Composite Wall Cantilever Rods Reduce Prefab Weight
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Solution Overview
Problem
The existing composite walls have thick prefabricated concrete parts, making them heavy and difficult to integrate decorative and thermal insulation layers, which leads to construction inefficiencies and potential damage during handling.
Innovation Solution
A composite wall design featuring a core concrete layer with an outer cantilevered decorative layer, an inner cantilevered formwork, a pre-perforated thermal insulation layer, and a reinforcement cage, all connected through precast adhesive layers and cantilever rods, allowing for reduced concrete thickness and easier integration of insulation and decoration.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the thickness of prefabricated concrete part is increased to avoid damage during handling and transportation, then the strength and reliability are improved, but the self-weight increases and construction efficiency decreases
Solution Approach 1:
The wall body is divided into two separate panels (first panel and second panel) that are prefabricated independently and then connected through reinforcement cages and grout injection. This segmentation allows each panel to be optimized for thinness while maintaining overall structural integrity through the connection system, reducing the need for excessively thick individual concrete sections.
Solution Approach 2:
The invention uses a composite structure combining concrete panels with steel reinforcement cages and grout material. The reinforcement cages provide tensile strength while the concrete provides compressive strength, creating a composite system that achieves high strength-to-weight ratio. This allows thinner panels to maintain adequate strength and damage resistance during handling.
2Strength
If the thickness of prefabricated concrete part is increased to ensure structural integrity, then the strength is improved, but the construction efficiency and productivity decrease
Solution Approach 1:
By segmenting the wall into two separate prefabricated panels connected by reinforcement cages and grout, the invention enables parallel production of panels in the prefabrication stage. This segmentation allows for faster overall construction as panels can be prepared simultaneously and assembled quickly on-site through the connection system, improving productivity while maintaining structural integrity.
Solution Approach 2:
The reinforcement cages are pre-installed within the concrete panels during prefabrication, and the connection details are prepared in advance. This preliminary action ensures that when panels are assembled on-site, the structural integrity is immediately established through the pre-positioned reinforcement system, eliminating the need for time-consuming on-site reinforcement work and improving construction efficiency.
3Adaptability or versatility
If the composite wall structure is designed to accommodate decorative and thermal insulation layers, then the adaptability is improved, but the structural complexity increases
Solution Approach 1:
The outer surfaces of the prefabricated concrete panels are designed with universal characteristics that can accommodate various decorative finishes and thermal insulation layers. The panels serve multiple functions: structural support, base for insulation, and substrate for decoration. This multi-functionality is achieved through the flat, stable surface provided by the precast panels, which can receive different cladding and insulation systems without requiring fundamental structural changes, thereby improving adaptability while keeping the basic structure relatively simple.
Data Source
AI summary
The present application relates to the technical field of building walls and provides a composite wall being lightweight, easy to be prefabricated and convenient for on-site construction. By making the composite wall such that a decorative layer and a formwork are overhung on both sides of a core concrete layer, it is formed a structure similar to a core-wall and steel structure that has rigidity and is elastically deformable. A thermal insulation layer is filled between the decorative layer and the core concrete layer which are connected by a precast outer cantilever rod. The amount of concrete in the prefabricated part of the composite wall is greatly reduced. The composite wall does not require flipping in the prefabrication process and has a significantly shortened production cycle.