Construction apparatus and construction method

Abstract: A construction apparatus comprising a framework (103) installed above a completed structure of a building (100) so as to form a working space for construction work including installing permanent columns (106) over the completed structure, guide posts detachably held on the completed structure, elevating and locking mechanisms (150) provided on the framework for elevating the framework to form the working space (114) and for locking the framework to the guide posts, and construction means mounted on the framework and capable of carrying out the construction work in the working space. The framework (103) is provided with a cover (116) for covering the working space. A construction method of constructing a multistory building in ascending order of stories, comprising steps of elevating a framework (103) placed on a completed structure (110) of the building to form a working space (114) over the completed structure, locking the framework at an elevated position to the completed structure, sequentially installing permanent columns (106) in the working space, installing beams (107) between the fixed permanent columns (106), executing construction work in a structure formed of the permanent columns (106) and the beams (107), and disengaging the framework (103) from the completed structure. The construction apparatus and the construction method can be fabricated at a reduced cost and, in constructing multistory buildings, and the construction apparatus saves labor and enables the uninterrupted execution of construction work regardless of weather conditions. The construction apparatus is sufficiently resistant to earthquakes.

Description: The present invention relates to a construction apparatus and a construction method advantageously applicable to carrying out the construction of various structures including low buildings and high buildings using the least necessary labor and capable of enabling the construction work to be carried out regardless of weather conditions. In constructing a multistory building, a conventional construction method erects columns for all the stories, lifts up the component members of the multistory building preassembled on the ground including slabs by lifting machines including cranes, and then joins the component members to the columns. Another conventional construction method stacks up stories one on another by completing a lower story, and then lifting the component members of an upper story by lifting machines including cranes and assembling the component members on the lower story. Fig. 1 is an illustration of the latter conventional construction method, in which the first and second stories of a building have been completed and the third story is under construction. A worker H standing on the floor of the third story receives building members S lifted by a crane C, and then the worker H assembles the building members S by fixing the building members S at predetermined positions by suitable means including welding and bolts. J. P. Pat. Provisional Pub. (Kokai) No. 62-244941 proposes a construction method which completes one story of a building in a plant installed in the first story of the building by using machines including industrial robots, and then pushes up the complete story by a distance corresponding to the story height. This procedure is repeated to complete a multistory building. In constructing a multistory building by the foregoing conventional construction method which erects all the columns first, and then assembles the building components lifted up by lifting machines and the other conventional construction method which constructs the stories of a multistory building one by one from the lower stories to the upper stories require, much time and labor is necessary, the progress of the construction schedule is dependent on weather conditions, the construction period is often extended due to various restrictions (for example not to work at night), and various measures must be taken for the safety of the workers. Although the construction method proposed in J. P. Pat. Provisional Pub. (Kokai) No. 62-244941 solves most of those problems involved in the foregoing conventional construction methods, this construction method has a problem that the height of the building is limited by the strength of the supporting members for pushing up a completed story of the building in view of the weight of the building and so on. Furthermore, since the weight supported by the supporting members during the construction work increases with the progress of the construction work and the plant is installed on to the ground floor, it is possible that the stability of the support of the completed stories against earthquake deteriorates with the progress of the construction work. DE-C-929089 describes a protective hut with working platforms and conveying devices which can be used around a transverse wall of a building under construction. It comprises four hydraulically adjustable supports to enable its height to be altered according to the progress of the work. Further prior art references relate to frameworks disposed above completed structures of a building under construction to provide working areas under the framework. In DE-A-2917972 extensible columns 11 are rigidly connected to the building foundation, and additional columns are stacked above them. FR-A-2214019 recites extension means which extend upwards on installation of permanent columns on the extended structure. In FR-A-862806 a roof is supported by a rack mounted on the building