Modular Walled Spa Construction Using Segmented Frame Assemblies
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Solution Overview
Problem
Traditional construction of walled systems, particularly spa structures, is labor-intensive and costly due to in-situ construction difficulties and variations in quality and standards, with additional challenges posed by the need for a water-tight structure that withstands significant structural load.
Innovation Solution
A modular construction approach for spa systems using standardized components, including an outer frame, medial frame, and inner frame with brace assemblies and rebar grids, allowing for efficient assembly and concrete pouring, along with a kit that includes various components for installation and protection features.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If traditional in-situ construction methods are used for walled spa systems, then the structure can be built on-site, but the construction process becomes labor-intensive and costly with wide variation in quality and standards
Solution Approach 1:
The spa structure is divided into modular wall panels, frames, and components that can be manufactured separately and assembled on-site. This segmentation allows for standardized production of individual units while simplifying the overall construction process through systematic assembly of pre-manufactured elements.
Solution Approach 2:
Wall panels and structural components are manufactured in advance in a controlled factory environment before being transported to the construction site. This preliminary manufacturing action ensures consistent quality standards are met during production, while the on-site assembly process is streamlined and less labor-intensive.
2Reliability
If traditional construction methods are used for spa structures, then the walls can be built to hold water, but the construction process is labor-intensive and relatively costly
Solution Approach 1:
The water-containing structure is segmented into modular wall panels with integrated sealing systems. Each panel is designed as a complete unit with built-in water-tight features, allowing for reliable assembly through standardized connections rather than complex on-site sealing processes.
Solution Approach 2:
The construction approach transitions from traditional masonry or concrete pouring to modular panel assembly with standardized dimensions and pre-applied sealing parameters. This parameter change in the manufacturing process enables factory-controlled quality assurance for water-tightness while reducing on-site labor requirements.
3Productivity
If modular construction approach is used, then construction time and costs are reduced with higher quality and consistency, but the system requires standardized components and frames
Solution Approach 1:
Standardized wall panels and frame components are designed to serve multiple functions: structural support, water containment, and aesthetic finish. The universal design of these modular units allows them to be used in various configurations while maintaining consistent quality standards and simplifying the assembly process through repeated use of the same standardized elements.
Data Source
AI summary
Systems and methods for modular walled systems, such as modular walled spas and modular walled privacy fences and can protect pool and spa equipment from the public. In one embodiment, the modular walled system includes an outer frame disposed within a medial frame, and an inner frame disposed within the medial frame, wherein each frame includes a set of brace assemblies that connect to rebar grids. The brace assemblies may include a foot plate and threaded couplers. The wall system also provides protective room for electrical raceways and a secure anchor substrate to attach electronics, panels, boxes or lighting systems.