Lightweight Concrete MIC Connection System
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Solution Overview
Problem
Current modular integrated construction (MiC) techniques face limitations in high-strength connections for concrete-based modules, especially in harsh environments, and require complex on-site wet trade work due to existing connection joint designs.
Innovation Solution
A connection system using lightweight concrete modules with grout-accepting cavities and vertical alignment connectors attached to horizontal load-distributing plates, which embeds steel bars for secure and robust intermodule connections, eliminating the need for mechanical elements like nuts and bolts.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If normal concrete MiC is used with shear wall structural system, then structural strength and stability are improved, but architectural layout flexibility deteriorates due to inability to remove structural shear walls
Solution Approach 1:
The structural system is segmented into load-bearing concrete columns and non-load-bearing partition walls. The partition walls can be removed or reconfigured without compromising structural integrity, as the load-bearing function is carried by the concrete column frame rather than continuous shear walls.
Solution Approach 2:
The load-bearing function is extracted from the traditional shear wall system and concentrated into discrete concrete columns. This allows the removal of non-structural wall elements to create flexible architectural layouts while maintaining structural strength through the column framework.
2Stability of the object's composition
If traditional connection joint design with lapping rebars and on-site concrete is used, then structural continuity is improved, but construction complexity and wet trade work increase
Solution Approach 1:
Connection elements including grout-accepting cavities, alignment connectors, and load-distributing plates are pre-installed on modules during factory fabrication. This preliminary action eliminates the need for complex on-site rebar lapping and concrete pouring, reducing construction complexity while maintaining structural continuity through pre-engineered connection details.
Solution Approach 2:
The traditional mechanical rebar lapping system is replaced with a grout-based connection system. Grout is pumped into pre-formed cavities to create continuous structural connections, substituting complex mechanical reinforcement detailing with a simpler fluid-based bonding mechanism that achieves the same structural continuity.
3Strength
If heavy normal concrete modules are used, then structural strength is improved, but transportation and foundation costs increase due to weight limitations
Solution Approach 1:
The module construction uses composite material strategy combining high-strength normal concrete for load-bearing columns with lightweight concrete for non-structural elements such as partition walls, floor slabs, and ceiling panels. This composite approach maintains structural strength where needed while minimizing overall module weight for transportation and foundation efficiency.
4Manufacturing precision
If more workers are deployed for on-site concrete casting and finishing, then construction quality can be monitored, but construction time increases due to linear sequential process
Solution Approach 1:
All interior finishes including electrical wiring, hydraulic systems, cabinetry, and surface finishes are completed in the factory before module assembly. This preliminary action allows quality control to be performed in the controlled factory environment rather than on-site, enabling faster on-site assembly without compromising construction quality.
Solution Approach 2:
Multiple construction activities including structural fabrication, interior finishing, and systems installation are merged into a single factory fabrication process. This integration allows parallel execution of tasks that would otherwise be sequential on-site, significantly improving overall construction productivity while maintaining quality through centralized factory control.
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
This solution enhances the flexibility of architectural layouts, reduces construction time and labor, and provides high-strength connections suitable for extreme conditions, while simplifying the assembly process and reducing the weight of modules, thus lowering foundation costs and improving safety.
Implementation Method 1
In-situ grout embeds the vertical alignment connector in each grout accepting cavity
Data Source
AI summary
The present invention provides a multi-storey modular building including at least a first and a second lightweight concrete-based prefabricated modules each having at least a beam, a column, and one horizontal structure selected from a ceiling or a floor at least partially attached to two or more of the beams and columns. A connection system includes at least one vertical alignment connector attached to a horizontal load-distributing plate positioned between the first and second lightweight concrete-based prefabricated modules for connecting the first and second lightweight concrete-based prefabricated modules, where a top portion thereof is positioned in a grout accepting cavity in the bottom end of the column of the second lightweight concrete-based prefabricated module and that in the top end of the column of the first lightweight concrete-based prefabricated module. In-situ grout embeds the vertical alignment connector in each grout accepting cavity.