Corrugated Concrete Wall Panel Form for Thermal Efficiency
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Solution Overview
Problem
The high construction and material costs, labor-intensive processes, and equipment requirements for traditional concrete wall construction make it impractical for low-rise residential buildings, and existing prefabricated concrete wall solutions are not thermally efficient or suitable for residential applications.
Innovation Solution
A prefabricated concrete wall panel with a 2-inch thick exterior shell and six 5.5-inch deep ribs, integrated with a corrugated metal sheet and mesh reinforcement, allowing for a single pour of concrete and eliminating the need for heavy equipment, with built-in insulation and utility conduit channels, enabling easier handling and installation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If traditional cast-in-place concrete wall construction is used, then wall strength and durability are improved, but construction cost and labor intensity increase
Solution Approach 1:
The wall panel is segmented into a thin exterior concrete shell (2 inches thick) and a separate insulation core, with only the necessary structural ribs included. This segmentation allows the wall to achieve required strength through the ribbed structure while reducing the amount of concrete material needed, thereby lowering construction costs.
Solution Approach 2:
The invention uses a composite wall structure combining a thin concrete exterior shell with an insulation material core. This composite approach provides both structural strength from the concrete shell and thermal efficiency from the insulation, while reducing overall material costs compared to traditional solid concrete walls.
2Productivity
If traditional pre-cast concrete wall panels are used, then construction speed is improved, but shipping and erection costs increase
Solution Approach 1:
The wall panel thickness parameter is changed from traditional 6+ inches to just 2 inches for the concrete shell, with insulation filling the remaining space. This parameter change dramatically reduces the panel weight and volume, lowering shipping costs while maintaining construction speed through the prefabricated design.
3Strength
If traditional 3-layer sandwich concrete walls are used, then structural strength is improved, but thermal efficiency and adaptability for residential use worsen
Solution Approach 1:
The wall uses a composite structure with a thin concrete exterior shell providing structural strength and a separate insulation material filling the core space. This composite design explicitly addresses both structural requirements and thermal efficiency, unlike traditional 3-layer sandwich walls that use concrete throughout.
Solution Approach 2:
The concrete material is applied locally only where structurally necessary - forming a thin exterior shell and vertical ribs - rather than throughout the entire wall thickness. This local quality approach provides structural strength at critical locations while allowing insulation to occupy the non-structural portions, improving thermal efficiency.
4Reliability
If traditional concrete walls are used, then durability is improved, but weight and handling difficulty increase
Solution Approach 1:
The wall is segmented into a thin 2-inch concrete shell that provides durability and protection, with the remaining wall thickness filled with lighter insulation material. This segmentation maintains the durability benefits of concrete where needed while dramatically reducing overall wall weight for easier handling.
Data Source
AI summary
The present disclosure provides a corrugated concrete wall panel form and a method of constructing a prefabricated concrete wall panel thereof. The method comprises the steps of placing a layer of insulation boards horizontally on a flat surface on site or in pre-cast plant; laying and attaching one layer of corrugated metal thin sheets, as the bottom concrete form, on top of the horizontally placed insulation boards; closing the sides of the corrugated metal sheets by peripheral angles as side forms; and then pouring concrete on top of the metal sheets. After concrete hardens the wall structure is ready for erection. This low cost lightweight wall panel system is self-containing and requires only one pour of concrete. It requires no complicated form structure and less labor work for form installation.