Modular Wall Structure Minimizes Field Welding
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The combination of cast-in-place reinforced concrete walls and structural steel framing in mid-rise to high-rise building construction poses logistical challenges, including interference between concrete formwork and steel framing, leading to increased construction time and costs due to the need for extensive field welding and high-skilled labor.
Innovation Solution
A composite building construction system that minimizes field welding by using prefabricated double steel plate modules with concrete infill, employing field-bolted connections and shop-welded anchors to achieve structural continuity, allowing for faster and more economical construction.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If cast-in-place reinforced concrete walls and structural steel framing are used together, then structural integrity is achieved, but construction time increases due to sequential installation requirements
Solution Approach 1:
The wall assembly is segmented into modular components: pre-fabricated steel plate modules with integrated reinforcement cages and formwork, allowing parallel fabrication and installation. The steel plates are divided into manageable modules that can be erected independently of concrete curing schedules.
Solution Approach 2:
Reinforcement cages and formwork are pre-assembled with steel plates in the fabrication shop before delivery to site. This preliminary action eliminates on-site cage assembly and formwork installation, enabling faster construction without compromising structural integrity.
2Stability of the object's composition
If cast-in-place concrete construction is used, then structural continuity is achieved, but manufacturing precision decreases due to greater construction tolerances
Solution Approach 1:
The continuous concrete structure is segmented into discrete modules with standardized connection details. Each module is fabricated to precise factory tolerances, and the modular interface design ensures accurate field assembly while maintaining overall structural continuity.
Solution Approach 2:
Steel connection plates and grout joints serve as intermediaries between pre-fabricated modules, ensuring precise alignment and continuous load transfer while accommodating minor dimensional variations from factory fabrication.
3Stability of the object's composition
If extensive field welding is used to connect steel modules, then structural continuity is achieved, but construction costs increase due to high-skilled labor requirements
Solution Approach 1:
Welding operations are replaced with mechanical connection systems including bolted flange connections, pinned joints, and friction-grip fasteners. These mechanical connections achieve structural continuity without requiring skilled welders, reducing labor costs and simplifying quality control.
Solution Approach 2:
The connection method transitions from permanent welded joints to reversible mechanical connections. This parameter change allows for easier inspection, adjustment, and disassembly while maintaining adequate structural continuity for the application.
Data Source
AI summary
A method of construction of composite wall module system in which a first wall module and a second wall module are coupled to the first wall module by a vertical joint. The vertical joint is comprised of plurality of anchors and reinforcement bars as well as steel side plates allowing composite wall steel faceplates to be discontinuous across the vertical joint. The faceplates of the first and second modules are not made continuous across the vertical joint through continuous welding. The vertical wall joint further includes fill disposed between faceplates and side plates adjacent to anchors and reinforcement bars.