Modular Shuttering Elements with Interlocking Nesting for Curved Walls
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Solution Overview
Problem
Conventional shuttering blocks are limited in width, unsuitable for large section reinforcement cages, and difficult to handle, especially for structures requiring significant wall thickness and curvature, and are often made of mineral aggregate concrete, which is not suitable for plant fiber concrete applications.
Innovation Solution
A set of stackable and nestable formwork elements with U-shaped longitudinal sections and interlocking notches, allowing for the creation of walls of varying widths and curvatures, made from materials like plant fiber concrete, which facilitates the installation of reinforcement cages and reduces handling difficulties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If conventional shuttering blocks are used, then vertical alignment is facilitated, but significant overlap of reinforcing bars is required and large section reinforcement cages cannot be installed
Solution Approach 1:
The shuttering system is divided into modular blocks with standardized dimensions (20cm, 25cm, 30cm widths) that can be combined in various configurations. The blocks feature standardized recesses and protrusions that segment the reinforcement cage installation process, allowing bars to pass through predetermined paths while maintaining vertical alignment through interlocking mechanisms.
Solution Approach 2:
The shuttering blocks are designed with universal interlocking features (recesses and protrusions) that serve multiple functions: vertical alignment, horizontal connection, and reinforcement cage guidance. The same block design accommodates both small and large section reinforcement cages by adjusting the arrangement and number of blocks, making the system versatile for different structural requirements.
2Ease of manufacture
If shuttering blocks are made in limited widths (20-30 cm), then manufacturing is simplified, but walls thicker than 30 cm cannot be created
Solution Approach 1:
The wall thickness requirement is solved by segmenting the wall into multiple blocks placed side-by-side. Standardized block widths (20cm, 25cm, 30cm) are manufactured using simple molding processes, and desired wall thicknesses are achieved by assembling the appropriate number of blocks in horizontal rows, maintaining manufacturing simplicity while providing versatility in wall thickness.
Solution Approach 2:
Multiple standardized blocks are merged horizontally to create walls of various thicknesses. The interlocking mechanisms (recesses and protrusions) ensure that combined blocks maintain structural integrity and proper alignment, allowing the system to create walls thicker than any single block width while keeping individual block manufacturing simple.
3Strength
If shuttering blocks are made of mineral aggregate concrete, then structural strength is achieved, but weight becomes significant (20-24 kg per block)
Solution Approach 1:
The block weight issue is addressed by changing the density parameter of the concrete material. Instead of using dense mineral aggregate concrete throughout, the invention employs lightweight concrete with lower density (typically using lightweight aggregates such as expanded clay, perlite, or vermiculite). This parameter change reduces block weight to facilitate handling while maintaining adequate structural strength through proper mix design and reinforcement integration.
4Ease of operation
If shuttering blocks are designed for straight walls, then assembly is simplified, but curved wall construction becomes delicate and random
Solution Approach 1:
Curved wall construction is achieved by segmenting the curve into a series of straight block segments arranged in an arc. The standardized block dimensions allow for precise angular calculations to create smooth curves. Blocks are positioned at specific angles relative to each other, with the interlocking mechanisms maintaining alignment throughout the curve, transforming a complex curved construction problem into a series of simple straight block placements.
Solution Approach 2:
The shuttering blocks incorporate asymmetric features (such as offset recesses and protrusions, or angled connection surfaces) that enable curved arrangements. These asymmetric elements allow blocks to be positioned at varying angles while maintaining proper interlocking, facilitating curve construction without requiring custom-shaped blocks, thus preserving assembly simplicity while enabling curvature.
Data Source
Figure 1~2
Figure 3~4
Figure 5~6
AI summary
The invention relates principally to a shuttering element which is essentially characterized in that it comprises a facial longitudinal wall (14) and two opposite lateral walls (9, 10) each extending from said longitudinal wall (14) to a free end edge (8) forming a free end piece, in that the respective external faces (19, 20) of the two lateral walls (9, 10) have nesting crenellations that are alternately proud (7) and set back (6), and in that the free end edge (8) of the first lateral wall (9) has a first nesting element (11) that cooperates with a second nesting element (12) located on the free end edge (8) of the second, opposite lateral wall (10). The invention also relates to a set of shuttering elements which comprises at least one such shuttering element (1, 1bis, 3, 4, 5, 5bis), and at least one insert (2) having a first free edge (15) forming a free end piece provided with a first nesting element (12) that cooperates with the first nesting element (11) of the free end piece (8) of the first lateral wall (9) of the shuttering element (1, 1bis, 3, 4, 5, 5bis), and a second, opposite free edge (26) forming a free end piece provided with a second nesting element (11) that cooperates with the second nesting element (12) of the free end piece (8) of the second lateral wall (10) of the shuttering element (1, 1bis, 3, 4, 5, 5bis).