Concrete Wall Cladding With Undercut Anchors During Pouring
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Solution Overview
Problem
Constructing and cladding concrete walls with integrated utility lines is time-consuming and expensive, especially when using modular systems like SIPs and ICFs, as accessing the wall cavity after concrete setting is difficult, and traditional cladding methods require separate steps post-construction.
Innovation Solution
A method involving undercut anchors and cementitious material engaging elements (CMEEs) that allow simultaneous construction and cladding of concrete walls, using pre-fabricated cementitious boards with blind holes for secure attachment, and flaring anchors within these holes for rigid attachment during concrete pouring.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If traditional cladding methods are used (gluing after wall construction), then the process is simple and cheap for internal walls, but it requires separate post-construction steps that increase time and labor costs
Solution Approach 1:
The patent merges wall construction and cladding attachment into a single simultaneous process. Cementitious material engaging elements (CMEEs) are embedded in the concrete wall during pouring, and cladding elements are attached to these CMEEs while the wall is still being constructed, eliminating the need for separate post-construction cladding steps
Solution Approach 2:
The CMEEs are preliminarily positioned and embedded in the concrete wall during the pouring process, before the cladding elements are attached. This preliminary placement of attachment points enables subsequent cladding installation to occur concurrently with wall construction rather than as a separate phase
2Productivity
If modular wall systems (SIPs and ICFs) are used, then wall construction is efficient, but accessing the wall cavity for utility lines after concrete setting is difficult and expensive
Solution Approach 1:
Utility lines are preliminarily routed through the wall cavity during the construction phase, while the wall is still accessible and flexible. The CMEEs provide attachment points for cladding that can be installed before the concrete fully sets, allowing utility lines to be positioned and secured without requiring post-construction demolition or difficult access through hardened concrete
3Stability of the object's composition
If cladding is attached after wall construction, then the wall structure is complete and stable, but the process becomes time-consuming and expensive
Solution Approach 1:
The patent combines wall construction and cladding attachment into a single integrated process occurring simultaneously. The CMEEs are embedded in the concrete during pouring, and cladding elements are attached to these CMEEs while the wall is still being constructed, eliminating sequential delays and accelerating overall construction speed without compromising wall stability
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
Enables efficient and cost-effective simultaneous construction and cladding of concrete walls with integrated utility lines, reducing time and labor costs by allowing for secure attachment of cladding elements during the construction process.
Implementation Method 1
screwing a flaring element into the undercut anchor, so as to allow the undercut anchor to flare inside the hole and beyond the internal walls of the hole, while compressing material of the end-cladding element surrounding the hole
Implementation Method 2
applying the cementitious material into the formwork; and allowing the cementitious material to harden with the cementitious material engaging elements penetrating therein
Data Source
AI summary
Methods of concurrently constructing and cladding concrete walls are disclosed. Methods of securing undercut anchors into the back surface of end-cladding elements are further disclosed. Walls and structures generated thereby are also disclosed.