Modular Prefabricated Floor System Using Steel C-Channels
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Solution Overview
Problem
Conventional structural floor systems are heavy, require formwork and concrete pumping, leading to increased construction time and costs, especially in high-rise buildings exposed to extreme weather conditions and seismic loads, and lack versatility in material choices and structural compliance.
Innovation Solution
A modular prefabricated floor system using commercially available materials like structural steel C-shaped channels, S or W/I beams, precast aerated concrete, laminated wood, and post-tensioned recycled plastic, assembled on-site without formwork, offering lightweight, flexible, and structurally compliant solutions with integrated sound, heat, and fire insulation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional structural floor systems are used, then structural strength is achieved, but weight increases and construction time extends due to formwork and concrete pumping requirements
Solution Approach 1:
The floor system is divided into modular units comprising perimeter frames, primary and secondary lattice supports, and floor membranes. These pre-fabricated modules are assembled on-site without requiring formwork, reducing both weight and construction time while maintaining structural integrity through standardized connection details
Solution Approach 2:
The system employs composite construction combining steel C-channels for perimeter frames, S or W/I beams for primary lattice supports, and floor membranes for cladding. This multi-material approach optimizes the strength-to-weight ratio by selecting materials suited to specific functional requirements rather than using homogeneous heavy concrete throughout
2Strength
If conventional floor systems with formwork are used, then structural support is provided, but construction time and costs increase
Solution Approach 1:
The perimeter frames, lattice supports, and floor membranes are pre-fabricated off-site with all structural connections prepared in advance. This preliminary action eliminates the need for formwork assembly and concrete curing time on-site, reducing construction time while maintaining full structural support capability
Solution Approach 2:
The formwork system and concrete pouring process are completely extracted from the construction process. The structural support function is achieved directly through the assembled metal framework and membrane system, eliminating the time-consuming formwork assembly, concrete placement, and curing operations
3Force
If heavy conventional floor systems are used, then load bearing capacity is ensured, but foundation and principal structure weights increase
Solution Approach 1:
The floor system applies load bearing capacity locally through the lattice support structure rather than relying on overall heavy construction. The S or W/I beams and C-channel frames are sized and spaced to provide adequate load bearing at specific locations, allowing the principal structure to be optimized for actual load requirements rather than supporting excessive floor system weight
4Productivity
If modular prefabricated systems are used, then construction efficiency improves, but material selection versatility must be maintained
Solution Approach 1:
The modular floor system employs universal C-channel perimeter frames and standardized lattice support configurations that can accommodate various floor membrane materials including metal panels, concrete panels, wood panels, or insulated panels. This universal structural framework maintains construction efficiency while allowing full material selection versatility to meet specific project requirements for insulation, fire resistance, or acoustic performance
Data Source
AI summary
The invention provides a modular structural prefabricated floor system, its manufacture, choice or options of the materials used, dependent on its use or specific application, are all commercially available standard construction materials or elements which are field, or job site assembled and then installed unto the main principal structure. A method of forming a modular floor system and a kit of parts for forming a modular floor system are also provided.