Modular Stair Formwork with Adjustable Support Plates
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Solution Overview
Problem
The construction industry faces challenges with the need for diverse stair formwork due to varying storey heights, slab thicknesses, and tread widths, leading to high formwork costs and storage issues, as existing systems require multiple types of formwork for different dimensions and often result in inefficient production and storage.
Innovation Solution
A modular formwork system with adjustable step depth and width, utilizing prefabricated support plates and clamping elements, allowing for quick assembly and adjustment to accommodate various stair geometries, reducing the need for multiple formwork types and enabling 'just-in-time' production.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If multiple types of formwork are manufactured to accommodate different stair dimensions (storey heights, slab thicknesses, tread widths), then the adaptability to various stair geometries is improved, but the device complexity and storage requirements increase significantly
Solution Approach 1:
The formwork system is divided into modular components including formwork elements with standardized connections, adjustable support plates with multiple positioning holes, and separable clamping mechanisms. This segmentation allows individual components to be reconfigured for different stair geometries without requiring complete formwork sets for each dimension variant.
Solution Approach 2:
The formwork system incorporates adjustable and movable components such as support plates that can be positioned at different heights and locations, formwork elements that can be reconfigured, and clamping mechanisms with variable positioning. This dynamic adjustability enables a single formwork system to adapt to multiple stair configurations rather than requiring static, dimension-specific formwork types.
2Adaptability or versatility
If formwork is manufactured on demand to match specific project requirements, then the adaptability to different stair types is improved, but the production time and costs increase due to frequent formwork changes
Solution Approach 1:
The formwork system is pre-configured with standardized connection points, pre-positioned support plates, and pre-assembled modular elements that can be quickly reconfigured. This preliminary preparation of adjustable features allows rapid adaptation to different stair geometries without requiring time-consuming custom fabrication or complex assembly procedures for each new configuration.
Solution Approach 2:
The system enables quick adjustment of key parameters such as support plate positions, formwork element orientations, and clamping locations through standardized mechanisms. By designing for parameter variability rather than fixed dimensions, the formwork can be rapidly reconfigured between different stair types while maintaining production efficiency.
3Productivity
If formwork is manufactured for stock to meet future demand, then the productivity and delivery time are improved, but the storage costs and space requirements increase significantly
Solution Approach 1:
The formwork system is designed as a universal platform that can produce multiple stair types and configurations using the same core components. A single set of formwork elements, support plates, and clamping mechanisms can be reconfigured to manufacture various stair geometries, eliminating the need to store multiple specialized formwork types for different stair dimensions.
Solution Approach 2:
The modular formwork components are designed to be disassembled, stored in compact configurations, and rapidly reassembled for different production runs. This allows the same formwork elements to be recovered and reused across multiple projects rather than requiring dedicated formwork sets for each stair type, significantly reducing storage requirements.
4Manufacturing precision
If individual wooden formwork is added to supplement precast concrete systems, then the manufacturing precision and fit are improved, but the ease of manufacture and production complexity worsen
Solution Approach 1:
The system merges the advantages of precast concrete efficiency with the flexibility of custom formwork by integrating adjustable support plates and modular formwork elements into a unified system. This combination provides the precision of customized fit while maintaining the standardized manufacturing processes and productivity of precast systems, eliminating the need for separate supplemental wooden formwork.
Data Source
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Figure 2
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AI summary
A formwork (4) for a hardenable material, in particular concrete, for the production of a staircase, with a support structure (2), has a formwork wall (3) for the underside of the staircase and mutually adjustable formwork elements (1) for forming steps, as well as at least one support plate (12) against which the formwork elements (1) rest, and tensioning elements (19) to tension the formwork elements (1) against the support plate (12).