Multi-Storey Insulated Concrete Form Alignment Method
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Solution Overview
Problem
Multi-storey insulated concrete form (ICF) construction faces challenges in maintaining alignment of foam forms during concrete pouring, especially above the first storey, due to hydrostatic forces and lack of access for external support, leading to misaligned structures and costly repairs.
Innovation Solution
A method involving a two-step concrete pouring process where the inner and outer forms are erected with the outer form extending higher, allowing for a concrete bearing surface to support floors and subsequent pours, with embedded form ties and secondary concrete sections providing stability and alignment support between storeys.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If foam forms are used for ICF construction, then insulation and structural form are provided, but alignment is lost during concrete pour due to hydrostatic force
Solution Approach 1:
The concrete pour is divided into two separate operations: first pouring concrete to a level below the top of the outer form, then after the first concrete sets, pouring the remaining concrete to complete the form. This segmentation reduces the hydrostatic force on the forms during each pour, preventing misalignment while maintaining the insulation benefits of the foam forms.
Solution Approach 2:
The outer form is extended higher than the inner form before the concrete pour begins. This preliminary extension provides additional support surface area for the forms during the pour, preventing them from being pushed out of alignment by hydrostatic pressure, while still allowing the forms to provide their full insulation value.
2Stability of the object's composition
If supplementary supports are added to maintain alignment, then structural stability is improved, but construction time and cost increase
Solution Approach 1:
The extended outer form itself provides the necessary support and alignment stability during the concrete pour, eliminating the need for additional supplementary supports. The form's own structure is designed to resist the hydrostatic force, reducing construction time by removing the installation and removal of extra support elements.
3Manufacturing precision
If outer form is tied into support members, then alignment is maintained, but construction complexity and time increase
Solution Approach 1:
The complex system of tying the outer form into separate support members is removed entirely. Instead, the outer form is designed to be self-supporting through its extended height, which provides sufficient surface area to resist hydrostatic pressure without requiring additional tie-down systems or complex support structures.
4Manufacturing precision
If two-step concrete pouring is used, then alignment is maintained and structural integrity is improved, but pouring time increases
Solution Approach 1:
The concrete pour is segmented into two phases: first pouring to a level that allows the concrete to set and provide initial support, then pouring the remaining concrete. This segmentation prevents form misalignment during each phase while the total duration is managed by allowing concurrent preparation activities during the setting period between phases.
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 method ensures stable storey-by-storey construction with reduced misalignment risks, allowing for easier alignment corrections and improved structural integrity by bonding secondary concrete sections, thus enabling the construction of multi-storey ICF structures with enhanced stability and reduced construction time and costs.
Implementation Method 1
pouring concrete between the forms upto an upper portion of the inner form and allowing the concrete to set creating a first concrete bearing surface
Data Source
AI summary
A method of constructing one or more storeys of a multi-storey insulated concrete form structure using insulated forms and a multi-storey insulated concrete form structure built using the method. An aspect of the method comprises erecting a set of forms comprising an inner form and an outer form a set distance apart, the outer form extending higher than the inner form when erected. Pouring concrete between the forms upto an upper portion of the inner form and allowing the concrete to set creating a first concrete bearing surface. Positioning a floor on the first concrete bearing surface above the inner form. Pouring concrete between the floor and the outer form to an upper portion of the outer form and allowing the concrete to set creating a second bearing surface substantially in-line with the upper portion of the outer form.