due to lesser waste production and less site disturbance;
• scalability, flexibility, consistent supply and availability; and
• cost efficiency due to reduced labor, time costs and lower maintenance costs.

OBJECTIVES
Some of the objects of the present disclosure, which at least one embodiment herein satisfies, are as follows:
The main objective of the present invention is to provide a system and a method comprising arapid construction technology for construction of precasted reinforced concrete reservoirs used in storage of a liquid. More particularly, reinforced concrete elevated service reservoir constructed by rapid construction technology is used for storage of water.
Another objective of the present invention is to provide a system and a method comprising offsite precasting of components in casting yard under controlled conditions; transportation of precasted components to the site of construction; assembling of the precasted components in specific alignment and levels; filling of joints with concrete to give strength to the structure and then constructing a liquid service reservoir on the elevation at the construction site.
Yet another objective of the present invention is to provide a system and a method for construction of reinforced concrete elevated reservoir which saves construction time avoiding on-site casting and erecting the elevated reservoir. As the instant invention involves precasting of components followed by assembling it at the construction site, it saves the skilled personnel requirement and construction time by 80%.
Still another objective of the present invention is to provide a system and a method for construction of reinforced concrete elevated reservoir with high and stringently controlled quality and good strength as compared to the reinforced concrete elevated reservoir which are constructed on-site due to maintenance of controlled conditions at the casting yards, controlled curing parameters and specific alignment and levels of joints as well as the modules of the elevated reservoir.
Further objective of the invention is to provide the system and the method for precasted reinforced elevated reservoir that is used for the storage of fluid with capacity of 10,000 litres to 50 lakh litres and staging height of 6 meters to 30 meters.
Other objects and advantages of the present disclosure will be more apparent from the following description, which is not intended to limit the scope of the present disclosure.
SUMMARY OF THE INVENTION
This summary is not intended to identify all the essential features of the claimed subject matter, nor is it intended to use in determining or limiting the scope of the claimed subject matter.
In a non-limiting embodiment of the present invention, the system for construction of precasted reinforced elevated reservoir comprises of a reservoir (vessel) with a precasted steel reinforced concrete, a supporting structure with a precasted steel reinforced concrete and a foundation. The reservoir (vessel) and the supporting structure comprises of a beam form assembly and a column form assembly which are used to construct cast in place structurally reinforced concrete columns, beams and floor slabs. The connections involved in these systems are: beam to column, beam to beam, column to column and column to the base. Connection is the critical factor in the concrete structures which transfers forces between the components, determines the strength, stiffness and ductility of the whole structure. The column form assembly is preferably precast of concrete reinforced with steel wire or bars. The column form assembly may take alternate shapes and proportioned column form assemblies are within the scope of the present invention. The beam form assembly is preferably precast of concrete reinforced with steel wire or bars. The beam form assembly may take alternate shapes and proportioned beam form assemblies are within the scope of the present invention.
According to the embodiment of the present invention, the pre-casted components comprise a shaped form and integrated structural reinforcement, wherein the shaped form material can be the concrete. The shaped form comprises of cement, water, sand, aggregate chemical admixtures and a reinforcing matrix. The reinforcing matrix comprises of at least one member selected from the group consisting of steel wire /steel fibre. The integrated structural reinforcement comprises a form of the material selected from the group consisting of steel bars, steel wire, steel sheets / steel fibre.
According to the embodiment of present invention, the prefabricated assembly components comprise of keying geometries adapted to restrict improper assembly on-site.
According to the embodiment of the present invention the integrated structural reinforcement is applied to the shaped form and partially exposed, allowing for subsequent reinforcement of an additional concrete infill.
Yet another embodiment of present invention relates to the integrated structural reinforcement which is applied to the shaped form by casting or by fastening.
One more embodiment of the present invention refers to a supporting structure comprising of the column form assembly and the beam form assembly with the base slab locked into the H frame. The reservoir vessel can be constructed as precasted concrete rings which are interlocked. Alternatively the reservoir vessel can be made up of mixed oxides of metals such as zinc and aluminium.
One more embodiment of the present invention relates to the method of construction of the elevated reservoir. The method comprises of construction of a pre-casted components which includes a column form assembly and a beam form assembly, assembling of the prefabricated assembly components to provide a permanent concrete mold, wherein the permanent concrete mold has integrated structural reinforcement and structural splices for a cast in place concrete structure; casting concrete in the permanent concrete mold to provide the cast in place concrete structure.
In yet another embodiment of the invention, the casting of components which are assembled to give final structure i.e. precasted and prefabricated column form assembly as well as precasted and prefabricated beam form assembly is done in casting yards under controlled environmental conditions. Controlling the temperature and humidity in the casting yard is important so as to providefavourable conditions for the chemical process involved in concrete formation and curing of concrete.
In yet another embodiment of the invention, the method for rapid construction of precasted reinforced elevated reservoir comprises of assembling the precasted components i.e. precasted column form assembly and precasted beam form assembly in a specific alignments and level to construct the strong structure. The precasted column form assembly and precasted beam form assembly are casted as a whole structure at a casting yard and plurality of precasted components are assembled as a centre point where there is a minimal stress by dry joints.
BRIEF DESCRIPTION OF THE ACCOMPANYING DRAWING
Figure 1illustrates a reinforced elevated reservoir in accordance with the present disclosure.
Figure 2 illustrates a ground level part of the elevated storage reservoir in accordance with the present disclosure.
Figure 3 illustrates a ring beam and column that can be used at level 1 and 2 of the elevated storage reservoir in accordance with the present disclosure.
Figure 4 illustrates a frame structure in ‘H’ shape in accordance with the present disclosure.
Figure 5 illustrates a base slab for the elevated storage reservoir in accordance with the present disclosure.
Figure 6 illustrates a wall of the elevated storage reservoir in accordance with the present disclosure.
Figure 7 illustrates the connections between the tank base slab and the H frame in accordance with the present disclosure.
Figure 8(a) illustrates a the connections done at the interface of the foundation, pedestal, beam and column in accordance with the present disclosure.
Figure 8(b) illustrates the connections at interface of the beam and the column in accordance with the present disclosure.
Figure 9 illustrates a manner in which the wall rings are connected in accordance with the present disclosure.
Figure 10 illustrates a method for rapid construction of precasted reinforced elevated reservoirin accordance with the present disclosure.

