Modular Formwork System with Integrated Sheet Metal Water Barriers
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Solution Overview
Problem
Existing formwork systems for concrete construction face challenges in efficiently and cost-effectively sealing angled joints in floor/ceiling plates, often requiring custom-made parts and increased workload, leading to higher costs and complexities on construction sites.
Innovation Solution
A modular formwork system comprising standard, angle, and passel elements with sheet metal strips acting as water barriers, allowing for easy assembly and sealing of non-linear joints without the need for custom adaptations, using a combination of prefabricated elements and a seal coating for enhanced stability and water resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If custom-made formwork components are used for non-linear joints, then the sealing capability is improved, but the manufacturing cost and complexity increase
Solution Approach 1:
The formwork system is divided into standardized modular elements (corner elements, straight elements, T-elements, cross elements) that can be combined to form non-linear joints. Each module contains integrated sheet metal strips for sealing, eliminating the need for custom-made components while maintaining sealing capability through systematic assembly of predefined segments.
Solution Approach 2:
The standardized formwork elements are designed with multi-functionality, serving both structural support and sealing functions through integrated sheet metal strips. The same modular elements can be used to create various joint configurations (angled, T-shaped, cross-shaped), reducing the need for specialized custom components for different sealing scenarios.
2Reliability
If custom-made formwork components are used for non-linear joints, then the sealing capability is improved, but the manufacturing cost increases
Solution Approach 1:
The formwork system is divided into standardized modular elements (corner elements, straight elements, T-elements, cross elements) that can be combined to form non-linear joints. Each module contains integrated sheet metal strips for sealing, eliminating the need for custom-made components while maintaining sealing capability through systematic assembly of predefined segments.
Solution Approach 2:
The system uses standardized elements with fixed geometric parameters (angles, dimensions) that can be combined in various configurations. By changing the arrangement and combination of these standardized parameters rather than creating custom components, the sealing capability is achieved at lower manufacturing cost through economies of scale in producing standardized parts.
3Adaptability or versatility
If improvised formwork components are joined on-site, then the adaptability is improved, but the labor intensity increases
Solution Approach 1:
The formwork system is divided into standardized modular elements (corner elements, straight elements, T-elements, cross elements) that can be combined to form non-linear joints. Each module contains integrated sheet metal strips for sealing, eliminating the need for custom-made components while maintaining sealing capability through systematic assembly of predefined segments.
Solution Approach 2:
The standardized formwork elements are designed with self-aligning features and integrated connection mechanisms that facilitate easy assembly on-site. The elements come pre-configured with sheet metal strips and connection points, allowing workers to assemble complex non-linear joints using simple connection operations without requiring skilled improvisation or additional fastening steps.
4Strength
If large steel formwork elements are used, then the structural strength is improved, but the weight increases
Solution Approach 1:
The formwork elements combine wood or composite materials for the main structure with thin sheet metal strips for sealing. This composite approach provides sufficient structural strength for formwork applications while keeping the weight significantly lower than all-steel construction. The sheet metal strips add minimal weight while delivering the required sealing function.
Solution Approach 2:
The formwork system is divided into standardized modular elements (corner elements, straight elements, T-elements, cross elements) that can be combined to form non-linear joints. Each module contains integrated sheet metal strips for sealing, eliminating the need for custom-made components while maintaining sealing capability through systematic assembly of predefined segments.
Data Source
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AI summary
This document describes a formwork system for concrete construction comprising at least one standard element S, at least one angle element W, and at least one adapter element P. All three elements feature a horizontal strip of sheet metal, designed as a water barrier, which runs in the installed direction. The sheet metal strip of the standard element S and the angle element W is freely accessible at one end edge, meaning it is not connected to any formwork component. To form the formwork, the standard element S and the angle element W are positioned so that the two freely accessible sections of the sheet metal strips are aligned and adjacent to each other.Since the horizontal extent PA of the horizontal sheet metal strip P2 of the fitting element P in the plane of the formwork part P1 corresponds to the sum of the horizontal extent SA1 of the freely accessible area of the first surface S3a of the horizontal sheet metal strip S3 of the standard element S in the plane of the upper formwork part S2 plus the horizontal extent WA1 of the freely accessible area of the first surface W31a of the first sheet metal strip section W31 of the angle element W in the plane of the first upper formwork part WO1, the fitting element P can be inserted between the standard element S and the angle element W. The formwork parts of the three elements are then arranged in a common plane and form a continuous, closed formwork.