walls. Accordingly, it is an object of the present invention to provide a construction apparatus and a construction method advantageously applicable to the construction of various structures including high and low buildings requiring the least necessary labour and low costs. It is another object of the present invention to provide a construction apparatus and a construction method capable of enabling construction work to be carried out regardless of weather conditions. It is a further object of the present invention to provide a construction apparatus and a construction method capable of securing sufficient resistance to earthquakes for a structure under construction. Accordingly the invention provides a construction method of constructing a multistory building in ascending order of stories by sequentially repeating steps of: elevating a framework construction placed on a completed structure of the building to form a working space over the completed structure; locking the framework construction to the completed structure at an elevated position; sequentially placing and fixing permanent columns on the completed structure in the working space; executing construction work in a structure formed by the permanent columns to complete the structure; unlocking the framework construction from the completed structure after finishing construction work; and sequentially repeating the steps in that order to construct the next upper structure and characterised by a step of installing beams between the permanent columns after the fixing of the permanent columns and before the execution of construction work; and in that the framework construction is elevated along guide posts fixed to the completed structure, each guide post having a rack and the elevating and locking means comprising pinions located on the framework construction. The invention also provides a construction apparatus comprising: a framework construction installed above a completed structure of a building; characterised in that the construction apparatus further comprises: guide posts detachably held upright on the completed structure of the building; elevating and locking mechanisms provided on the framework construction to elevate the framework construction along the guide posts to form the working space over the completed structure of the building for construction work including the installation of permanent columns, and to lock the framework to the guide posts so that the framework construction can be fixed to the completed structure of the building; and construction means provided on the framework to execute the construction work in the working space. The elevating and locking means provided on the framework are fastened to the columns supported on the columns to hold the framework firmly on the underlying completed structure. Since the elevating and locking means are locked to the columns during construction work within the working space, the vibration resistance of the construction apparatus can be sufficiently secured throughout the construction work. In forming another working space over the next upper structure, the elevating and locking means are unlocked, the framework is elevated along the columns to form another working space, and then the elevating and locking means is locked again to the columns. When the elevating and locking means are locked to the columns, the columns serve as members for forming the working space to support the framework. Then, permanent columns are erected one by one in the working space and beams are joined firmly to the permanent columns by construction means to complete a structure for the next upper story on the underlying completed structure. Such a construction work including forming a working space and constructing a structure is repeated to construct structures for the upper stories sequentially. Thus, the construction work is advanced upward in steps by alternately repeating the elevation and locking of the framework to form working spaces sequentially. In thus carrying out the construction work by regularly advancing the working space upward in the foregoing manner and constructing a structure by using the construction means provided on the framework, the elevation of the framework and the operation of the construction means can be easily controlled automatically, and the construction apparatus, in cooperation with automatic construction equipments, enables automatic construction work. The framework is provided with a covering for covering the working space to shield the working space from the outside, and hence the construction work can be carried out regardless of weather conditions without giving public nuisance to the environment. Furthermore, the columns are provided with racks respectively, and the elevating and locking means are provided with pinions respectively. The combination of the columns and the elevating and locking means may be a screw-and-rod mechanism, a center hole jack mechanism or a hydraulic jack mechanism. The construction means include column erecting robots, column welding robots, beam welding robots and external wall installing robots. The columns may be either temporary columns or permanent columns. The framework may be provided with traveling cranes and construction robots mounted on the traveling cranes. In some cases the traveling cranes and the construction robots are controlled on a cylindrical coordinate system or a polar coordinate system. Lifts for lifting up construction materials may be installed in the internal space of the structure, and each lift may be provided with a rotary floor