DETAILED DESCRIPTION
Embodiments, of the present disclosure, will now be described with reference to the accompanying drawings.Embodiments are provided so as to thoroughly and fully convey the scope of the present disclosure to the person skilled in the art. Numerous details are set forth, relating to specific components, and methods, to provide a complete understanding of embodiments of the present disclosure. It will be apparent to the person skilled in the art that the details provided in the embodiments should not be construed to limit the scope of the present disclosure. In some embodiments, well-known processes, well-known apparatus structures, and well-known techniques are not described in detail.
The terminology used, in the present disclosure, is only for the purpose of explaining a particular embodiment and such terminology shall not be considered to limit the scope of the present disclosure. As used in the present disclosure, the forms "a,” "an," and "the" may be intended to include the plural forms as well, unless the context clearly suggests otherwise. The terms "comprises," "comprising," “including,” and “having,” are open ended transitional phrases and therefore specify the presence of stated features, integers, steps, operations, elements, modules, units and/or components, but do not forbid the presence or addition of one or more other features, integers, steps, operations, elements, components, and/or groups thereof. The particular order of steps disclosed in the method and process of the present disclosure is not to be construed as necessarily requiring their performance as described or illustrated. It is also to be understood that additional or alternative steps may be employed.When an element is referred to as being "mounted on," “engaged to,” "connected to," or "coupled to" another element, it may be directly on, engaged, connected or coupled to the other element. As used herein, the term "and/or" includes any and all combinations of one or more of the associated listed elements.
The terms first, second, third, etc.,should not be construed to limit the scope of the present disclosure as the aforementionedtermsmay be only used to distinguish one element, component, region, layer or section from another component, region, layer or section. Terms such as first, second, third etc., when used herein do not imply a specific sequence or order unless clearly suggested by the present disclosure.Terms such as “inner,” “outer,” "beneath," "below," "lower," "above," "upper," and the like, may be used in the present disclosure to describe relationships between different elements as depicted from the figures.
The present invention relates to a construction system and a method for staging of the reinforced concrete elevated reservoirs. Particularly, the system and the method involve rapid construction technology for construction of reinforced concrete elevated reservoirs used in the storage of a liquid.
The present invention relates to a construction system and a method for construction of precasted reinforced concrete elevated reservoirs. Reinforced concrete elevated reservoir is employed for the storage of liquids, particularly water. The existing method and a system used for staging of a concrete elevated reservoir requires skilled personnel, high cost, time consuming and no stringent control on quality is observed. The present invention overcomes the hurdle by providing a system and a method that utilizes the rapid construction technology. The present method of construction of elevated service reservoir i.e. cast in situ method requires very high quality safety precautions. Otherwise there are high chances of accidents and loss of human life.
The present invention is typically applied to the construction of reservoirs for storage of a fluid such as water where the fluid is collected and stored so that it may be drawn off for later use. Figure 1 depicts non-limiting examples of a reinforced elevated reservoir, which utilizes the present invention. The reinforced concrete elevated reservoir features a reservoir (vessel) with a precasted steel reinforced concrete, a supporting structure with a precasted steel reinforced concrete and a foundation. The reservoir (vessel) and the supporting structure comprises of a beam form assembly and a column form assembly. The column form assembly is preferably cast of concrete reinforced with steel wire or bars. The column form assembly may take alternate shapes and proportioned column form assemblies are within the scope of the present invention. The entire elevated reservoir structure can be divided into four levels, namely, ground level, level 1, level 2 and level 3. All the elements of the elevated reservoir can be casted within 10 working days using a single table mould and a single cylindrical mould.
