Hydraulic Underlayment Delivery System for Rapid Installation
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Solution Overview
Problem
Current methods for delivering and installing building materials, such as concrete underlayment, are inefficient, environmentally unfriendly, and pose occupational hazards, with high costs and long construction times due to traditional methods and materials.
Innovation Solution
A system and process utilizing a silo, pump, crane, and distribution hose with a remote pump, incorporating a high-solids styrene acrylic polymer primer and a self-leveling underlayment compound made from fly ash and other low-energy cementitious components, which can be installed without mechanical preparation of the concrete surface, allowing for rapid and environmentally friendly installation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If traditional concrete delivery and installation methods are used, then material delivery is achieved, but construction time is excessive and labor costs are high
Solution Approach 1:
The patent employs a pump system with hoses to deliver liquid concrete mixture directly to the installation location, replacing traditional mechanical transport methods. This hydraulic delivery system enables continuous flow of material, significantly increasing installation speed and reducing construction time while maintaining material integrity during transport.
Solution Approach 2:
The concrete mixture is prepared in advance with specific compositional ratios (cement, sand, aggregate, water) and delivered ready-to-install. The preliminary mixing and preparation of the concrete composition eliminates on-site mixing time and allows immediate installation upon delivery, thereby reducing overall construction time.
2Ease of manufacture
If traditional concrete mixing and delivery systems are used, then material delivery is achieved, but equipment complexity and cost are high
Solution Approach 1:
The delivery system is divided into distinct functional components: a pump unit for pressurization, flexible hoses for transport, and a delivery mechanism for placement. This segmentation allows each component to be optimized independently and facilitates easier maintenance and replacement, reducing overall system complexity while maintaining delivery effectiveness.
3Object-affected harmful factors
If traditional concrete installation methods are used, then floor covering installation is achieved, but environmental impact is negative due to dust and packaging waste
Solution Approach 1:
The hydraulic delivery system transports concrete as a contained liquid mixture through closed piping and hoses, preventing material from becoming airborne during transport and installation. This eliminates dust generation and associated occupational health hazards while reducing packaging waste from traditional bagged concrete delivery methods.
4Strength
If conventional cementitious materials are used, then structural strength is achieved, but energy consumption is high
Solution Approach 1:
The concrete composition is optimized with specific water-cement ratios and aggregate sizes to achieve required compressive strength with minimal cement content. By adjusting compositional parameters and using efficient mixing techniques, the system maintains structural strength requirements while reducing the energy-intensive cement production component.
Solution Approach 2:
The concrete mixture combines cement with sand, aggregate, and water in optimized proportions to create a composite material that achieves structural strength through synergistic material interactions. This composite approach reduces reliance on pure cement, thereby lowering energy consumption associated with cement manufacturing while maintaining required mechanical properties.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This solution reduces construction time, costs, and environmental impact by enabling quick installation of a durable, LEED-certified underlayment that is receptive to various floor coverings, while minimizing dust and allowing faster site access, with enhanced compressive strength and reduced water loss.
Implementation Method 1
The system can comprise at least one silo, at least one pump, at least one crane, and at least one distribution hose
Implementation Method 2
The method utilizes a high-solids styrene acrylic polymer primer that penetrates the surface of the concrete slab floor, and acts as an adhesive intermediary between the new material and the concrete slab, thus maximizing the adhesion of the cementitious composition to the slab
Implementation Method 3
curing it to a minimum of strength such as up to 4,000 PSI. This material forms a permanent alkali barrier to the concrete it is installed over
Data Source
AI summary
There is disclosed a system for depositing building materials comprising a motor vehicle, a container comprising a material depositing system and at least one device for removing the container from the motor vehicle. The device can comprise one or more outriggers which are adapted to remove the container from the motor vehicle and which can be used to deposit the container on a job site. In addition there is a system which includes a hydraulically controlled crane and silo doors for allowing material to be automatically added to containers for mixing building materials.