Embedded Mesh in Precast Concrete Wall Panels
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Solution Overview
Problem
Existing methods for attaching screens to pre-stressed or precast concrete wall panels are expensive and time-consuming, often requiring after-pour installation procedures.
Innovation Solution
Embedding a mesh screen into the concrete form during the pouring process, using a window form with a fixed base and removable cap that creates a seal to prevent concrete entry, allowing for secure attachment and elimination of post-pour installation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If screens are attached to concrete wall panels using conventional methods (concrete nails, bolts, or anchors), then the screen can be securely attached to the wall, but the installation process becomes expensive and time-consuming
Solution Approach 1:
The mesh is placed in the window form before the concrete is poured, embedding it during the manufacturing process. This preliminary action eliminates the need for post-pour installation, reducing both time and cost while maintaining secure attachment as the mesh becomes integrated with the hardened concrete structure.
Solution Approach 2:
The screen attachment process is merged with the concrete pouring process. Instead of separate operations (pouring concrete then attaching screens), both actions are combined into a single manufacturing step where the mesh is embedded in the form before pouring, achieving both structural integration and screen installation simultaneously.
2Adaptability or versatility
If conventional attachment methods are used, then screens can be installed on existing walls, but the process requires expensive materials and multiple installation steps
Solution Approach 1:
The screen attachment is merged into the concrete manufacturing process. The mesh is positioned in the form before pouring, and both operations (concrete placement and screen installation) occur in a single manufacturing step, simplifying the overall process while maintaining adaptability for different wall configurations.
Solution Approach 2:
The mesh is pre-positioned in the window form before concrete is poured. This preliminary placement during manufacturing eliminates the need for separate installation steps on-site, reducing complexity while allowing flexibility in design configurations through proper mesh positioning in the form.
3Productivity
If the window form is completely removed after pouring, then the form can be reused, but the mesh may become dislodged or misaligned
Solution Approach 1:
The mesh is preliminarily secured to the window form before pouring using weights or adhesives. This preliminary securing ensures the mesh remains in precise position during the concrete pouring process, maintaining manufacturing precision even when the form is later removed and reused for subsequent production cycles.
Data Source
AI summary
Systems and methods for securely attaching a screen or mesh to a pre-stressed or precast concrete wall panel are provided. A screen or mesh is embedded in a concrete form when the concrete form is poured. Portions of the concrete form can be stripped and the wall panel can be easily removed from the form without binding on the form itself and without requiring removal of the portion of the form which creates the window opening.