Brace Insert Device for Concrete Panel Fastening
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Solution Overview
Problem
The existing brace inserts in tilt-up and precast concrete wall panels face issues with secure fastening due to plastic plugs being stripped or torn, hindering the insertion of metal bolts, which affects the rigidity and stability of the wall panels during construction.
Innovation Solution
A brace insert device is integrated with a fastener that is threadably engaged with an anchor insert during concrete casting, featuring a cap that conceals the fastener head, allowing access after curing to facilitate secure attachment of a wall brace without thread disruption by liquid concrete.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a plastic plug is used to cast the brace insert, then the insert can be formed in the concrete panel, but the plug is stripped or torn during removal which hinders secure bolt insertion
Solution Approach 1:
The device separates the forming function (anchor insert) from the fastening function (metal bolt with cap), eliminating the need for a plastic plug. The anchor insert provides the forming structure while the metal bolt provides reliable fastening, with the cap protecting the threads during concrete casting.
Solution Approach 2:
The cap acts as an intermediary protective element that shields the metal bolt threads from liquid concrete during casting. This prevents concrete from interfering with the threaded engagement while allowing the bolt to be securely fastened after the cap is removed.
2Ease of operation
If the fastener is exposed during casting, then it can be accessed for attachment, but liquid concrete interferes with the threaded engagement
Solution Approach 1:
The cap is installed on the metal bolt before concrete casting to preemptively protect the threads from concrete interference. This preliminary protective action ensures that the threaded engagement remains reliable while the concrete is poured and cured.
Solution Approach 2:
The cap serves as a protective intermediary between the metal bolt threads and the liquid concrete. It prevents direct contact between the concrete and threads, ensuring reliable threaded engagement while allowing the fastener to be accessed after cap removal.
3Ease of operation
If the cap is removed to access the fastener, then the wall brace can be attached, but the fastener head must be exposed which complicates the process
Solution Approach 1:
The cap is designed to be easily removed from the metal bolt after concrete curing, extracting the protective function only when needed. This simple removal action exposes the fastener head for wall brace attachment without requiring complex disassembly procedures.
Solution Approach 2:
The cap is discarded after serving its protective purpose during concrete casting. Its removal is a simple, one-time action that enables fastener access, and the discarded cap does not interfere with the subsequent wall brace attachment process.
Data Source
AI summary
A brace insert device that is configured to be cast in concrete includes an anchor insert that has a hub with a threaded inner surface and a plurality of legs extending from the hub. A fastener has a shank portion that is threadably engaged with the threaded inner surface of the hub, where a head portion of the fastener is coupled to an end of the shank portion. A cap has an inner surface that is disposed over and conceals the head portion of the fastener. The cap is configured to be removed from a cured concrete structure to expose and allow operable access to the head portion of the fastener for use in attaching a wall brace.