Gapless Formwork Profiles With Recessed Interlocking Ends
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Solution Overview
Problem
Existing formwork systems for precast concrete parts often result in gaps at the interfaces between formwork profiles, leading to aesthetic issues and requiring significant effort to fill and remove filler materials like Styrofoam.
Innovation Solution
A formwork system with divisible profiles, where the second group is further divided into subgroups with specific recess configurations on their end faces to accommodate inclined surfaces from the first group, allowing for gapless alignment and enabling the system to be reused with fixed lengths, allowing for precise construction of any desired formwork.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If formwork profiles with recesses on both end faces are used to achieve certain overall lengths, then the formwork can be assembled to desired lengths, but gaps form at the interface points where end faces abut each other, leading to concrete oozing and aesthetic defects
Solution Approach 1:
The second group of formwork profiles is segmented into three subgroups based on recess configuration: first subgroup with recess on exactly one first end face, second subgroup with recess on exactly one second end face opposite the first end face, and third subgroup with no recesses on either end face. This segmentation allows precise control over interface gaps while maintaining assembly simplicity.
Solution Approach 2:
Different end faces of formwork profiles have different local qualities - some have recesses while others don't. This local differentiation enables seamless interfaces at specific locations while maintaining overall structural integrity and simplicity.
2Reliability
If filler material is manually applied to fill gaps, then concrete oozing is prevented, but significant labor is required for both application and removal of the filler material
Solution Approach 1:
The formwork profiles are pre-configured with recesses on specific end faces during manufacturing, so that when assembled correctly, the interfaces are automatically gapless without requiring any preliminary filling action. This preliminary design eliminates the need for manual filler application.
Solution Approach 2:
The formwork system is designed to be self-sealing through its profile geometry. When profiles from different subgroups are joined, the recess configurations automatically prevent gaps, making the system self-sufficient without external filler materials or manual intervention.
3Reliability
If disposable formwork elements are used to fill gaps, then gaps are sealed, but individual cutting and disposal increases complexity and waste
Solution Approach 1:
The formwork profiles serve multiple functions through their universal design. Profiles from different subgroups can be combined in various configurations to achieve different lengths and sealing requirements, eliminating the need for specialized disposable filler elements.
Solution Approach 2:
The formwork system is designed for recovery and reuse rather than disposal. The reusable profiles with fixed lengths can be disassembled and reused for subsequent formwork applications, eliminating waste and reducing overall system complexity compared to disposable solutions.
Data Source
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Figure 3a~3e
AI summary
Formwork system (1) for producing formwork for a precast concrete element, comprising formwork profiles (7 to 26, 65) each having two longitudinal sides (27, 28, 29, 30) and two intermediate end faces (31, 32, 33, 34), wherein the formwork profiles are divisible into a first group (2) and a second group (3), the formwork profiles (7 to 24, 65) of the second group (3) are provided to be arranged substantially perpendicular to one or more formwork profiles (25, 26) of the first group (2), and at least the formwork profiles (25, 26) of the first group (2) have a projecting inclined surface (35) on at least one longitudinal side (29, 30) for forming a chamfer in a precast concrete element, wherein the second group (3) of formwork profiles (7 to 24, 65) is divided into a first subgroup (4), a second subgroup (5, 65) (5) and a third subgroup (6) can be subdivided,wherein the formwork profiles (7 to 13) of the first subgroup (4) have a recess (36) on exactly one first end face (32) – viewed from a direction perpendicular to one of the longitudinal sides (27, 28) – for receiving the inclined surface of a formwork profile from the first group (2), the formwork profiles (14 to 20) of the second subgroup (5) have a recess (36) on exactly one second end face (31) opposite the first end face (32) – viewed from a direction perpendicular to one of the longitudinal sides (27, 28) – for receiving the inclined surface of a formwork profile from the first group (2), and the formwork profiles (21 to 24, 65) of the third subgroup (6) do not have a recess on either of the two end faces (31, 32) – viewed from a direction perpendicular to one of the longitudinal sides (27, 28) – for receiving the inclined surface of a formwork profile from the first group (2).