Load-Bearing Formwork with Prefabricated Service Core Modules
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Solution Overview
Problem
Conventional formworks in the construction industry face inefficiencies due to on-site assembly, lack of load-bearing capacity before concrete hardening, suboptimal working conditions, and coordination challenges among trades, leading to increased costs and safety risks, particularly in multistory building applications like service cores.
Innovation Solution
The development of load-bearing fill material formation structures with prefabricated components that include nonforming vertical load-bearing enhancement members and modular service core modules, allowing for preinstallation of building components and reduced need for external bracing, enabling improved working conditions and trade coordination.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If conventional formworks are assembled on-site using standardized panels, then flexibility in adapting to job site conditions is improved, but assembly time and labor costs increase
Solution Approach 1:
The formwork system is designed with pre-configured modular components that include integrated load-bearing capabilities and attachment points for construction elements. The standardized panel configurations are predetermined to match common building geometries, allowing rapid deployment without on-site customization while maintaining adaptability through modular combinations.
Solution Approach 2:
The formwork panels are designed with multi-functional capabilities, serving both as molding surfaces for concrete and as load-bearing structures that can support construction elements during and after concrete placement. The standardized connections allow the same panel system to accommodate various building configurations through different panel arrangements.
2Ease of manufacture
If conventional formworks use standardized panel configurations, then manufacturing and inventory management are simplified, but on-site customization requires cutting and additional labor
Solution Approach 1:
The formwork system divides the structure into standardized modular panel segments that can be combined in different configurations. Each panel is a self-contained unit with standardized connection interfaces, eliminating the need for on-site cutting while allowing flexible arrangement to match various building geometries through modular assembly.
Solution Approach 2:
The system provides dynamic adaptability through modular panel arrangements rather than requiring physical modification of panels. The standardized connections allow panels to be quickly reconfigured for different building shapes and sizes, maintaining manufacturing simplicity while achieving on-site flexibility through dynamic reassembly.
3Device complexity
If conventional formworks lack load-bearing capacity before concrete hardening, then the formwork itself can be simpler and less expensive, but external bracing and ancillary support systems are required
Solution Approach 1:
The formwork system merges the molding function with load-bearing support functions into a single integrated structure. The panels and their connections are designed to simultaneously contain concrete during placement and support construction elements like stairs and service platforms, eliminating the need for separate external bracing systems and ancillary support structures.
Solution Approach 2:
The formwork panels utilize composite construction combining rigid framing members with reinforced panel surfaces, creating a structure with sufficient load-bearing capacity to support construction elements while maintaining relative simplicity. The integrated design allows the same composite structure to serve both as concrete containment and as support for building elements during construction.
4Strength
If construction elements are attached after concrete hardening, then the formwork doesn't need to support them during construction, but the construction process requires waiting periods and sequential operations
Solution Approach 1:
The formwork system enables preliminary attachment of construction elements such as stairs and service platforms to the panels before concrete placement and hardening. The standardized connections are designed to securely hold these elements in position during concrete placement, eliminating the need to wait for concrete hardening before attachment and allowing parallel construction operations.
5Ease of manufacture
If conventional formworks require external bracing and ancillary systems, then the formwork panels themselves can be simpler, but the overall system requires more components and coordination
Solution Approach 1:
The system merges the bracing and support functions into the panel structure itself through integrated rigid framing and reinforced connections. This eliminates the need for separate external bracing components and ancillary support systems, reducing overall system complexity while maintaining panel manufacturing simplicity through standardized integrated designs.
Data Source
AI summary
Methods and apparatus for the formation of structures utilizing fill materials capable of hardening, such as concrete. The methods and apparatus may include the employment of enhanced load-bearing capabilities, which may yield substantial efficiencies in time, labor, materials and costs attendant to fill material formation. The methods and apparatus may be particularly suited for use with manufacturing and prefabrication processes.