Modular Formwork Rebate Formation for Building Panel Sealing
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Solution Overview
Problem
Existing building systems, including modular wall panels and formwork, face challenges in modularity, connectivity, adaptability, sealing, and structural support, leading to issues with repeatability, accuracy, and suitability for forming suitable ground or base structures to support panels.
Innovation Solution
A panel system with modular panels featuring apertures for alignment and sealing, and a formwork system with releasable seals and void formers that align with panel apertures, allowing for secure and accurate fitting and sealing with concrete slabs, along with a coupling mechanism for formwork members to ensure precise alignment and abutment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If traditional formwork members are cut to length and jointed at mitre joints, then the formwork can be adapted to different slab sizes, but the repeatability and accuracy of rebate formation deteriorates
Solution Approach 1:
The formwork system is divided into modular sections with standardized lengths that can be combined in different configurations. Each module contains integrated rebate formation capabilities, ensuring consistent geometry regardless of total slab size. The modular nature allows adaptation to various slab dimensions while maintaining precision through repeated use of the same standardized components.
Solution Approach 2:
The formwork members are designed as universal components that can be used across different slab sizes and configurations. The standardized modules with integrated rebate formation can serve multiple purposes - forming both the slab surface and the rebate in a single operation, eliminating the need for custom-cut pieces and mitre joints for each application.
2Productivity
If modular panels are stood on supporting ground surface and interconnected by connectors, then construction speed increases, but the weatherproof sealing between panels and concrete slab deteriorates
Solution Approach 1:
The formwork members are prepared in advance with integrated sealing features and rebate geometries that ensure proper sealing positions. The rebates are formed during the slab pouring process itself, creating pre-positioned sealing surfaces that align with the modular panels. This preliminary preparation eliminates the need for field adjustments and ensures consistent weatherproof sealing across all panel-to-slab connections.
3Device complexity
If traditional formwork members are used without integrated seals, then the formwork structure remains simple, but additional sealing steps and materials are required
Solution Approach 1:
The sealing function is merged directly into the formwork member structure itself. The rebate formation and sealing surface creation are combined in a single integrated component rather than being separate operations. This eliminates the need for additional sealing materials and steps, as the formwork member itself creates the sealing interface when removed from the cured slab.
Data Source
AI summary
A building system (5) including a panel system (10) and a formwork system (78). The panel system (10) includes a plurality of modular panels (12) arranged to fit with one another in a predetermined grid arrangement (13) to form side walls of a building in a fitted condition. At least the bottom sides (24) of each of the modular panels (12) includes a plurality of apertures (34) that are arranged at predetermined spaced apart locations along the bottom side (24) so as to coincide with the predetermined grid arrangement (13). The formwork system (78) includes a plurality of modular formwork members (80) that are associated with each of the modular panels (12) to provide a supporting slab (72) having slab apertures (76) to allow coupling with the modular panels (12). Modular panels (12), formwork members (80) and associated methods of use are also disclosed.