Interlocking Precast Base Frames for Fast Single-Worker Assembly
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Solution Overview
Problem
Conventional concrete base or foundation systems are expensive, time-consuming, and weather-dependent, requiring multiple skilled laborers and taking several days to construct, whereas there is a need for a lightweight, easy-to-assemble, and weather-independent precast base system that can be installed quickly by one worker.
Innovation Solution
A universal precast base system comprising interlocking channel and side elements with notches, allowing for easy assembly of various shapes and configurations without special training, using precast cementitious materials that can be manufactured offsite and assembled onsite in a few hours.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional concrete base systems are used, then structural strength is achieved, but construction time increases to several days and requires multiple skilled laborers
Solution Approach 1:
The base system is divided into modular precast frames that can be independently manufactured and then assembled onsite. Each frame is a complete structural unit with integrated channels and notches, allowing rapid assembly without complex on-site formwork and concrete pouring operations.
Solution Approach 2:
The frames are precast at a manufacturing facility with all structural elements (channels, notches, reinforcement) already in place. This preliminary preparation eliminates time-consuming on-site activities such as formwork construction, concrete mixing, and curing, enabling quick onsite assembly.
2Ease of manufacture
If conventional concrete base systems are used, then structural integrity is achieved, but labor costs increase due to requiring multiple skilled workers
Solution Approach 1:
The precast frames are designed to be self-assembling through interlocking mechanisms. The channels and notches provide inherent alignment and connection features that allow a single worker to assemble the frames without requiring multiple skilled laborers for formwork, reinforcement placement, and concrete pouring.
3Reliability
If conventional concrete base systems are used, then foundation stability is achieved, but weather-related delays occur during construction
Solution Approach 1:
The frames are manufactured in a controlled factory environment where weather conditions do not affect the construction process. This eliminates weather-related delays associated with on-site concrete pouring and curing, as all structural elements are prepared beforehand and only require simple assembly onsite.
4Productivity
If precast frames with interlocking edges are used, then assembly time is reduced to a few hours, but manufacturing complexity increases
Solution Approach 1:
The complex structural requirements are segmented into standardized frame modules with repeating patterns of channels and notches. This segmentation allows the complexity to be managed through modular design, where each frame type (corner, end, intermediate) follows consistent manufacturing procedures despite varying configurations.
Data Source
AI summary
A universal precast base system formed from a plurality of interlocking frames, each frame includes at least two channel elements and at least one side element. A channel extends along the channel elements and is open on each end. The external surface of the side element includes an interlocking edge for mating adjacent frames together. Channels of adjacent frames connect to form a continuous channel for receiving vertical wall panels therein.