Keystone Connector Formwork for Ribbed Concrete Slabs
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Solution Overview
Problem
The existing methods for forming ribbed or waffle concrete slabs are labor and time intensive due to the need for precise placement and fixing of formwork blocks, which requires the use of spacers and reinforcing bars, increasing construction time and costs.
Innovation Solution
A method and apparatus using keystone connectors to hold blocks in place, allowing for easier alignment and stabilization of the formwork, with blocks having ledges for precise spacing and ventilation ducts for airflow, reducing the need for extensive reinforcing bar networks and minimizing labor and time required for setup.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If blocks are placed immediately adjacent one another without spacers, then the placement process is simplified, but the spacing precision between blocks cannot be ensured
Solution Approach 1:
The block is segmented into a main body and an integrated ledge portion. The ledge acts as a built-in spacer that protrudes from the base of each block, providing precise spacing between adjacent blocks without requiring separate spacer components. This segmentation allows the block to simultaneously achieve ease of placement and precise spacing control.
Solution Approach 2:
The ledge is merged with the block as an integrated structure rather than a separate component. This combining of the spacing function into the block itself eliminates the need for separate spacers while maintaining precise spacing, thereby simplifying the overall placement process without sacrificing spacing accuracy.
2Stability of the object's composition
If a rigid network of rebars is used to fix blocks in place, then the stability of the formwork is improved, but the labor and time required for assembly increases significantly
Solution Approach 1:
The complex rebar network is extracted and replaced with a simpler interlocking mechanism. The ledges of adjacent blocks interlock to provide formwork stability, eliminating the need for extensive rebar assembly while maintaining structural integrity during concrete pouring.
Solution Approach 2:
The ledge acts as an intermediary structural element between adjacent blocks, providing mechanical interlocking and stability without requiring additional rebar components. This intermediary structure simplifies the assembly process while ensuring formwork stability.
3Manufacturing precision
If spacers are used for each block to ensure precise spacing, then the spacing accuracy is improved, but the time required for placement increases
Solution Approach 1:
The spacing function is performed in advance during block manufacturing by integrating the ledge structure. Rather than adding spacers during placement, the precise spacing capability is built into the block itself before placement, thereby eliminating time-consuming spacer installation while maintaining spacing accuracy.
Data Source
AI summary
A method and apparatus for forming a formwork for a ribbed or waffle concrete slab is provided. The apparatus includes a rectangular block having a ledge around the base, the ledge having a dimension of half the desired width of the base ribs of the concrete slab, and a keystone connector. The keystone connector has an engagement portion configured to attach to an engagement portion on each block. In a method, the blocks are laid out so that the ledges of adjacent blocks are in contact. A keystone connector is then placed at each intersection of four blocks by attaching the respective engagement portions of the keystone connector and each block so that the keystone connector holds each of the four blocks in place relative to one another. The keystone connector is also configured to retain a reinforcing rod laid in the channel between adjacent blocks.