Reusable Concrete Form System with Optical Alignment
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Solution Overview
Problem
Existing methods for creating conduit pathways in concrete slabs are time-consuming, risk damaging the concrete and reinforcing bars, and lack efficient alignment and filling mechanisms, especially in multi-level buildings, and often result in material and cost waste due to non-reusable forms.
Innovation Solution
A flexible, reusable form assembly with ribs and a tool dock for easy removal, along with an alignment system using an optical reticle for precise positioning, which allows for the inclusion of reinforcing material and easy filling of the conduit voids.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If cutting holes after concrete has set is used to create passageways, then conduit pathways can be created, but the process is time-consuming and risks damaging the concrete and reinforcing bars
Solution Approach 1:
The form is inserted into the concrete slab before the concrete sets, creating the conduit pathway void space in advance. This preliminary action eliminates the need for time-consuming post-setting cutting operations and prevents damage to reinforcing bars, as the pathway is formed during the pouring process itself
2Ease of manufacture
If non-reusable forms are used to create conduit voids, then conduit pathways can be formed, but there is significant waste in material and cost
Solution Approach 1:
The form is designed to be removed from the cured concrete slab, allowing it to be recovered and reused for creating conduit pathways in other slabs. This recovery and reuse eliminates the material waste associated with disposable forms while maintaining ease of conduit void formation
Solution Approach 2:
The form can be used to create conduit pathways in multiple different concrete slabs, serving universal purposes across various construction locations. This multi-functionality reduces the total number of forms needed and minimizes material waste through repeated use
3Loss of substance
If reusable forms are used to create conduit voids, then material waste is reduced, but there is no easy way to align forms in successive floors and no way to include reinforcing material or fill the conduit voids
Solution Approach 1:
Alignment marks are pre-established on the form and corresponding locations on the building structure before the form is removed and reused. This preliminary marking system enables quick and accurate alignment of forms in successive floors without complex alignment operations
Solution Approach 2:
The form design includes features that facilitate the insertion of reinforcing materials and the subsequent filling of conduit voids with concrete or other materials. These intermediary features bridge the gap between form removal and final conduit completion, making the process straightforward
Data Source
AI summary
A reusable form for creating conduit paths in concrete slabs is described. The form comprises a flexible tube that is positioned prior to pouring a concrete slab. The form includes a keep to keep material out of the hole formed by the form. The form also includes a key structure to permit easy removal of the form once the concrete is set. The system further includes a sighting device to permit rapid and precise alignment for placement of a form when forming conduits in a multi-level building. An accessory is also provided permitting filling in the opening created by the form once wiring, piping and other objects have been installed within the conduit.