Modular Ledger Rail for Integrated Construction System
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Solution Overview
Problem
Conventional formwork and shoring systems require large inventories of components, leading to inefficiencies in assembly and high loss rates, and lack the versatility to handle both vertical and horizontal concrete construction aspects, as well as provide safe worker access during construction.
Innovation Solution
The integrated construction system employs modular, non-welded lightweight aluminum components with mechanical fasteners, allowing for configuration as both formwork and shoring systems, and includes features like adjustable ledger struts and rail systems to support vertical and horizontal loads, and provide safe access solutions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If conventional formwork and shoring systems are used, then various configurations can be achieved, but the inventory requires significantly large amounts of components
Solution Approach 1:
The patent applies universality by designing a single standardized component (the ledger rail with specific hole pattern) that can serve multiple functions: vertical formwork, horizontal shoring, and safety deck construction. The standardized rail with universally spaced holes replaces the need for multiple specialized components, allowing one inventory item to fulfill roles previously requiring different dedicated parts.
Solution Approach 2:
The patent segments the conventional monolithic formwork and shoring systems into modular components based on the standardized ledger rail. By dividing the system into repeatable units with consistent hole patterns, the design enables flexible assembly for various configurations while maintaining a reduced, standardized inventory. The segmentation allows components to be easily assembled and disassembled for different applications.
2Adaptability or versatility
If conventional systems with large inventories are used, then various configurations can be achieved, but assembly efficiency is low
Solution Approach 1:
The patent applies parameter changes by establishing a standardized hole pattern with specific spacing parameters along the ledger rail. This standardized parameter system enables rapid assembly through pre-determined connection points, eliminating the need for field measurements and custom positioning. The consistent parameter pattern across all components allows for quick, efficient assembly while maintaining versatility for various configurations.
3Adaptability or versatility
If conventional systems with many components are used, then various configurations can be achieved, but component loss is high
Solution Approach 1:
The patent reduces component loss by designing a universal ledger rail that can be reused across multiple projects and applications. Instead of having specialized components for each function that are lost or damaged, the standardized rail serves as a durable, multi-purpose element that maintains its integrity and can be recovered and reused, thereby reducing overall component loss.
4Reliability
If independent formwork and shoring systems are used, then specific functions are optimized, but the system lacks integration for safe worker access
Solution Approach 1:
The patent merges the formwork and shoring systems into a single integrated structure using the standardized ledger rail. By combining these previously separate systems into one unified platform with consistent components, the design simultaneously provides optimized structural functions and integrated safe worker access pathways, eliminating the need for separate access systems.
Data Source
AI summary
Various implementations described herein are directed to a modular ledger of an integrated construction system. In one implementation, the modular ledger includes a rail, having a first end and a second end. Each end of the rail is configured to receive a coupling component. The rail has a plurality of holes configured to couple to bracing components of the integrated construction system.