Integral Precast Concrete Module for Leakage and Cost Reduction
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Solution Overview
Problem
Existing precast concrete structures face issues with leakage and cracking due to connections between components during assembly, and high transportation and labor costs, especially in large apartment houses, where units are expensive to produce and transport.
Innovation Solution
A precast concrete module is designed with a floor, perimeter walls, and interior walls cast as an integral unit, featuring horizontal flat plates for accurate vertical alignment and leveling without wedges, and a pre-stressed concrete roof with cables for enhanced tensile strength to prevent cracks and leakage, allowing for efficient assembly and transportation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If precast concrete structures are assembled from individual components (floor, walls, roof), then manufacturing flexibility and quality control are improved, but connection leakage and cracking occur
Solution Approach 1:
The patent combines floor, perimeter walls, and interior walls into a single integral precast concrete module cast as one piece. This eliminates the connections between separate components that cause leakage and cracking, while maintaining manufacturing flexibility through standardized modular production.
2Productivity
If precast concrete units are produced for large apartment houses, then construction efficiency is improved, but transportation and labor costs increase
Solution Approach 1:
The patent divides large apartment houses into standardized modular units that can be produced efficiently and transported cost-effectively. Each module is a self-contained unit with floor, walls, and roof integrated together, optimizing the balance between unit size for construction efficiency and transportability.
3Measurement precision
If horizontal flat plates are used for vertical alignment, then leveling accuracy is improved without wedges, but manufacturing precision requirements increase
Solution Approach 1:
The horizontal flat plates are designed to be self-leveling through their own geometric properties and weight distribution, eliminating the need for external wedges or complex leveling mechanisms. The plates automatically adjust to provide accurate horizontal alignment during module assembly.
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
The solution ensures accurate horizontal alignment and vertical load transmission, reduces the risk of cracking and leakage, and minimizes transportation costs by allowing for efficient assembly and use of low-capacity construction teams, while improving vibration resistance and reducing the need for on-site finishing.
Implementation Method 1
a pre-stressed concrete roof with cables for enhanced tensile strength to prevent cracks and leakage
Data Source
AI summary
A precast module built specifically with a dimension of 28′−0″×11′−8″ vertical exterior walls 4″ thick, horizontal walls 3″ thick and a floor 4″ thick. The horizontal walls are connected with attachment of rods to the vertical wall, while providing a number of openings in the horizontal and vertical walls allow access to the interior of the building unit and carrying out various plates weld in the top of the walls. The roof is constructed separately from the module, pouring concrete and is provided with through holes for locating screws and passes, and several welding plates to attach or connect to the roof and walls and have a connection to the roof and thus form an integral unit of construction.