Figure 2 represents a ground level part of the elevated storage reservoir. It comprises of a precast footing (100) with pedestal casted as one precast unit, a precast column (102) erected on top of the ring beam (101).
Figure 3 represents a ring beam and column that can be used at level 1 and 2 of the elevated storage reservoir. It comprises of a ring beam (101) and a cantilever slab (103) that can be casted on a table mould.
Figure 4 represents a frame structure that can be a single piece of a frame in ‘H’ shape. The beam cross-section for the same can be less than 500mm x 500 mm and has an outside dimension less than 3.5 m x 6.50 m.
Figure 5 represents a base slab for the elevated storage reservoir comprising of three solid slab pieces of which two are identical. All the three pieces can be erected on top of the H frame. All the pieces are tied through 75 mm thick structural topping. No propping is required during installation.
Figure 6 shows a wall of the elevated storage reservoir. The wall comprises of a plurality of cylindrical pieces resting against each other. A cylindrical mould is required for the preparation of these pieces. Every cylindrical piece may weigh in the range of 6-7 T and has a wall thickness less than 250 mm.
Figure 7 shows the connections between the tank base slab and the H frame. Dowels from H-Frame pass through solid slabs and grouted after erection of solid slabs. Bars are bent and overlapped with topping mesh before pouring concrete. There is also a provision of the shear key to connect the tank base slab to the other base slab. This ensures the monolithic behaviour. While connecting the tank base slab with the column and the beam, dowels from the columns pass through the precast beam through dowel tube (which is grouted after erection of beams) then bent to overlap with topping mesh after erection of solid slab and before casting of structural topping.
Figure 8(a) shows the connections done at the interface of the foundation, pedestal, beam and column. Grout based coupler which is connected with column rebars receives dowel bar below. It is grouted after erection of columns. Side propping of columns is required till grout gains 75% strength. Dowel bars pass through the beam through corrugated dowel tube which is grouted after erection of plinth beam.
Figure 8(b) represents the connections at interface of the beam and the column. Dowel bars pass through the beam through corrugated dowel tube which is grouted after erection of plinth beam. Grout based coupler which is connected with column rebars receives dowel bar below. It is grouted after erection of columns. Side propping of columns is required till grout gains 75% strength.
Figure 9 shows the manner in which the wall rings are connected. The wall rings are placed one on top of another with dowel tubes aligned. 9.6Ø strand is passed through these dowel tubes upto bottom of solid slab where it is anchored. Post tensioning is done after erection of wall is completed. All the dowel tubes are filled with grout. There is also an arrangement to achieve the locking between the wall rings. Where walls are resting on top of one another, a shear key is provided to ensure better monolithic behaviour.
Further Figure 10 shows the method (200) for rapid construction of precasted reinforced elevated reservoir comprising
construction of a pre-casted components including a column form assembly and a beam form assembly (201);
assembling of the prefabricated assembly components to provide a permanent concrete mold (202); and
casting concrete in the permanent concrete mold to provide the cast in place concrete structure (203);
such that the permanent concrete mold has integrated structural reinforcement and structural splices for a cast in place concrete structure.

