Anchor Rail Retaining Bracket with Breakaway Flange
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Solution Overview
Problem
Existing methods for installing anchor rails in concrete structures face challenges such as nail-related injuries, rust, and complex assembly due to the use of nails for fixing and removing formwork components, which complicate the installation process and leave behind hazardous and unsightly remnants.
Innovation Solution
An anchoring element featuring an anchor rail with multiple anchor webs and a strip-shaped receptacle, secured by retaining clips that allow for indirect attachment to formwork components via flanges connected to fixing elements like nails or staples, which can be easily removed without leaving residues in the concrete.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If nails are used to fix the anchor rail to the formwork component, then the anchor rail can be securely positioned, but the nails remain in the concrete after formwork removal causing safety hazards and rust
Solution Approach 1:
The retaining bracket is divided into a permanent part (attached to anchor rail) and a temporary part (flange with fixing element). The flange is connected via a predetermined breaking point that allows it to break off during formwork removal, separating the temporary fixing function from the permanent anchoring function.
Solution Approach 2:
The fixing element (nail) is extracted from the final concrete structure by designing the flange to break off during formwork removal. The fixing element remains attached to the temporary flange portion which is removed along with the formwork, leaving no nails in the concrete.
2Reliability
If nails are inserted into small openings in the anchor rail, then the anchor rail can be fixed to the formwork, but the installation process becomes time-consuming
Solution Approach 1:
The retaining bracket acts as an intermediary component between the anchor rail and the formwork. It provides larger flanges that are easier to access and fix to the formwork compared to directly inserting nails into small openings in the anchor rail, thereby speeding up installation.
Solution Approach 2:
The fixing interface is moved from the one-dimensional small openings in the anchor rail to the two-dimensional flange surface of the retaining bracket. This dimensional change allows for easier access and faster fixation using standard nail guns.
3Strength
If flanges with large thickness are used in the retaining bracket, then the structural strength is improved, but the indentation in concrete after removal becomes significant
Solution Approach 1:
The flange thickness is optimized to a specific range (1-5 mm) that balances structural strength during installation with minimal indentation after removal. This parameter optimization ensures the flange is strong enough to facilitate installation but thin enough to create negligible visual impairment when removed.
Data Source
Figure 1
Figure 2A~2C
Figure 3A~3C
AI summary
An anchoring element for casting in concrete comprises an anchor rail (1), which has a plurality of anchor protrusions (2), and a strip-shaped receptacle for mounting fastening means, at least one retaining bracket (20) being fixed to the anchor rail (1), by means of which retaining bracket the anchor rail (1) can be fastened to a formwork component (10). Furthermore, at least one flange (22) laterally protruding from the anchor rail (1) is formed on the retaining bracket (20), which flange is connected to a central portion (21) of the retaining bracket (20) by means of a predetermined breaking point (24) and thus can be easily removed. Thus, the anchoring element can be fixed to a formwork component using simple means. A method for mounting an anchor rail in a construction element made of concrete is also provided.