Composite Floor with Prefabricated Panels for Wider Spans
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Solution Overview
Problem
There is a desire in construction to produce shallower floor cross-sections and wider span floors between supporting columns in steel-concrete composite construction, while maintaining structural integrity and load-bearing capacity.
Innovation Solution
A composite floor design featuring spaced apart metal beams with prefabricated concrete panels supported by the beams and embedded with reinforcing elements, where the panels have elongate side members and a concrete main body with ribs and attachment members, allowing for efficient construction with reduced self-weight and increased span capabilities.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Length of moving object
If traditional steel-concrete composite construction methods are used, then structural integrity and load-bearing capacity are maintained, but floor cross-section depth increases and span capability is limited
Solution Approach 1:
The floor construction is segmented into distinct components: steel beams, prefabricated concrete panels, and concrete infill. The prefabricated panels are manufactured separately with integrated reinforcement and seating features, allowing for optimized design of each component. This segmentation enables the creation of shallower floor sections while maintaining span capability, as each segment can be independently optimized for its specific function.
Solution Approach 2:
The invention transitions from traditional vertical stacking of floor components to a more integrated three-dimensional arrangement. The prefabricated panels incorporate vertical ribs and seating features that engage with the steel beams in multiple dimensions, creating a composite structure that achieves greater span capability with reduced depth by utilizing spatial efficiency in three dimensions rather than simple vertical accumulation.
2Productivity
If prefabricated panels are used to reduce construction time, then productivity increases, but manufacturing precision requirements increase
Solution Approach 1:
The prefabricated concrete panels are manufactured in advance with all reinforcement, ribs, and seating features integrated during the casting process. This preliminary action allows for controlled factory conditions where precision can be maintained more easily than on-site construction. The panels arrive ready for installation, significantly improving construction productivity while the factory setting enables consistent quality control.
Solution Approach 2:
The invention changes the state of the concrete from plastic to hardened during the prefabrication process. By casting the panels in a controlled factory environment where concrete parameters (temperature, humidity, curing time) can be precisely controlled, the manufacturing precision is improved. The concrete is cast with the reinforcement and features in place, then cured under optimal conditions before delivery to site, reducing the precision demands on the construction phase.
3Weight of moving object
If self-weight of composite construction is reduced, then span capability and building height increase, but structural strength may be compromised
Solution Approach 1:
The invention employs a composite construction combining steel beams with prefabricated concrete panels and concrete infill. The steel provides high strength-to-weight ratio, while the concrete panels and infill add mass and strength. This composite approach reduces overall self-weight compared to traditional all-concrete construction while maintaining or enhancing structural strength through the synergistic combination of materials with complementary properties.
Solution Approach 2:
The structure uses local quality by concentrating reinforcement and material where needed rather than uniformly throughout. The prefabricated panels have vertical ribs and integrated reinforcement at critical locations, and the concrete infill is placed specifically in gaps and at connection points. This localized concentration of material provides structural strength where required while minimizing overall self-weight in non-critical areas.
Data Source
AI summary
A composite floor comprises a plurality of spaced apart beams, at least one prefabricated panel being situated between and supported by adjacent spaced apart beams. A layer of concrete may be cast in-situ, the layer of concrete overlying the at least one prefabricated panel and at least a part of each of the beams supporting the at least one panel.