Modular Breakwater Blocks with Interlocking Shear Keys
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Solution Overview
Problem
Existing breakwater construction blocks face issues with stability, breakage, and high production costs, particularly when subjected to eccentric movement and consolidation on slopes, limiting their application in coastal and riverine erosion control.
Innovation Solution
A modular-type multi-form breakwater construction block molding system employing form attachments, inserts, and filler segments to design varying geometrical features, including truncated leg portions and void zones, which increases stability and allows for rapid production of blocks with different shapes and void ratios, enabling flexible and cost-effective manufacturing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If concrete armor shapes are used to protect marine structures, then stability against wave attack is improved, but production cost increases and production time extends
Solution Approach 1:
The construction element is divided into a central core portion and multiple leg portions that can be independently formed using separate mold components. This segmentation allows parallel casting of multiple elements and simplifies mold design, enabling rapid production while maintaining the interlocking stability of the assembled structure
Solution Approach 2:
The mold system uses a universal base mold that can accommodate different leg configurations through interchangeable leg molds. This allows the same casting facility to produce various armor unit types (tetrapods, accropodes, etc.) without retooling, significantly increasing production versatility and rate while maintaining structural stability
2Reliability
If complex geometric features are added to increase stability, then performance improves, but manufacturing complexity increases
Solution Approach 1:
The complex geometry is segmented into a simple central core and attachable leg portions. The core mold remains simple and universal, while leg complexity is isolated to separate, interchangeable mold components that attach to the base mold only when needed, keeping the core system simple while achieving complex final geometry
Solution Approach 2:
The molding system is made dynamic through interchangeable leg molds that can be attached or removed from the base mold based on production requirements. This allows the system to adapt its complexity level - simple for high-volume production, complex for specialized applications - without permanent increases in overall system complexity
Data Source
AI summary
Improved breakwater construction blocks and interlocking shear key blocks for use in constructing diverse systems and works, in broad fields of use including, but not limited to, coastal engineering: river, stream and torrent control, bulkhead designed projects, scour control, check dams, permeable and impermeable groins-both river and ocean structures and other hydraulic works including marinas.