Multi-Storey ICF Wall Straightness via Inverted Concrete Support

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Solution Overview

Problem

Insulated concrete form (ICF) buildings face challenges in constructing multi-storey structures beyond three stories due to difficulties in maintaining wall straightness without supplementary supports, which are costly and labor-intensive, and fail to meet stringent fire regulations, especially in high-rise buildings.

Innovation Solution

A method of constructing multi-storey ICF buildings using forms with two layers of foam spaced apart by ties, where the uppermost row of forms has an unopposed outside foam layer supported by inwardly extending supports anchored directly or indirectly to the previously poured concrete, allowing for straightening and embedding these supports in the wall, eliminating the need for external supplementary supports and enabling compliance with fire regulations.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If external supplementary supports are used to maintain wall straightness during concrete pouring, then wall alignment is improved, but construction cost and labor intensity increase significantly

Engineering Contradiction:

Improvewall straightnessVSAvoidsupport structure

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

Instead of supporting the foam forms from the outside with external supplementary supports, the patent inverts the approach by having the concrete wall itself provide support from the inside. The concrete is poured to a height that exceeds the foam forms, and the hardened concrete then serves as the supporting structure for subsequent forms, eliminating the need for external supports entirely.

Inventive Principle:

Principle #13The other way round (Inversion)

Solution Approach 2:

The concrete wall performs a dual function: it is both the structural element being constructed and the support system for subsequent construction stages. The hardened concrete from lower levels automatically supports the foam forms at higher levels, making the system self-supporting without requiring separate external support structures.

Inventive Principle:

Principle #25Self-service

2Manufacturing precision

If external supplementary supports are used to maintain wall straightness, then wall alignment is improved, but construction time increases due to installation and removal of supports

Engineering Contradiction:

Improvewall straightnessVSAvoidconstruction time

Core Design Contradiction:

Manufacturing precisionVSLoss of time

Solution Approach 1:

The patent eliminates the temporary support system entirely by inverting to a self-supporting method where concrete walls support subsequent foam forms. This removes both the installation and removal operations of external supports, significantly reducing construction time while maintaining wall alignment through the inherent rigidity of hardened concrete.

Inventive Principle:

Principle #13The other way round (Inversion)

Solution Approach 2:

The construction process becomes continuous without interruptions for support installation and removal. Each completed concrete wall immediately becomes the support for the next level, allowing uninterrupted progression of construction and eliminating downtime associated with support system management.

Inventive Principle:

Principle #20Continuity of useful action

3Ease of operation

If foam forms are made lightweight for ease of handling, then installation ease is improved, but wall straightness becomes difficult to maintain

Engineering Contradiction:

Improveform installationVSAvoidwall straightness

Core Design Contradiction:

Ease of operationVSManufacturing precision

Solution Approach 1:

The patent resolves this contradiction by inverting the support relationship: lightweight foam forms are easily installed by hand, and once concrete is poured beyond them, the heavy hardened concrete provides the stabilizing support that the lightweight forms cannot provide themselves. This allows the forms to remain lightweight for ease of installation while achieving straight walls through the self-supporting concrete structure.

Inventive Principle:

Principle #13The other way round (Inversion)

4Length of stationary object

If ICF buildings exceed three stories, then building height is increased, but fire regulation compliance becomes difficult

Engineering Contradiction:

Improvebuilding heightVSAvoidfire safety

Core Design Contradiction:

Length of stationary objectVSReliability

Solution Approach 1:

The patent changes the material parameter of the exterior cladding from traditional combustible materials to concrete, which is non-combustible and has excellent fire resistance. By making the exterior wall concrete rather than wood or metal siding, the building achieves fire safety compliance for high-rise structures while exceeding three stories in height.

Inventive Principle:

Principle #35Parameter changes

Data Source

PatentUS8186128B2Multi-storey insulated concrete foam building

Publication Date: 2012.05.29 WAY ALVEN J

AI summary

Multi-storey ICF building having concrete walls poured into insulated concrete forms with adjustments mounted between floors and an outside foam layer and guides for an inside for layer. ICF buildings can be constructed with greater than three stories and masonry or stucco exteriors without the use of supplementary forms.