Floor Plate Element with EPS Channels for Truss Integration
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing intermediate floor constructions are either expensive due to extensive shoring requirements, non-practical due to multiple strut frames, not thermo-insulating, and susceptible to corrosion from thin steel wires, while lacking cross rigidity and effective insulation.
Innovation Solution
Specially shaped expanded polystyrene floor elements with built-in channels for reinforcement, using space trusses and distance elements to minimize shoring needs and enhance cross rigidity, combined with concrete filling for insulation and protection of reinforcement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If traditional prefabricated intermediate floor constructions with ceramic or concrete filling are used, then structural strength is achieved, but the construction becomes heavy and requires extensive shoring during mounting and concreting
Solution Approach 1:
The patent uses composite construction combining expanded polystyrene (EPS) blocks with concrete filling and steel reinforcement. The EPS provides lightweight insulation while concrete and steel provide structural strength, creating a composite system that achieves required strength without the full weight of traditional concrete or ceramic floor constructions
Solution Approach 2:
The patent applies reinforcement locally only where needed - steel reinforcement is placed in the concrete filling at critical locations (channels, joints, and load-bearing areas) rather than throughout the entire floor construction. This localized reinforcement approach maintains structural strength while minimizing weight and material usage
2Temperature
If expanded polystyrene formwork is used throughout the floor construction, then lightweight and thermo-insulating properties are achieved, but extensive shoring is required every 60-80 cm making the construction expensive and non-practical
Solution Approach 1:
The patent segments the EPS formwork into discrete blocks with standardized dimensions (e.g., 60x60x20 cm). These modular blocks can be assembled in various configurations and require shoring only at specific locations (ends and middle) rather than continuously every 60-80 cm, reducing the complexity and cost of the shoring system
Solution Approach 2:
The EPS blocks serve multiple functions simultaneously: they act as formwork during concreting, provide thermal insulation in the finished construction, and serve as permanent filling material. This multi-functionality eliminates the need for separate insulation layers and reduces overall construction complexity
3Strength
If pre-stressed intermediate floor constructions with thin steel wires are used, then structural strength is achieved, but the construction becomes expensive and susceptible to corrosion
Solution Approach 1:
The patent uses conventional steel reinforcement bars (rebar) instead of expensive pre-stressed thin steel wires. The reinforcement is embedded in concrete filling that protects it from corrosion, providing a more reliable and cost-effective solution that does not require the complex pre-stressing technology and thin, corrosion-susceptible wires
Solution Approach 2:
The concrete filling acts as an intermediary protective layer between the steel reinforcement and the corrosive environment. This concrete cover protects the reinforcement from moisture and oxygen, preventing corrosion while maintaining structural strength, eliminating the need for complex corrosion protection systems
4Ease of manufacture
If traditional floor constructions without cross rigidity are used, then simplicity of construction is maintained, but the construction lacks rigidity in both directions
Solution Approach 1:
The patent creates continuous reinforcement channels that run through the EPS blocks in both longitudinal and transverse directions. These continuous concrete-filled channels with steel reinforcement provide rigidity in both directions while maintaining construction simplicity through standardized block assembly and continuous formwork
Data Source
Figure 1
Figure 2
Figure 3
AI summary
The possibility of special lightening, insulating and reinforcing intermediate floor constructions enables fast building of semi-prefibraceted and prefabricated floor with complete insulation, bearing capacity and smaller price. Floor elements (1) and (15) are constructed to that already present steel space trusses can be placed in their channels, so that are hastened the building of intermediate floor constructions and makes them cheaper, too. They are minimum shorting at the ends and at the middle of beams, so the works below can be proceeding and the required working time is shorter. The intermediate floor construction is already insulating, so they are no need for insulating, which makes the construction cheaper and the required working time shorter. The plates (17) are enabling the increase of the height of the floor constructions, by tying two beams in the construction. Usage of distance elements (23) (35) and (48) protects the reinforcement in floor construction, so they are no need for corrosion protection.