TECHNICAL ADVANCEMENTS
The present disclosure described herein above has several technical advancements including, but not limited to, the realization of:
The embodiments herein and the various features and advantageous details thereof are explained with reference to the non-limiting embodiments in the above description.
Descriptions of well-known components and processing techniques are omitted so as to not unnecessarily obscure the embodiments herein.
• increased construction speed due toreduction in time required for the construction of reinforced concrete elevated reservoir by 80% leading to increased productivity;
• reduction of construction cost required for reinforced concrete elevated reservoir;
• removes on-site casting needs like setting up steel forms, bending and positioning rebar, pouring and vibrating concrete and then waiting for the concrete to cure;
• better in strength as compared to the reinforced concrete elevated reservoirs which are constructed in situ due to specific alignment of the precasted components and filling of joints with cementitious grout and controlled curing process;
• high quality control due to construction of components offsite, inspection by skilled manpower offsite;
• useful for rural areas where there is scarcity of skilled manpower;
• efficient and durable structure that can resist the seismic forces and very high wind forces; and
• reduces the risk to human life in the existing method of constructions i.e. cast in situ.
The many features and advantages of the invention are apparent from the detailed specification, and thus, it is intended by the appended claims to cover all such features and advantages of the invention which fall within the true spirit and scope of the invention. Further, since numerous modifications and variations will readily occur to those skilled in the art, it is not desired to limit the invention to the exact construction and operation illustrated and described, and accordingly, all suitable modifications and equivalents may be resorted to, falling within the scope of the invention.
The embodiments, examples and alternatives of the preceding paragraphs or the description and drawings, including any of their various aspects or respective individual features, may be taken independently or in any combination. Features described in connection with one embodiment are applicable to all embodiments, unless such features are incompatible.
The preferred embodiments of the present invention are described in detail above. It should be understood that ordinary technologies in the field can make many modifications and changes according to the concept of the present invention without creative work. Therefore, all technical solutions that can be obtained by those skilled in the art through logical analysis, reasoning or limited experiments based on the concept of the present invention on the basis of the prior art should fall within the protection scope determined by the claims.

