Lightweight Permanent Form–Steel Assembly Coupling Without Temporary Supports
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Solution Overview
Problem
Existing formwork systems for constructing concrete structures require significant time, materials, and cost, pose safety risks due to high-altitude installations, and cause environmental pollution, while conventional prefabricated systems need precise alignment and may leak concrete paste.
Innovation Solution
A combination structure of permanent forms and prefabricated steel assemblies using 'L'-shaped support bars and protrusions that allow easy coupling of forms to steel members, eliminating the need for temporary supports and precise alignment, and incorporating corner stiffeners for enhanced stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If self drilling screws are used to fasten forms to horizontal support members, then the forms can be securely attached, but lots of time is required for attaching the forms one by one and concrete paste may leak
Solution Approach 1:
The support bar is divided into multiple segments with protrusions at regular intervals, allowing multiple attachment points along a single support bar. This enables parallel attachment of multiple form sections, significantly increasing productivity while maintaining secure attachment at each point.
Solution Approach 2:
Protrusions serve as intermediary elements between the support bar and the form. These protrusions engage with corresponding recesses in the form, providing a reliable mechanical connection that prevents concrete paste leakage while allowing rapid attachment without individual self-drilling screws.
2Ease of operation
If deck form is moved from lower side to upper side to couple to prefabricated frame, then form can be easily coupled irrespective of fixing bar positions, but spare space is needed on lowermost portion and lower portion must be finished with separate form
Solution Approach 1:
Instead of moving the form from below to above the member, the support bars extend outward from the member surface, allowing the form to be attached directly at the intended final position. This inverts the conventional approach by bringing the support structure to the form rather than moving the form to the support structure.
Solution Approach 2:
The support bars with protrusions automatically provide attachment points that self-align with the form during installation. The protrusions engage with form recesses without requiring precise pre-positioning or movement, allowing the form to be coupled directly in its final position without additional construction steps.
3Manufacturing precision
If first fixing bars and second fixing bars must accurately correspond, then precise alignment is achieved, but high accuracy is required in making the member
Solution Approach 1:
The protrusions are designed with a universal geometry that can engage with corresponding recesses in the form regardless of minor position variations. This universal interface design allows the same support bar structure to accommodate slight manufacturing tolerances without requiring high-precision alignment between support bars and form elements.
Solution Approach 2:
The engagement between protrusions and form recesses is designed to be tolerant of position variations through controlled changes in engagement depth and angle. This parameter flexibility allows accurate alignment to be achieved without requiring high manufacturing precision, as the system can accommodate minor deviations through the mechanical design of the connection interface.
Data Source
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AI summary
The present invention relates to a combination structure of permanent forms and a prefabricated steel assembly for a steel concrete composite member, the combination structure including: the prefabricated steel assembly having a plurality of shape steel members and a plurality of support bars; and each permanent form having a flat plate, 'L'-shaped protrusions, a bent corner, and a 'L'-shaped outer protrusion.