to unloaded the construction materials selectively at a desired position. A control room may be constructed in the upper space of the framework. Figure 1 is a pictorial view of assistance in explaining a conventional construction method; Figures 3(A) and 3(B) are fragmentary sectional views of essential portions of extension columns (extension means) and holding mechanisms employed in the construction apparatus embodying the present invention; Figures 5(A) to 5(G) are schematic perspective views of assistance in explaining the principle of a construction apparatus according to the present invention; Figure 6 is a partially cutaway schematic perspective view of the construction apparatus according to the present invention as applied to an actual construction work; Figure 7 is a schematic sectional view taken in Fig. 6. The principle on which a construction apparatus according to the present invention is based will be described with reference to Figs. 5(A) to 5(G) prior to the description of the construction apparatus. The construction apparatus comprises, as the essential components, a framework construction 103 installed above a completed structure of a building 110 to form a working space 114 in which permanent columns 106 are installed and the construction work is carried out over the completed structure of the building 110, guide posts 140 removably supported on the completed structure of the building 110, elevating and locking mechanisms 150 provided on the framework construction 103 to lock the framework 103 to the guide posts 140 so that the framework construction 103 can be fixed to the completed structure of the building 110 and to elevate the framework construction 103 in forming the working space 114 between the framework construction 103 and the completed structure of the building 110, extension devices 101 provided on the framework construction 103 and capable of extending downward to press the permanent columns 106 against the completed structure of the building 110, and construction equipments for the construction work in the working space 114. The construction equipments include a column welding robot 104, a column installing robot 109, a beam welding robot 112, and a wall installing robot, not shown. The framework construction 103 may be provided with a cover 116 for covering the working space 114. Each of the guide posts 140 is provided longitudinally with a rack 141. Each of the elevating and locking mechanisms 150 comprise a pinion 151 engaging the rack 141. In a typical example of the construction apparatus shown in Figs. 5(A) to 5(G), four extension devices 101 are hydraulic cylinders each having a rod 102 capable of moving by a stroke slightly greater than the story height of the building 110. The hydraulic cylinders may be substituted by the device shown in Fig. 3(A) or 3(B). Fig. 3(A) shows a combination of a rod 2 provided with a rack 20 along the entire length thereof, a sheath 13 fixed to the framework 3 and slidably receiving the rod 2 therein, and a pinion 21 rotatably supported on the sheath 13 and engaging the rack 20 to extend or contract the rod 2 along the sheath 13. Fig. 3(B) shows a combination of a rod 2 externally provided with helical thread 22, and a sheath 13 internally provided with a helical groove 23 engaging the helical thread 22 of the rod 2, which is similar to a screw jack. The rod 2 is extended or contracted by rotating the rod 2 relative to the sheath 13. The shape of the framework 103 is substantially the same in the plan as that of the top surface of the building 110. In this example, the framework 103 is rectangular in the plan. The extension devices 101 are attached to the framework 103, respectively, at the four corners of the same. A travelling crane 105 is mounted on the opposite frame members 103a and 103b of the framework 103, and one of the construction equipments, for example the column installing robot 109, is held on the traveling crane 105. The guide posts 140 are set upright, fastened temporarily at the lower ends thereof to beams of the completed structure of the building 110, and slidably received through guide rings 131 provided on pairs of frame members 103c and 103d, respectively. The racks 141 are welded to the guide posts 140 in suitable pitches so as to extend longitudinally along the guide posts 140, respectively. The pinions 151 are provided on the frame members 103d so as to engage the racks 141. Each pinion is driven by a driving source such as a motor. The rack 141, the pinion 151 and the driving source constitute the elevating and locking mechanism 150. Each of the elevating and locking mechanisms 150 may be a screw rod mechanism, a center hole jack mechanism or a hydraulic jack mechanism. Thus, the framework 103 of the construction apparatus is held securely relative to the completed structure of the building 110 by the engagement of the pinions 151 of the elevating and locking mechanisms 150 with the racks 141 fixed to the guide posts 140 supported on the completed structure of the building 110. The firm connection of the elevating and locking mechanisms 150 and the guide posts 140, namely, the engagement of the racks 141 and the pinions 151, secures sufficient resistance to vibration, for example earthquakes, for the construction apparatus. The framework 103 is elevated by driving the pinions 151 of the elevating and locking mechanisms 150 to form the working space 114 over the completed structure of the building 110, and the rods 102 of the extension columns 101 are fully retracted to form spaces 115 for receiving permanent columns 