Modular Formwork for Reinforced Concrete Floors
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Solution Overview
Problem
Existing modular formworks for reinforced concrete floors with cross ribbing are limited in their ability to quickly lay and easily remove modular elements, and they do not efficiently create floors with customizable rib thickness and height for structural and design requirements.
Innovation Solution
A modular formwork system comprising central, joist, and dome-shaped elements made of rigid plastic, which can be reused, allowing for quick assembly and disassembly, and enabling the creation of reinforced concrete floors with square or rectangular mesh ribbing by resting on temporary parallel beams.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If disposable foam formworks are used, then the floor surface is obtained after removal, but the formworks cannot be reused and require more labour
Solution Approach 1:
The formwork is divided into modular plane elements that can be independently assembled and disassembled. Each element has standardized coupling devices that enable rapid connection and separation, allowing the formwork to be segmented for easy handling while maintaining structural integrity during use.
Solution Approach 2:
The formwork elements are designed to be reusable rather than disposable. After concrete curing, the elements are removed and can be reused for subsequent flooring operations, reducing waste and labor costs associated with disposing of single-use formworks.
2Ease of operation
If reusable plastic formworks are used, then labour is reduced and durability is improved, but the ability to create customizable ribbed structures is limited
Solution Approach 1:
The formwork consists of modular plane elements that can be arranged in different configurations. The elements can be coupled to form ribbed structures with varying dimensions, allowing customization of floor designs while maintaining the ease of use and durability of reusable plastic components.
Solution Approach 2:
The standardized plane elements serve multiple functions: they can form flat floor surfaces, create ribbed structures, and accommodate different spacing requirements. The universal coupling devices enable the same elements to be used in various structural configurations without requiring specialized components.
3Manufacturing precision
If modular elements are used for ribbed floors, then structural requirements can be met, but the assembly and disassembly time increases
Solution Approach 1:
The plane elements are pre-manufactured with integrated coupling devices and precise geometric features that enable rapid assembly. The coupling mechanisms are designed to lock into place quickly without requiring complex alignment procedures, reducing assembly time while maintaining manufacturing precision for ribbed floor structures.
Data Source
Figure 1~1b
Figure 2~2a
Figure 3
AI summary
Modular formwork (F) for making reinforced concrete ribbed floors, comprising central modular elements (A) suited to rest on a temporary bearing structure, defining the nodes of a grid (E) with square or rectangular meshes, a plurality of joists (B), each one suited to rest and be constrained with its ends (B22) between two of said central modular elements (A) aligned with each other, said joists (B) being arranged in such a way as to define the lines of said grid (E), a plurality of dome-shaped modular elements (C), each one suited to rest on and be constrained to said joists (B) and/or to said central modular elements (A) with its edges (C1), in order to cover each one of said meshes.