Modular Slab Formwork With Self-Locking Dropheads
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Solution Overview
Problem
Existing slab formwork systems require significant labor and time for installation and de-installation due to the use of props and drop heads, leading to increased costs and complexity.
Innovation Solution
A modular slab formwork system with a quick shuttering and de-shuttering assembly, featuring a formwork panel with side connectors, a base frame, and a drophead mechanism that includes a top plate, fly plate, wedge, stem, bottom plate, and locking bolt, allowing for self-aligning and rapid installation and detachment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If traditional props and drop heads are used for formwork installation, then the formwork can be supported and secured, but the installation and de-installation process becomes time-consuming and labor-intensive
Solution Approach 1:
The formwork system is divided into modular components: panels with integrated side shutters, drop heads with built-in locking mechanisms, and prop legs. This segmentation allows each component to be independently optimized for rapid assembly while maintaining overall structural integrity, enabling faster installation compared to traditional monolithic formwork systems
Solution Approach 2:
Multiple functions are merged into single components: the drop head combines support, positioning, and locking functions; the prop leg integrates support and adjustment capabilities; the panel includes integrated side shutters and reinforcement features. This merging eliminates the need for separate components and reduces the number of assembly steps, directly improving installation speed
2Ease of operation
If traditional props and drop heads are used for formwork installation, then the formwork can be supported and secured, but the labor requirements and costs increase
Solution Approach 1:
The formwork components are designed with self-aligning features and automatic locking mechanisms that reduce the need for skilled labor. The drop heads and prop legs self-position and secure themselves through integrated locking features, while the panel geometry guides proper assembly, enabling less skilled workers to complete installation quickly with minimal supervision
Solution Approach 2:
The prop legs and drop heads are designed as universal components that can be used across different panel sizes and configurations. This multi-functionality reduces the variety of components workers must learn to handle, simplifying operations and reducing labor requirements while maintaining ease of installation and de-installation
3Productivity
If formwork panels are made larger to cover more area, then the number of panels decreases and installation becomes faster, but the panels become more prone to rupture and require stronger materials
Solution Approach 1:
The formwork panels use composite construction combining rigid materials (such as engineered woods or composite panels) with integrated reinforcement features. This composite approach allows larger panel sizes while maintaining strength through the combined properties of multiple materials and structural reinforcements, preventing rupture under concrete loads
Solution Approach 2:
The panels are pre-reinforced during manufacturing with embedded strengthening features, and the side shutters are pre-positioned to provide lateral support before the concrete is poured. This preliminary reinforcement action prevents panel rupture during the critical pouring and setting phases, allowing use of larger panels without compromising strength
4Reliability
If the formwork system uses multiple components for support and securing, then the formwork can be stable and reliable, but the system complexity increases
Solution Approach 1:
Multiple support and securing functions are merged into integrated components: the drop head combines support, positioning, and locking functions; the prop leg integrates support and adjustment; the panel includes integrated side shutters and reinforcement. This merging reduces the number of separate components and connections needed, simplifying the overall system while maintaining stability through the unified design of each component
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
Facilitates rapid and stable installation with reduced labor requirements, enabling faster cycle times and lower costs through self-centering and gravity-assisted detachment of panels.
Implementation Method 1
a wedge, a stem, a bottom plate and a locking bolt
Implementation Method 2
gravity-assisted detachment of panels
Data Source
Figure 1
Figure 2a~2b
Figure 2c~2d
AI summary
The various embodiments of the present invention provide a modular slab formwork with easy shuttering and de- shuttering assembly. The formwork comprises a formwork panel and a drophead. The formwork panel comprises a plurality of side connectors, a base frame, and a form-lining. The base frame comprises a comer element on each corner. The drophead is connected to each comer of the formwork panel through the corner element. The comer element forms a locking notch to lock at least two formwork panel with each other as well as with the drophead.