106 directly below the rods 102 as shown in Fig. 5(A). The permanent columns 106 are installed, respectively, in the spaces 115 by the column installing robot 109 as shown in Fig. 5(B). As shown in Fig. 5(C), the permanent column 106 is positioned correctly since the rod 102 of one of the extension columns 101 is extended slightly to press the permanent column 106 at the upper end 106a thereof against the upper end of a corresponding member of the completed structure of the building 110, and then the lower end of the permanent column 106 is welded to the upper end of the corresponding member of the completed structure of the building 110 by the welding robot 104 held on the traveling crane 105. Although the stroke of the rods 102 of the extension columns 101 may be as small as a value sufficient to press the permanent columns 106 against the completed structure of the building 110, the stroke is set as large as the story height of the building 110 to enable the extension columns 101 to serve as temporary columns for supporting the framework 103 on the completed structure of the building 110 in this embodiment. Then, as shown in Fig. 5(D), the adjacent permanent column 106 is installed and fixed in place in the same manner Then, as shown in Fig. 5(E), beams 107 previously joined to the adjacent permanent columns 106 so as to extend toward each other are welded together by the welding robot 112 held on the traveling crane 105. It is also possible to place a beam 107 having a length corresponding to the span between opposite beam joints attached to the opposite sides of the adjacent permanent columns 106 and to weld the beam 107 to the beam joints by the welding robot 112. The foregoing construction procedure is repeated to complete the skeleton of an upper story on the previously completed structure of the building 110 by fixedly installing all the permanent columns 106 and joining together the beams 107 as shown in Fig. 5(F). Subsequently, the guide posts 140 are raised to positions shown in Fig. 5(G), and then finishing work necessary for completing the story is carried out to complete the upper story. The finishing work includes setting external walls 111 on the skeleton (Fig. 6), installing partitions, constructing booths including a service room, a bathroom and a lavatory, installing utensils and equipments, flooring the slabs and hanging the ceiling. After completing the story, the elevating and locking mechanisms 150 are driven to elevate the framework 103 as shown in Fig. 5(A) to form a working space 114 for constructing the next upper story. The next upper story, similarly to the underlying story, is constructed by carrying out the steps of the construction procedure as illustrated in Figs. 5(A) to 5(G). The construction procedure is repeated a number of times corresponding to the number of stories of the building 110 to construct upper stories on the lower stories one by one. After the uppermost story of the building 110 has thus been completed, the construction apparatus including the framework 103 and the extension columns 101 is disassembled and removed, and then finishing work necessary for completing the uppermost story is carried out to complete the building 110. When the extension columns 101 and the framework 103 are formed of members equivalent strength to or superior one to those forming the permanent columns 106 and the beams 107, the extension columns 101 and the framework 103 may be used as the components of the uppermost story, which simplifies the work for disassembling and removing the construction apparatus. Fig. 6 is a perspective view showing the construction apparatus as applied to practical construction, in which parts like or corresponding to those previously described with reference to Figs. 3(A), 3(B) and 5(A) to 5(G) are denoted by the same reference characters, and Fig. 7 is a schematic sectional view of assistance in explaining the function of the construction apparatus shown in Fig. 6. Shown in Fig. 6 is a building 110 having the shape of a polygonal cylinder. Elevators are installed in elevator shafts formed in the internal space of the building 110 to transport construction materials including permanent columns 106 and beams 107. A framework 103 is constructed in a shape substantially the same in the plan as the building 110 and covered with a cover 116. A control room 132 is formed in a space covered with the cover 116. An operator operates a controller 133 including a computer and installed in the control room 132 for the automatic control of the construction work illustrated in Figs. 5(A) to 5(G). The permanent columns 106 provided with the beams 107 are transported from the ground to a story under construction by the elevator, not shown, installed sequentially at positions directly below the fully retracted rods 102 of the extension columns 101 by a column installing robot 109 and welded sequentially to the upper end of the permanent columns 106 of the underlying story by a column welding robot 104. The beams 107 of the adjacent permanent columns 106 are welded together by a beam welding robot 112. After all the permanent columns 106 have been thus installed in place and all the corresponding beams 107 have been welded together, construction work necessary for completing the story including setting external walls 111 is carried out by using construction robots held on the traveling crane 105. After the story has been completed, elevating and locking mechanisms 150 are driven to elevate the framework 103 to form a working space for constructing the next upper story. Then