Corrosion-Resistant Lifting Inserts for Precast Insulated Panels
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Solution Overview
Problem
Removing precast insulated panels from molds is challenging due to their large size and weight, requiring strong yet non-obtrusive stripping lifting inserts that are also corrosion resistant to maintain visual aesthetics.
Innovation Solution
A stripping lifting insert with an elongated connecting shaft and adjustable wythe engagement members made from fiber-reinforced polymer, featuring protrusions that embed into the panel's wythes, allowing for secure lifting while maintaining a slim profile and resisting corrosion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If stripping lifting inserts are made strong enough to handle large precast panels, then lifting capability is improved, but the inserts become too large and protrude, interfering with visual aesthetics
Solution Approach 1:
The engagement members are designed with localized protrusions that extend only where needed for concrete engagement, while the overall insert profile remains slim. The protrusions are distributed at specific locations on the engagement members, providing localized structural reinforcement and concrete interlocking without increasing the overall insert dimensions that would interfere with panel aesthetics.
Solution Approach 2:
The stripping lifting inserts are constructed using composite materials that provide high strength-to-size ratio, allowing the inserts to be strong enough for lifting large panels while maintaining a slim profile. The composite construction enables the insert to achieve necessary lifting capability without requiring excessive dimensional size.
2Reliability
If stripping lifting inserts are made corrosion resistant, then durability is improved, but manufacturing complexity increases
Solution Approach 1:
The inserts are manufactured from fiber-reinforced polymer composites that inherently provide corrosion resistance. This material selection eliminates the need for additional corrosion protection layers or complex manufacturing processes, as the corrosion-resistant property is built into the base material itself.
Solution Approach 2:
The manufacturing process utilizes pultrusion technology, which is a specialized extrusion process for composite materials. This parameter-based manufacturing approach (using controlled pultrusion parameters) simplifies production while ensuring consistent corrosion-resistant properties throughout the insert structure.
3Reliability
If wythe engagement members are embedded in wythes, then lifting security is improved, but the height of engagement members must be controlled to avoid protrusion
Solution Approach 1:
The engagement members are segmented with protrusions that extend radially from the hub, allowing the engagement function to be distributed across multiple protrusion points rather than requiring a single tall engagement structure. This segmentation enables secure embedding in the wythes while keeping the overall height controlled.
Solution Approach 2:
Instead of increasing the height of engagement members vertically, the design uses radial protrusions that extend in a different dimension (radially outward from the shaft axis). This dimensional change allows the engagement members to embed securely in the wythes without increasing the vertical profile height that would interfere with panel aesthetics.
Data Source
AI summary
A stripping lifting insert is provided for precast insulated panels having an insulating material layer between opposing wythes, the insulating material layer, wythes, and precast insulated panel having respective widths. The stripping lifting insert includes an elongated connecting shaft having a shaft axis. First and second spaced apart wythe engagement members are connected to the connecting shaft in spaced apart relation to each other. Each wythe engagement member includes a hub and a plurality of three or more protrusions connected to and emanating from hub. Each of the protrusions extending radially outward from the shaft axis. The wythe engagement members have a height less than the width of the wythes, whereby each wythe engagement member can be completely embedded in a respective wythe of the precast insulated panel. A precast insulated panel and a method of making a precast insulated panel are also disclosed.