C-Shaped Channel Composite Floor Panel Formwork
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Traditional composite decking systems with in-situ reinforced concrete require formwork for setting and achieving a level floor surface, which can be cumbersome and time-consuming.
Innovation Solution
A structural panel system comprising C-shaped channels with a corrugated deck continuously welded to the channels, allowing a concrete slab to fill the interior volume and extend above the top flanges, providing a composite action that reduces the need for reinforcement and simplifies the construction process by using the channels as formwork and shear connectors.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional composite decking systems use in-situ reinforced concrete with formwork, then the concrete can set in the desired structure and create a level floor surface, but the construction process becomes cumbersome and time-consuming
Solution Approach 1:
The C-shaped channels are pre-formed with integrated formwork capabilities, allowing the concrete to be poured directly into the channels without requiring separate formwork assembly. The channels themselves serve as the formwork, eliminating the need for additional formwork materials and assembly steps while maintaining the desired structural shape and level surface.
Solution Approach 2:
The C-shaped channels serve multiple functions simultaneously: they act as structural support elements, as formwork for the concrete, and as shear connectors for composite action. This multi-functionality eliminates the need for separate formwork components and reduces the overall number of elements required in the system.
2Strength
If traditional composite decking systems use in-situ reinforced concrete, then the concrete provides structural strength, but steel reinforcement is required to increase strength properties
Solution Approach 1:
The system creates a composite structure where the C-shaped channel (steel or alternative material) works together with the concrete slab to provide structural strength. The channel and concrete act as a composite material system, where the channel provides tensile strength and the concrete provides compressive strength, eliminating or reducing the need for separate steel reinforcement within the concrete.
Solution Approach 2:
The steel reinforcement traditionally embedded within the concrete is extracted and replaced by the external C-shaped channel structure. The channel takes on the reinforcement function that would otherwise require steel bars or mesh within the concrete, simplifying the overall reinforcement system.
3Shape
If traditional composite decking systems require formwork, then the concrete can be contained and shaped, but additional materials and assembly steps are required
Solution Approach 1:
The C-shaped channels serve as both structural support elements and formwork for the concrete. The channels' C-shape naturally contains and shapes the concrete pour, eliminating the need for separate formwork materials such as plywood sheets, bracing, and fasteners that would traditionally be required to create the same structural shape.
Solution Approach 2:
The C-shaped channels are self-contained structures that inherently provide the formwork function. The channels' geometry itself creates the necessary containment and shaping for the concrete, requiring no additional formwork components. The structure serves its own formwork needs through its inherent design.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This solution enables faster construction by eliminating the need for traditional formwork, reducing the requirement for concrete reinforcement, and enhancing the structural panel's bending strength through composite action between the concrete slab and the C-shaped channels.
Implementation Method 1
The deck has a first edge continuously welded to an inner surface of the web of the first C-shaped channel and a second edge continuously welded to an inner surface of the web of the second C-shaped channel
Implementation Method 2
The interaction between the concrete slab and the first and second C-shaped channels provides a composite action
Data Source
AI summary
Disclosed herein is a structural panel, flooring system and method of constructing the flooring system. The structural panel includes two C-shaped channels, a corrugated deck extending between the first C-shaped channel and the second C-shaped channel, wherein the deck, the first C-shaped channel, and the second C-shaped channel define an interior volume, and a concrete slab substantially filling the interior volume and extending above the first and second C-shaped channels, the slab defining a top surface extending above the top flanges of the first and second C-shaped channels. The flooring system defines a first and second structural panel secured together through an interface component. A corresponding method is disclosed including abutting the two structural members, securing through the interface component, and pouring a concrete slab within the interior volume and extending above the top flanges of the first and second C-shaped channels.