Pre-fabricated Modular Stone Element with Self-compacting Grout
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Solution Overview
Problem
Traditional stone laying methods are time-consuming, environmentally challenging, and require skilled labor, leading to prolonged project durations, traffic disruptions, and suboptimal work environments, especially in cold climates, due to the manual nature of the work and the need for extensive preparation and jointing.
Innovation Solution
A pre-fabricated modular element comprising stones and a self-compacting cement-based grout, designed to be manufactured in a form with a flexible bottom, allowing for efficient production and immediate use, reducing the need for on-site manual labor and jointing, and enabling machine-based installation, which shortens project timelines and improves work conditions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If manual stone laying is performed with careful foundation preparation and jointing, then the stone surface becomes stable and secure, but the project duration extends to several months or years
Solution Approach 1:
The patent applies preliminary action by pre-assembling stone modules with integrated foundation layers and jointing materials in a controlled factory environment. The modules are manufactured with pre-placed stones, sand layers, and binding agents before being transported to the construction site, eliminating the need for time-consuming on-site foundation preparation and jointing work.
Solution Approach 2:
The patent segments the stone surface into modular units that can be independently manufactured, transported, and installed. Each module contains a complete set of stones with integrated foundation and jointing components, allowing parallel production of multiple modules and rapid sequential installation without waiting for previous sections to cure or set.
2Reliability
If manual stone laying with foundation preparation is performed, then the stone surface achieves proper stability, but the work requires extensive skilled labor and experience
Solution Approach 1:
The patent transfers the skilled labor requirements from the construction site to the factory environment, where modules are pre-assembled by skilled workers under controlled conditions. The modular design standardizes the assembly process, allowing less skilled workers to install the pre-fabricated modules using simple mechanical equipment, thereby reducing the skill requirement on-site.
Solution Approach 2:
The patent replaces manual mechanical stone laying operations with machine-based module installation. Heavy machinery is used to position and compact the modular units, substituting the need for skilled manual labor in foundation preparation, stone placement, and jointing with automated or semi-automated mechanical systems.
3Ease of operation
If manual stone laying is performed on-site, then the stone surface can be created, but the work is physically demanding and creates suboptimal work environment especially in cold climates
Solution Approach 1:
The patent moves the labor-intensive stone assembly operations to an indoor factory environment where workers are protected from adverse weather conditions. Modules are manufactured in controlled environments with stable temperatures and protected working conditions, eliminating the physical demands and environmental challenges of outdoor stone laying in cold climates.
Solution Approach 2:
The patent replaces physically demanding manual stone handling and placement operations with mechanical lifting and positioning equipment. Cranes, forklifts, and other heavy machinery are used to transport and install the heavy modular units, significantly reducing the physical strain on workers compared to manual stone laying.
4Ease of operation
If traditional manual stone laying with jointing is performed, then the stone surface is created, but traffic disruptions occur during the extended laying period
Solution Approach 1:
The patent completes all stone assembly, foundation preparation, and jointing operations in advance at the factory before the modules are transported to the site. This preliminary completion of all complex work eliminates the need for prolonged on-site construction activities that would disrupt traffic, reducing the disruption period to only the module installation phase.
Solution Approach 2:
The patent segments the construction process into factory-based module production and on-site installation, allowing the time-consuming fabrication work to occur off-site during periods when it does not affect traffic. The modular design enables rapid installation with minimal traffic disruption, as complete functional units are simply positioned and compacted in place.
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
The solution significantly reduces project duration, minimizes traffic disruptions, enhances work environment safety, and improves surface quality by eliminating the need for extensive on-site manual labor and jointing, allowing for faster and higher-quality stone surface creation regardless of weather conditions.
Implementation Method 1
A pre-fabricated modular element comprising stones and a self-compacting cement-based grout
Data Source
Figure 1
Figure 2~3
Figure 4a~4f
AI summary
This invention concerns an element 1 intended to be laid on a base A in order to obtain at least one of walking surfaces, traffic-bearing surfaces, decorative surfaces and other types of surface. The element 1 comprises stones 2 and a grout 3. The stones 2 are arranged at a distinct distance from each other. The grout 3 forms a slab 4 that is arranged under or behind each stone 2 and that holds the stones 2 together. The grout 3 fills the spaces 5 that are present between the stones 2. The grout 3 forms and constitutes together with one surface 2.1 of each stone 2 at least one of a wear surface, a decorative surface, an upper side and a front surface 6 of the element 1. The invention concerns also a method for the manufacture of an element 1 according to the invention and a form that is to be used during the manufacture of an element 1 according to the invention.