the same construction work is repeated to construct the next upper story. After all the stories of the building 110 have been completed, the construction apparatus and the control room 132 are removed, and then a roof is constructed on the uppermost story of the building 110. The framework 103 applied to the practical construction is provided with the cover 116 consisting of a temporary roof 138 and a temporary enclosure 139 to arrest noise generated by the construction work, to prevent the influence of environmental radiowaves and electromagnetic waves on electrical communication between the controller 133 installed in the control room 132 and the construction equipment including the construction robots and to shield the control room 132 and the construction space from rain and wind. Providing the cover 116 with a soundproof capability and a radiowave and electromagnetic wave intercepting capability enables maintaining the working environment in a satisfactory condition and prevents the uncontrolled operation of the controller 133 and the construction robots. As mentioned above, the extension columns 101, the rods 102 and the framework 103 can be used as the components of the building 110 if the extension columns 101, the rods 102 and the framework 103 are formed of members equivalent to or superior to the permanent columns 106 and the beams 107. The temporary roof 138 may be formed in the same construction as that of the roof of the building 110 to use the same also as the roof of the building 110. The guide posts 140 may be removed after completing the uppermost story of the building 110 or may be used as the permanent column of the story after removing the racks 141. If the guide posts 140 are intended for use as the permanent columns at positions for the coaxial permanent columns 106, the guide posts 140 may be such as having a length corresponding to the height of the building 110 and installed, respectively, or may be sectional guide posts extended section by section with the progress of the construction work. In latter case, the guide posts may be extended by lifting a sectional guide post by a crane or the line, inserting the sectional guide post through an opening 160 formed in the temporary roof 138 onto the upper end of the guide post previously constructed and joining the sectional guide post to the upper end of the guide post. It is also possible to extend the guide posts by previously setting the temporary roof 138 at a height sufficient to provide a space for extending the new sectional guide post, and adding the sectional guide post to the previous existing portion of the guide post within the working space 114. When the guide posts 140 are temporary sectional posts, each of the guide posts 140 may be extended upward by supporting the guide post 140 at a position above the lower end thereof on a base 142 placed on an auxiliary beam 107a for shifting the guide post 140, removing a portion of the guide post 140 below the position where the guide post 140 is supported on the base 142, and joining the removed portion of the guide post 140 to the upper end of the guide post 140 as indicated by an arrow a in Fig. 7. It is also possible to extend each of the guide post 140 upward by extending the rods 102 of the extension columns 101 so that the lower ends of the rods 102 are brought into firm contact with the upper ends of the previously installed permanent columns 106 to transfer the weight supported by the guide posts 140 to the permanent columns 106, driving the elevating and locking mechanisms 150 to shift the guide posts 140 upward relative to the framework 103, and seating the guide posts 140 on bases 142 placed on the beam 107 of the upper story as indicated by an arrow b in Fig. 7. The guide posts 140 of the construction apparatus in the second embodiment support only the framework 103, the cover 116 and the construction equipments mounted on the framework 103, which are far less in weight than those supported by the plant constructed on the ground in accordance with the construction method proposed in J. P. Pat. Provisional Pub. (Kokai) No. 62-244941. Accordingly, the construction apparatus of the present invention is applicable to the construction of buildings unlimited in height and has a sufficiently high earthquake resistance. The construction apparatus has the following advantages. The framework of the construction apparatus is held securely on a completed structure of a building during the construction work for constructing the next upper structure on the completed structure and hence the framework is sufficiently resistant to earthquakes throughout the construction period because the framework is locked securely to the guide posts firmly supported on the completed structure by the elevating and locking mechanisms during the construction work for constructing the next upper structure on the completed structure. The sequential upward shift of the working space formed under the framework by the cooperative operation of the elevating and locking mechanisms and the guide posts facilitates the automated control of the construction work and enables the advantageous application of automatic construction equipments to the construction work. The working space covered with the cover enables the construction work to be carried out regardless of weather conditions. The construction apparatus saves labour, and enables the uninterrupted day-and-night execution of the construction work, so that the construction period is shortened remarkably and the efficiency of the construction equipments is improved.

