Insulated Concrete Form Opening Forms for Multi-Storey Construction
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Solution Overview
Problem
Multi-storey concrete structures constructed using insulated concrete form (ICF) techniques face challenges in maintaining alignment, accessing the outside during construction, and creating openings like windows and doors, especially at upper storeys, due to the limitations of traditional methods which often require permanent wooden frames that can lead to water ingress, thermal inefficiencies, and compliance issues with building codes.
Innovation Solution
A method involving the use of opening forms bonded to a concrete core, where forms are erected, positioned around openings, secured, and filled with concrete in stages to create a structure opening, eliminating the need for permanent wooden frames by using temporary bulkheads and a two-step concrete pour process to ensure proper bonding and insulation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If traditional wooden frames are used to create openings in ICF structures, then openings can be created, but thermal insulation is compromised and water ingress risk increases
Solution Approach 1:
The form system is segmented into wall forms and separate opening forms that can be independently positioned and removed. The opening forms are divided into multiple sections (first opening form and second opening form) that can be placed at different stages of concrete pouring, allowing flexible creation of openings without compromising the continuous insulation of the wall forms.
Solution Approach 2:
Opening forms serve as temporary intermediary elements that facilitate the creation of openings during construction. These forms are positioned between the wall forms and concrete, acting as a mediator that enables opening creation while maintaining the integrity of the surrounding insulated concrete structure. The opening forms are removed after concrete setting, leaving clean openings without permanent wooden frames.
2Ease of manufacture
If permanent wooden frames are embedded in ICF structures, then openings are created, but the structure becomes prone to water ingress and rot
Solution Approach 1:
The opening forms are designed as temporary, disposable elements used only during the concrete pouring process. These forms are not permanently embedded in the structure like traditional wooden frames. After serving their purpose of defining the opening space during construction, the opening forms are removed, leaving no permanent organic material that could rot or allow water ingress in the finished structure.
Solution Approach 2:
The harmful element (permanent wooden frame) is extracted from the design. Instead of embedding permanent wood that causes rot and water ingress risks, the invention uses temporary opening forms that are completely removed after concrete setting. This extraction eliminates the source of potential water ingress and rot problems while still achieving the opening creation function during construction.
3Reliability
If ICF construction is used for multi-storey structures, then insulation is maintained, but alignment maintenance becomes difficult
Solution Approach 1:
The form system is divided into modular wall forms and separate opening forms. Each module can be independently manufactured to precise dimensions and assembled on site. The opening forms are segmented into multiple sections that can be positioned and secured independently, making alignment easier to maintain compared to creating large openings in continuous forms.
Solution Approach 2:
Opening forms are positioned and secured to the wall forms before concrete pouring begins. This preliminary positioning ensures that openings are correctly aligned with the structural grid before the concrete sets. The opening forms are temporarily secured to provide reference points for alignment, and this preliminary action prevents alignment errors that would be difficult to correct after concrete pouring.
4Ease of operation
If access to outside of structure is needed during upper storey construction, then construction can proceed, but alignment maintenance becomes more problematic
Solution Approach 1:
Opening forms are positioned and secured to the wall forms before concrete pouring begins. This preliminary positioning ensures that openings are correctly aligned with the structural grid before the concrete sets. The opening forms are temporarily secured to provide reference points for alignment, and this preliminary action prevents alignment errors that would be difficult to correct after concrete pouring.
Solution Approach 2:
The opening forms provide temporary dynamic access points during construction. These forms can be positioned to create openings at various heights and locations on upper storeys, allowing workers to access the outside for alignment verification and construction activities. The forms are dynamically adjusted and secured as needed, then removed after serving their temporary purpose, leaving permanent openings in the finished structure.
Data Source
AI summary
An insulated concrete form structure is provided that includes a structure opening through the structure. The structure opening being defined by form edges and opening forms bonded to a concrete core of the structure. A method is provided that includes erecting a set of spaced apart forms on a base, positioning opening forms in the space between the forms around a form opening through the forms, securing the opening forms around the form opening, and pouring concrete to fill the space between the forms, around the opening forms, to a top portion of the forms, thus creating the concrete core of the structure.