Brace Bracket for Form Wall with Channel Support
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Solution Overview
Problem
Existing form bracket supports become inadequate for maintaining stationary support of form walls with heights greater than 14 inches when filled with wet concrete, due to increased weight demands from taller tilt-up concrete panels.
Innovation Solution
A brace bracket design that includes a first planar portion with a lower surface for engaging the casting platform, and second and third planar portions perpendicular to the first, configured to securely hold a form wall at various angles from horizontal, using a combination of mechanical fasteners and an open channel to accommodate a plank.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If standard brackets (plastic, wood, or metal) are used to support form walls, then the brackets are easy to manufacture and install, but they become too small, weak, and ineffective for maintaining stationary support of form walls with height greater than 14 inches when filled with wet concrete
Solution Approach 1:
The bracket is divided into multiple planar portions (first, second, and third planar portions) that are coupled together at right angles to form a multi-dimensional support structure. This segmentation allows each portion to contribute to the overall strength while distributing the structural complexity across separate functional elements.
Solution Approach 2:
The bracket transitions from a two-dimensional planar structure to a three-dimensional structure by coupling the second and third planar portions perpendicular to the first planar portion. This dimensional expansion provides additional support planes and increases the bracket's effective support strength for taller form walls.
2Productivity
If form wall height is increased to construct taller buildings, then the productivity and building height are improved, but the weight of wet concrete increases beyond the support capacity of existing brackets
Solution Approach 1:
The bracket incorporates a curved or angled edge along the side or back edge of the first planar portion, which helps distribute the load from taller form walls more effectively. This curved geometry provides structural reinforcement that enables the bracket to support greater weights of wet concrete while maintaining construction efficiency.
3Strength
If the thickness of concrete panels is increased to support taller structures, then the load-bearing capacity is improved, but the panel thickness exceeds the width of standard 2x12 boards and requires larger support structures
Solution Approach 1:
The bracket can be constructed from composite materials or multiple materials combined to achieve the necessary strength for supporting thicker concrete panels. This allows the support structure to match the increased panel thickness and load-bearing requirements without being limited by standard lumber dimensions.
Data Source
AI summary
A brace bracket may include a first planar portion, a second planar portion coupled to the first planar portion, and third planar portion coupled to the first planar portion on a front edge of the first planar portion. The brace bracket may include a first and a second facing sidewall, each facing sidewall having a facing surface disposed perpendicular to the first planar portion, the facing surfaces of the first and second facing sidewalls face each other, wherein the first and second facing surfaces and a strip area of the first planar portion located between the facing surfaces define a channel extending from the first inner edge and the second inner edge towards the back edge of the first planar portion, and wherein the channel is configured to accept a plank having a thickness. Methods of use are disclosed for securing a form wall to a casting platform.