Claims: A construction method of constructing a multistory building in ascending order of stories by sequentially repeating steps of: elevating a framework construction (103) placed on a completed structure (110) of the building to form a working space (114) over the completed structure; locking the framework construction (103) to the completed structure (110) at an elevated position; sequentially placing and fixing permanent columns (106) on the completed structure in the working space (114); executing construction work in a structure formed by the permanent columns (106) to complete the structure; unlocking the framework construction (103) from the completed structure (110) after finishing construction work; and sequentially repeating the steps in that order to construct the next upper structure and characterised by a step of installing beams (107) between the permanent columns (106) after the fixing of the permanent columns (106) and before the execution of construction work; and in that the framework construction (103) is elevated along guide posts (140) fixed to the completed structure, each guide post having a rack (141) and the elevating and locking means (150) comprising pinions (151) located on the framework construction (103). A construction apparatus comprising: a framework construction (103) installed above a completed structure (110) of a building; characterised in that the construction apparatus further comprises; guide posts (140) detachably held upright on the completed structure (110) of the building; elevating and locking mechanisms (150) provided on the framework construction (103) to elevate the framework constructions along the guide posts (140) to form the working space (114) over the completed structure (110) of the building for construction work including the installation of permanent columns (106), and to lock the framework (103) to the guide posts (140) so that the framework construction can be fixed to the completed structure (110) of the building; and construction means provided on the framework to execute the construction work in the working space (114). A construction apparatus according to claim 2, wherein said framework construction (103) is provided with a cover (116, 138) for covering the working space. A construction apparatus according to claim 2 or 3, wherein said guide posts (140) are provided, respectively, with racks (141), and said elevating and locking mechanisms (150) are provided, respectively, with pinions (151) engaging the racks. A construction apparatus according to one of claims 2 to 4, wherein a mechanism comprising said guide post (140) and said elevating and locking mechanism (150) is of a center hold jack type. A construction apparatus according to one of claims 2 to 5, wherein said construction means is a column installing robot (109), a column welding robot (104), a beam welding robot (112) or an external wall setting robot. A construction apparatus according to one of claims 2 to 6, wherein said guide posts (140) are permanent columns. A construction apparatus according to one of claims 2 to 6, wherein said guide posts (140) are temporary columns. A construction apparatus according to claim 2 to 8, wherein a travelling crane (105) is mounted on said framework construction (103), and said construction means is held detachably on the travelling crane. A construction apparatus according to claim 9, wherein said travelling crane (105) and said construction means are controlled on a cylindrical coordinate system. A construction apparatus according to claim 9, wherein said travelling crane (105) and said construction means are controlled on a polar coordinate system. A construction apparatus according to one of claims 2 to 11, wherein said completed structure of the building is installed an elevator for transporting construction materials in the internal space thereof and the elevator has a rotary floor to discharge the construction materials in an optional direction. A construction apparatus according to one of claims 2 to 12, wherein a control room (132) is formed in the upper part of said framework construction.

Inventors: HORII SHUJI, TERAOKU HIROSHI, HORII, SHUJI, TERAOKU, HIROSHI
Applicants: OHBAYASHI CORP, OHBAYASHI CORPORATION
Application year: 1989
Main classification: E04B1
IPC codes: E04B1, E04G21