Modular Portal-Frame Enclosure for Weather-Controlled Construction
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Solution Overview
Problem
Construction projects, especially in sensitive areas like dark sky reserves, are hindered by external environmental factors and require extensive impact assessments, leading to inefficiencies and high costs due to weather interruptions and light pollution, necessitating a solution to create a controlled construction environment.
Innovation Solution
A modular assembly comprising portal frames, rails, and flexible panels that enclose the construction site, allowing continuous work and reduced environmental impact by controlling weather and light conditions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional construction is carried out in open environment, then construction can be performed with simple setup, but productivity is reduced due to weather interruptions and environmental factors
Solution Approach 1:
The patent employs flexible fabric panels as the enclosure material for the modular assembly. These flexible shells create a controlled environment that protects construction activities from weather interruptions while allowing rapid deployment and adaptation to different site configurations, thereby resolving the contradiction between productivity and environmental protection.
Solution Approach 2:
The construction enclosure is divided into modular panels and frames that can be assembled in segments. This segmentation allows the structure to be configured to specific site requirements while maintaining environmental protection benefits, enabling high productivity without compromising protection from harmful environmental factors.
2Productivity
If modular assembly is constructed to enclose site, then environmental impact is reduced and productivity improved, but device complexity increases
Solution Approach 1:
The modular assembly is divided into standardized panels and frames that can be independently manufactured and assembled. This segmentation reduces on-site construction complexity while maintaining the ability to create enclosed spaces that ensure continuous productivity, as components can be pre-fabricated and quickly assembled.
Solution Approach 2:
The modular panels and frames are designed with universal connection mechanisms that can be used across different assembly configurations. This universality reduces the complexity of the overall system by using standardized components rather than custom-designed elements, while still enabling continuous construction operations.
3Loss of time
If pre-assembled units are used for portal frames, then assembly time is reduced, but manufacturing complexity increases
Solution Approach 1:
The portal frames are constructed from pre-assembled units that segment the manufacturing process. This allows frames to be manufactured off-site with controlled complexity and then quickly assembled on-site, reducing overall assembly time while managing manufacturing complexity through standardized production processes.
Solution Approach 2:
Portal frame units are pre-assembled and prepared before being transported to the construction site. This preliminary action reduces on-site assembly time and complexity by having components ready in a pre-configured state, allowing rapid deployment of the modular enclosure structure.
Data Source
AI summary
The present disclosure relates to a modular assembly, a site factory, for at least partially enclosing a site during construction of a structure. The modular assembly comprising: a plurality of portal frames, each portal frame comprising two columns and a roof beam, each column and roof beam comprising a plurality of pre-assembled units; a jack-up frame for each column; at least two first rails, each of the first rails being mounted to at least one of the roof beams; at least one second rail slidably mounted to the at least two first rails; and a plurality of panels of a flexible material configured to provide a full enclosure of the site and mounted above the roof beam. The or each second rail is configured to slidably receive at least one lifting device. The pre-assembled units are configured to be connected on site, and lifted using said jack-up frames, to form the portal frames, and wherein each first rail, and the or each second rail are configured to be mounted on the portal frames on site.