EPS Foam Block Stairway Formwork for Monolithic Concrete
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Solution Overview
Problem
Existing methods for constructing tiered concrete structures, such as stairways and seating areas, face challenges in achieving dimensional accuracy, cost-effectiveness, and fire resistance, particularly in smaller projects where 'gang type' forms are not economically viable, and prior art methods using EPS foam blocks and compacted granular fill require additional time and expense.
Innovation Solution
A customizable system using pre-manufactured components including EPS foam blocks, structural interface elements, special form ties, and riser face forming elements to create a monolithic tiered concrete slab or stairway with minimal heat transfer properties, eliminating the need for retaining walls and allowing for accurate and efficient construction of straight or radial designs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If 'gang type' forms are used for larger structures, then dimensional accuracy and installed costs are improved, but device complexity and initial investment increase
Solution Approach 1:
The form system is divided into modular components including adjustable form panels, independent support legs, and separable bracing elements. This segmentation allows the complex form system to be assembled in sections, making it manageable for smaller projects while maintaining the dimensional accuracy benefits of gang forms.
Solution Approach 2:
The form system incorporates universal components that can adapt to different project sizes and configurations. Adjustable form panels and modular supports can be configured for various span lengths and heights, allowing the same basic system to serve both small lecture halls and larger stadium applications.
2Device complexity
If 'hand built' construction practices are used for smaller structures, then device complexity is reduced, but manufacturing precision and reliability deteriorate
Solution Approach 1:
Form components are pre-manufactured with precise dimensions and pre-assembled into modular units before arriving at the job site. This preliminary fabrication ensures dimensional accuracy is built into the components themselves, eliminating the need for complex on-site adjustments while maintaining simplicity of installation.
3Ease of manufacture
If EPS foam blocks are used as forms, then ease of manufacture is improved, but reliability deteriorates due to fire hazard
Solution Approach 1:
A fire-resistant barrier layer is introduced between the EPS foam blocks and the concrete pour. This intermediary protection layer prevents direct heat transfer to the foam during welding operations or fire events, allowing the use of easy-to-manufacture EPS blocks while eliminating the fire safety concern.
4Ease of manufacture
If compacted granular fill with retaining walls is used, then ease of manufacture is improved, but loss of time and device complexity increase
Solution Approach 1:
The retaining wall component is completely removed from the system by using EPS foam blocks that self-retain the granular fill through their interlocking geometry and friction characteristics. This extraction of the retaining wall eliminates the additional construction steps and time required while maintaining base preparation simplicity.
Data Source
AI summary
The assembly and method of the present invention is used for forming a monolithic tiered concrete slab or stairway. The assembly includes a plurality of foam blocks positioned adjacent one another and in a plurality of rows on a support base. The upper surfaces of the blocks are sloped and form a continuous included plane from the front row to the back row. Interface elements are attached to the upper surfaces so as to cover the joints between adjacent blocks. Riser ties are mounted on the interface elements, with riser face forms attached to the ties. After the blocks are positioned and the interface elements with riser ties and face forms assembled, concrete is poured under the blocks so as to cover the upper surface, the interface elements, and the ties, thereby forming a monolithic tiered series of risers and treads.