,CLAIMS:WE CLAIM:
1. A system for construction of precasted reinforced elevated reservoir comprising:
a reservoir with a precasted steel reinforced concrete;
a supporting structure with a precasted steel reinforced concrete; and
a foundation.

2. The system for construction of precasted reinforced elevated reservoir as claimed in claimed in claim 1, wherein said reservoir and said supporting structure comprises of a beam form assembly and a column form assembly to construct cast in place structurally reinforced concrete columns, beams and floor slabs.

3. The system for construction of precasted reinforced elevated reservoir as claimed in claimed in claim 1, wherein connections involved in said systems comprise beam to column, beam to beam, column to column and column to the base.

4. The system for construction of precasted reinforced elevated reservoir as claimed in claimed in claim 1, wherein said beam form assembly and said column form assembly comprise precast of concrete reinforced with steel wire or bars.

5. The system for construction of precasted reinforced elevated reservoir as claimed in claimed in claim 1, wherein said beam form assembly and said column form assembly take alternate shapes and are proportioned.

6. The system for construction of precasted reinforced elevated reservoir as claimed in claimed in claim 1, wherein the pre-casted components comprise a shaped form and an integrated structural reinforcement.

7. The system for construction of precasted reinforced elevated reservoir as claimed in claimed in claim 1, wherein the shaped form material is concrete comprising of cement, water, sand, aggregate chemical admixtures and a reinforcing matrix.

8. The system for construction of precasted reinforced elevated reservoir as claimed in claimed in claim 7, wherein said reinforcing matrix comprises of steel wire or steel fibre.

9. The system for construction of precasted reinforced elevated reservoir as claimed in claimed in claim 6, wherein said integrated structural reinforcement comprises of steel bars, steel wire, steel sheets or steel fibre.

10. The system for construction of precasted reinforced elevated reservoir as claimed in claimed in claim 6, wherein said integrated structural reinforcement is applied to the shaped form and partially exposed, for subsequent reinforcement of an additional concrete infill.

11. The system for construction of precasted reinforced elevated reservoir as claimed in claimed in claim 6, wherein said integrated structural reinforcement which is applied to the shaped form by casting or by fastening.

12. The system for construction of precasted reinforced elevated reservoir as claimed in claimed in claim 1, wherein said supporting structure comprise the column form assembly and the beam form assembly with a base slab locked into the H frame with a beam cross-section less than 500mm x 500 mm and outside dimension less than 3.5 m x 6.50 m.

13. The system for construction of precasted reinforced elevated reservoir as claimed in claimed in claim 1, wherein said reservoir is constructed as interlocked precasted concrete rings.

14. The system for construction of precasted reinforced elevated reservoir as claimed in claimed in claim 1, wherein said reservoir comprises mixed oxides of metals from zinc and aluminium.

15. The system for construction of precasted reinforced elevated reservoir as claimed in claimed in claim 1, wherein the prefabricated assembly components comprise of keying geometries adapted for restricting improper assembly on-site.

16. A method (200) of construction of the elevated reservoir comprising steps of:
construction of a pre-casted components including a column form assembly and a beam form assembly (201);
assembling of the prefabricated assembly components to provide a permanent concrete mold (202); and
casting concrete in the permanent concrete mold to provide the cast in place concrete structure (203);
such that the permanent concrete mold has integrated structural reinforcement and structural splices for a cast in place concrete structure.

17. The method of construction of the elevated reservoir as claimed in claim 16, wherein,said casting of components are assembled to give final structure for precasted and prefabricated column form assembly.

18. The method of construction of the elevated reservoir as claimed in claim 16, wherein, said precasted and prefabricated beam form assembly is done in casting yards under controlled environmental conditions to provide favourable conditions for the chemical process involved in concrete formation and curing of concrete.

19. The method of construction of the elevated reservoir as claimed in claim 16, wherein, said precasted column form assembly and precasted beam form assembly in specific alignments and level to construct the strong structure.

20. The method of construction of the elevated reservoir as claimed in claim 16, wherein, said precasted column form assembly and precasted beam form assembly are casted as a whole structure at a casting yard and plurality of precasted components are assembled as a centre point where there is a minimal stress by dry joints.

21. The system for construction of precasted reinforced elevated reservoir as claimed in claimed in claim 1, wherein said reservoir is for the storage of fluid with capacity of 10,000 litres to 50 lakh litres and staging height of 6 meters to 30 meters.