Composite Formwork Element for Self-Supporting Beams
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Solution Overview
Problem
Conventional self-supporting beams used in floor construction often suffer from thermal bridges at the beam level, compromising thermal insulation and fire resistance, and existing solutions for improving insulation are either ineffective or laboriously complex and heavy, failing to meet modern building standards.
Innovation Solution
A formwork element with a composite material profile featuring a U-shaped cross-section, longitudinal universal fixing grooves, and modular design, which ensures continuous thermal and fire resistance by embedding reinforcement and eliminating thermal bridges, while being lightweight and easy to assemble.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional self-supporting beams are used, then structural strength is achieved, but thermal bridges are formed compromising thermal insulation and fire resistance
Solution Approach 1:
The beam is constructed using composite materials consisting of a metallic reinforcement skeleton embedded in a thermally insulating material matrix. This composite structure eliminates thermal bridges by replacing conventional homogeneous concrete beams with a multi-material system where the insulating matrix (such as expanded polystyrene, polyurethane foam, or mineral wool) prevents thermal conduction while the metallic reinforcement provides structural strength.
Solution Approach 2:
Different regions of the beam are assigned different material properties: the reinforcement skeleton provides structural strength and fire resistance, while the thermally insulating matrix provides thermal insulation. This local differentiation of material qualities allows the beam to simultaneously achieve fire resistance and eliminate thermal bridges.
2Object-affected harmful factors
If insulating structures are added under beams, then thermal insulation is improved, but the joists become heavier and assembly becomes laborious and complex
Solution Approach 1:
The thermally insulating material is integrated directly into the beam structure itself, merging the functions of structural support and thermal insulation into a single composite beam component. This eliminates the need for separate insulating structures to be added underneath the beams, thereby reducing overall weight and simplifying assembly.
Solution Approach 2:
The beam uses composite materials where the thermally insulating material is embedded within the structural framework, creating a lightweight yet insulating structure that avoids the weight penalty of traditional concrete beams with separate insulation layers.
3Object-affected harmful factors
If insulating interjoists project cantilevered to cover beams, then thermal insulation is improved, but assembly becomes laborious and thermal bridges at beam ends remain
Solution Approach 1:
The beam is segmented into distinct functional components: the metallic reinforcement skeleton for structural strength and the thermally insulating material matrix for thermal insulation. This segmentation allows each component to be optimized independently and simplifies assembly, as the insulating material is pre-integrated into the beam sections rather than requiring complex cantilevered interjoist assemblies.
4Ease of manufacture
If conventional floors are used, then construction is simple, but thermal performance does not meet new building standards
Solution Approach 1:
The beam employs composite materials that inherently provide both structural strength and thermal insulation properties, enabling the floor construction to meet modern thermal performance standards while maintaining construction simplicity through the integrated nature of the composite structure.
Solution Approach 2:
The thermal performance parameters of the beam are changed by using materials with low thermal conductivity coefficients. The thermally insulating matrix (expanded polystyrene, polyurethane foam, or mineral wool) has significantly lower thermal conductivity than conventional concrete, allowing the beam to meet new building standards without complicating the construction process.
Data Source
Figure 1~4
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Figure 8~10
AI summary
The formwork element (100) has a section (101) fixed with a metal reinforcement (200) and receiving units for partially drowning the metal reinforcement. The section is made of composite material to ensure resistance against fire of a self-supporting girder (10). A connection plate (300) is molded with the section, and fixes the formwork element with a wall element. The connection plate is made of composite material. Two side wings (150) are arranged on both sides of a sole (110). The metal reinforcement is made of series of metal bars. An independent claim is also included for a self-supporting girder, comprising a metal reinforcement.