Prefabricated Concrete Block Fastening via Segmented Plate Assembly
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Solution Overview
Problem
Existing methods for connecting pre-fabricated concrete blocks on-site are cumbersome and expensive, especially for large projects like skyscrapers or bridges, as they require pre-fabrication and transportation, which is not feasible for complex structures.
Innovation Solution
A fastening system that includes a steel base plate on the pile head, a metal structure welded to the pile head to pass through prefabricated elements, and embedded metal elements in the concrete to secure the blocks, allowing for on-site assembly and connection of prefabricated concrete elements with piles.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional on-site connection methods are used (pouring concrete around pile heads with metal elements), then the connection between blocks and piles can be achieved, but the process becomes cumbersome and expensive for large projects
Solution Approach 1:
The connection system is divided into separate modular components: a base plate that attaches to the pile head, connector plates with stepped portions that interface with block embedments, and perforated plates for additional securing. This segmentation allows each component to be optimized independently and simplifies the overall assembly process on-site.
Solution Approach 2:
Metal embedments are pre-installed into the prefabricated concrete blocks during manufacturing, and the base plate is pre-attached to the pile head. This preliminary action eliminates the need for complex on-site concrete pouring and metal element installation, reducing both time and complexity of the connection process.
2Reliability
If pre-fabrication away from site is used for all connection elements, then connection capability is achieved, but transportation and assembly become prohibitively expensive and cumbersome for large projects
Solution Approach 1:
The system separates the connection function into two parts: simple metal embedments that can be easily integrated during block prefabrication, and a modular plate assembly (base plate, connector plates, perforated plates) that is assembled on-site. This allows reliable connections without requiring complex pre-assembled units that would be difficult to transport and install.
Solution Approach 2:
The connector plates are designed with stepped portions that can interface with various block configurations, and the perforated plates provide versatile securing options. This universality allows the same basic components to be used across different connection scenarios, improving assembly efficiency while maintaining reliable connections.
3Productivity
If the first layer of concrete blocks is not correctly aligned and secured, then assembly speed is maintained, but the whole building may be out of alignment
Solution Approach 1:
The base plate is pre-attached to the pile head with precise positioning features, and connector plates are pre-configured with stepped portions that guide block placement. This preliminary preparation ensures that when blocks are assembled on-site, they automatically achieve correct alignment without requiring slow, manual adjustment procedures.
Solution Approach 2:
The connector plates feature localized stepped portions at specific positions to interface with corresponding embedments in the blocks. This localized geometric feature provides precise alignment control at the critical connection points while maintaining overall assembly speed.
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 quick, economical, and efficient on-site assembly of precast concrete blocks, reducing the complexity and cost associated with traditional methods, and allows for the creation of large structures like skyscrapers or bridges without the need for extensive pre-fabrication and transportation.
Implementation Method 1
a metal structure is welded to the pile head of a length that allows it to pass through the prefabricated elements
Data Source
AI summary
A fastening apparatus for two or more prefabricated blocks, in which the apparatus includes a perforated plate, a first block with a step, a connector plate that sized and shaped to engage the step, and an upstanding wall that is spaced apart from the block member. The perforated plate is connected to the wall and extends away from it towards the step. The perforated plate is partially mounted on part of the connector plate so as to sandwich it between the perforated plate and the step.