Modular Formwork with Flexible Compensators for Spiral Staircases
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Solution Overview
Problem
Traditional formwork for spiral staircases is cumbersome, time-consuming, and expensive to set up, requiring specialized labor and oversized lifting gear, and does not guarantee the necessary quality and precision.
Innovation Solution
A formwork device with a central core that allows simultaneous adjustment of step heights and lengths, using a rotating mechanism with threaded shafts and arms, and flexible compensators made of composite materials to adapt to various staircase shapes, eliminating the need for expensive lifting gear.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional framework formwork is used for spiral staircases, then the structure provides sufficient strength and stability, but the installation is long and difficult requiring specialized labor
Solution Approach 1:
The formwork is divided into modular elements (side formwork pieces, riser formwork members, bench formwork sections) that can be independently manufactured and assembled. Each module is standardized with specific dimensions and connection mechanisms, allowing rapid assembly without specialized labor while maintaining structural integrity through standardized joining methods.
Solution Approach 2:
The formwork system incorporates adjustable and movable components including height-adjustable props, telescopic support elements, and formwork pieces that can be positioned and secured at various locations. This dynamic capability allows the same modular system to adapt to different staircase geometries while maintaining ease of installation through standardized procedures.
2Reliability
If traditional framework formwork is used for spiral staircases, then the structure provides sufficient strength and stability, but the installation time is about thirty hours
Solution Approach 1:
The formwork is divided into modular elements (side formwork pieces, riser formwork members, bench formwork sections) that can be independently manufactured and assembled. Each module is standardized with specific dimensions and connection mechanisms, allowing rapid assembly without specialized labor while maintaining structural integrity through standardized joining methods.
Solution Approach 2:
Formwork elements are pre-manufactured with standardized dimensions, pre-drilled connection holes, and pre-assembled joint mechanisms. The modular components are prepared in advance at the factory with precise tolerances and integrated connection systems, enabling rapid on-site assembly that reduces installation time from thirty hours to a fraction of that duration while ensuring structural reliability.
3Reliability
If traditional framework formwork is used for spiral staircases, then the structure provides sufficient strength and stability, but the formwork manufacturing is expensive and requires specialized labor
Solution Approach 1:
The modular formwork elements are designed with universal dimensions and standardized connection systems that can be used across multiple staircase projects and configurations. The same basic modules (side formwork pieces, riser formwork members, bench formwork sections) can be combined in various arrangements to create different staircase geometries, eliminating the need for custom-built formwork for each project and significantly reducing manufacturing costs while maintaining structural strength.
4Reliability
If traditional framework formwork is used for spiral staircases, then the structure provides sufficient strength and stability, but the quality and precision are not guaranteed
Solution Approach 1:
The formwork is divided into modular elements (side formwork pieces, riser formwork members, bench formwork sections) that can be independently manufactured and assembled. Each module is standardized with specific dimensions and connection mechanisms, allowing rapid assembly without specialized labor while maintaining structural integrity through standardized joining methods.
Solution Approach 2:
Formwork elements are pre-manufactured with standardized dimensions, pre-drilled connection holes, and pre-assembled joint mechanisms. The modular components are prepared in advance at the factory with precise tolerances and integrated connection systems, enabling rapid on-site assembly that reduces installation time from thirty hours to a fraction of that duration while ensuring structural reliability.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Enables quick and easy adaptation to all staircase shapes, reducing setup time from thirty hours to eight hours, ensuring high quality and precision without the need for oversized lifting equipment, and allowing for the reuse of formwork elements.
Implementation Method 1
a threaded shaft, a nut mounted on said threaded shaft and supporting a said axis of rotation carrying one end of a said arm
Implementation Method 2
at least one flexible mold supported on at least one compensator
Data Source
Figure 1
Figure 2~3
Figure 4~5
AI summary
The device has side compensators e.g. internal compensator (105), concave external compensator (106), convex external compensators (107), fixed to a fixed support, where each compensator comprises a concave cut and a convex cut. A mold (115) is flexibly supported on the compensator. The compensator is made of flexible material and composite material. The flexible mold comprises elements whose edges have a lesser thickness than that of the center, and a smooth face. The compensator presents a cut in L-shape with two plane surfaces forming a right angle between each other. An independent claim is also included for a method for forming a circular staircase.