Prefabricated Floor Panel Ledge Joining for Concrete Formwork
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Solution Overview
Problem
Existing floor panel systems for constructing multistory buildings are labor-intensive, pose safety risks, and increase construction costs due to the need for removable formwork and high crane lifting requirements.
Innovation Solution
A prefabricated floor panel system with ledges that allow adjacent panels to be joined to form channels, incorporating reinforcing bars supported by chairs to ensure structural integrity and ease of assembly, reducing the need for on-site reinforcing bar installation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If prefabricated floor panels with concrete and reinforcing bars are used, then construction time is reduced and worker safety is improved, but cost increases and crane lifting capacity requirements increase due to panel weight
Solution Approach 1:
The floor panel is segmented into a lightweight base panel structure and separate reinforcing bar components. The base panel contains ledges and channel formations but excludes heavy concrete and reinforcing bars, which are added separately on-site. This segmentation reduces the weight of the prefabricated portion that must be lifted by crane while maintaining the structural integrity benefits of reinforced concrete floors.
Solution Approach 2:
The base panel structure with ledges and channels is prefabricated in advance at a manufacturing facility, allowing precise formation of joining features and reinforcing bar positioning elements. This preliminary action prepares the panel framework before site assembly, reducing on-site construction time while keeping the prefabricated portion lightweight by excluding heavy materials that are added later.
2Productivity
If individual floor panels are lifted and placed between frame members, then construction speed increases, but the number of crane lifts increases due to panel weight
Solution Approach 1:
The floor system is divided into lightweight base panels that can be lifted and positioned quickly by crane, followed by rapid on-site assembly of reinforcing bars and concrete pouring. The segmentation allows the crane to handle only the lightweight panel frameworks rather than heavy completed floor sections, reducing lift time and increasing construction speed.
3Ease of manufacture
If ledges are provided on floor panels for joining, then panel connection and channel formation are enabled, but interfering structures may prevent proper ledge alignment
Solution Approach 1:
The ledges are designed with specific local characteristics: one ledge is provided with reinforcing bar support features while the adjacent ledge is kept free of interfering structures. This local differentiation ensures that the joining interface has the necessary support elements in precise positions without interference from other structures, achieving both ease of manufacture and manufacturing precision.
Data Source
AI summary
The present invention provides a prefabricated floor panel system used in stay in place formwork for pouring concrete floors. The prefabricated floor panel system includes a top and has walls depending downwardly at an upper lateral edge of the wall from each outermost lateral edge of the top, a lower lateral edge of each wall having a ledge extending outwardly away from the top. A first ledge of one prefabricated floor panel system is capable of overlying another ledge of an adjacent prefabricated floor panel system to allow for the one prefabricated floor panel system to be joined to the adjacent prefabricated floor panel system to form a channel. The first ledge of the prefabricated floor panel system is provided with a reinforcing bar spaced away from the wall and the first ledge of the prefabricated floor panel system, the reinforcing bar being supported by a plurality of a reinforcing bar chairs spaced along the length of the prefabricated panel system, the reinforcing bar chairs being attached to the first ledge or wall such that there are no significant interfering structures projecting from a lower surface of the first ledge. The other ledge of the prefabricated floor panel system is free of interfering structures above the ledge to allow the first ledge of one prefabricated floor panel system to overlie the other ledge of an adjacent prefabricated floor panel system to allow for the one prefabricated floor panel system to be joined to the adjacent prefabricated floor panel system to form a channel.