Modular Concrete Support Product With Interlocking Keyways for Pavement Repair
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Solution Overview
Problem
Existing pavement construction methods, whether flexible or rigid, are costly, require large material volumes, and generate high CO2 emissions, and are difficult to repair due to the need for extensive excavation and re-laying of materials.
Innovation Solution
A support product comprising a latticework of walls and cells with catches and partial keyways that connect adjacent products, allowing for efficient assembly and repair by pouring concrete into the cells and keyways, which can be filled with cementitious, bituminous, or granular materials.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If flexible pavement construction methods are used, then material cost is reduced, but construction depth and material volume increase significantly
Solution Approach 1:
The pavement structure is segmented into modular components: a modular support structure with cells and keyways, and separate fill materials. This segmentation allows the support structure to be manufactured once and reused, eliminating the need for deep excavation and extensive material volume while maintaining structural integrity.
Solution Approach 2:
The invention uses a composite construction approach combining a modular support structure (providing structural framework) with various fill materials (cementitious, bituminous, or granular). This composite approach replaces the traditional layered flexible pavement construction, reducing overall material volume while maintaining load-bearing capacity.
2Strength
If rigid pavement construction methods are used, then structural integrity is improved, but construction cost and CO2 emissions increase significantly
Solution Approach 1:
The rigid pavement is divided into modular support structures with cells that can be assembled together. This segmentation reduces the overall concrete volume required compared to traditional rigid pavements while maintaining structural integrity through the modular design and keyway connections.
Solution Approach 2:
The modular support structure incorporates cells and keyways that create a porous, interconnected framework. This porous structure reduces material volume while maintaining strength through the geometric configuration and distribution of load across multiple connected units.
3Ease of repair
If traditional flexible pavement repair methods are used, then surface damage can be addressed, but extensive excavation and re-laying is required
Solution Approach 1:
The pavement is divided into modular support structures that can be independently accessed and repaired. Damage can be addressed by accessing specific cells through the modular structure rather than excavating the entire pavement section, significantly reducing repair time and disruption.
Solution Approach 2:
The modular support structure with its cells and keyways serves as an intermediary framework that provides access to underlying layers. This intermediary structure allows repair materials to be introduced through controlled access points rather than requiring complete excavation, reducing repair duration.
4Ease of repair
If traditional rigid pavement repair methods are used, then structural defects can be corrected, but cutting out and pouring new concrete is required
Solution Approach 1:
The rigid pavement structure is segmented into modular units with accessible cells. Structural defects can be corrected by accessing specific modular units rather than cutting out entire concrete slabs, reducing repair complexity while maintaining structural integrity.
Solution Approach 2:
The modular support structure acts as an intermediary that facilitates repair access. Instead of directly cutting and pouring new concrete in traditional rigid pavements, the modular structure allows introduction of repair materials through its cell and keyway system, simplifying the repair process.
Data Source
AI summary
A support product configured to receive poured concrete, the support product comprising a latticework of walls and a plurality of edges, wherein the walls extend between a lower surface and an upper surface and define a plurality of cells, wherein at least one edge comprises a catch and a partial keyway, wherein the catch is configured to connect with a catch of an adjacent support product to restrain relative movement of connected support products, and wherein the partial keyway is configured to be located adjacent to a partial keyway of a connected support product, so that adjacent partial keyways define a complete keyway between connected support products.