Composite Structural Wall Grout Bonding
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Solution Overview
Problem
Existing methods for constructing composite structural walls using prefabricated concrete modules fail to achieve the same vertical load-bearing capacity as monolithic cast-in situ walls, often requiring thicker combined walls or reduced building height, limiting design and construction flexibility.
Innovation Solution
A method involving vertically-stacking prefabricated wall panels with embedded guides and protruding rods, overlapping these guides to form channels, and filling the gaps with high-strength grout to create a monolithic composite structural wall, allowing for efficient horizontal and vertical connections of prefabricated modules.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If existing cast-in situ methods are used to construct monolithic walls, then vertical load-bearing capacity is high, but construction time and labor intensity are excessive
Solution Approach 1:
The wall is divided into multiple precast concrete segments that are manufactured separately in a factory and then assembled on-site. Each segment can be produced independently with optimized curing conditions, eliminating the time-consuming on-site formwork and curing processes while maintaining the structural integrity of the final monolithic wall.
Solution Approach 2:
The concrete segments are precast in a factory before being transported to the construction site. This preliminary action allows for controlled curing under optimal conditions, reducing the overall construction time while ensuring the segments achieve full strength before assembly.
2Productivity
If precast concrete walls are joined using existing methods, then productivity is improved, but the joined walls function as twin individual walls rather than a single monolithic wall
Solution Approach 1:
A grout mixture is introduced as an intermediary material between the precast concrete segments. The grout flows into the gaps and recesses between segments, bonding them together to form a continuous monolithic structure. This intermediary ensures that the joined walls function as a single unified wall rather than separate twin walls.
Solution Approach 2:
The design incorporates recesses and protrusions that nest together, with grout material filling the nested gaps between segments. This nesting arrangement ensures intimate contact between segments and allows the grout to penetrate and bond the interfaces, creating a true monolithic structure.
3Length of stationary object
If the combined width of individual precast walls is reduced to match monolithic wall dimensions, then vertical load bearing limit and building height are restricted
Solution Approach 1:
The grout mixture uses specific material parameters (composition, viscosity, strength) that enable it to effectively bond precast segments and transfer loads between them. By optimizing the grout's physical and mechanical properties, the combined wall achieves the same load-bearing capacity as a monolithic wall of comparable width.
Solution Approach 2:
The final wall structure is a composite of precast concrete segments and grout material. This composite construction allows the wall to achieve monolithic behavior through the combined properties of the concrete segments and the bonding grout, maintaining both dimensional efficiency and load-bearing capacity.
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
The solution enables the construction of composite structural walls with similar load-bearing capacity to monolithic cast-in situ walls while maintaining comparable dimensions, reducing construction time and labor, and enhancing productivity by forming a single, monolithic structure from prefabricated components.
Implementation Method 1
curing the grout to join the pair of wall panels
Data Source
Figure 1A~2
Figure 3A~3B
Figure 3C~3D
AI summary
The present invention relates to pre-cast wall panels and methods to join the wall panels to construct composite structural walls. The wall panel comprises a panel body, at least one guide protruding from at least one groove formed in the panel body. The composite wall is constructed by arranging a first wall panel adjacent to a second wall panel, wherein the at least one guide of the first and second wall panel are overlapped to form a channel; inserting a linking rod into the channel; dispensing grout into a gap between the first and the second wall panel; and curing the grout to join the first and the second wall panel to form the composite structural wall. The wall panel may be part of a prefabricated construction module.