Perforated Formwork Panels with Weak Points
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Solution Overview
Problem
Conventional formwork devices for creating concrete components face issues with stability, high material and labor costs, sensitivity to mechanical damage, and complexity in assembly and reuse, particularly when used as intermediate formwork for larger structures like ceilings and floors, where they often require multiple stages of construction and must accommodate reinforcement bars.
Innovation Solution
A formwork device featuring lightweight, perforated sheet metal panels with embedded reinforcement grids and predetermined weak points or depressions that allow for easy penetration of reinforcement elements and separation after concrete hardening, reducing the need for additional fastening and enhancing stability against mechanical forces.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If foam panels are used as permanent ceiling edge formwork, then thermal insulation is improved and thermal bridges are prevented, but the panels require a large number of supports at small distances to prevent breakage or deformation
Solution Approach 1:
The formwork panel uses a composite structure combining a foam core layer for thermal insulation with outer layers of more rigid material (such as fiberboard or particle board) that provide structural strength. This allows the panel to maintain insulation properties while reducing the need for numerous supporting brackets.
2Temperature
If foam panels are used as permanent ceiling edge formwork, then thermal insulation is improved, but the panels are very sensitive to mechanical damage from impacting tools or footsteps
Solution Approach 1:
The panel employs a composite construction where the foam core provides insulation while outer protective layers (such as fiberboard, particle board, or oriented strand board) provide mechanical strength and resistance to damage from tools and foot traffic.
Solution Approach 2:
The panel design includes a protective skin or film layer that covers the fragile foam core, providing a durable surface that resists mechanical damage while allowing the underlying foam to maintain its insulation function.
3Ease of operation
If conventional slab edge formwork is used as intermediate formwork, then passage openings for reinforcement bars must be created on site, but the formwork cannot be reused more than once
Solution Approach 1:
The formwork panels are manufactured with predetermined passage openings for reinforcement bars before being delivered to the construction site. This eliminates the need for on-site drilling or cutting operations and allows the panels to be reused multiple times without compromising their structural integrity or sealing properties.
4Ease of manufacture
If nets clamped in frames are used for intermediate formwork, then the structure can be assembled, but the nets are difficult to produce in satisfactory quality and have insufficient sealing properties
Solution Approach 1:
The formwork panel uses composite material construction with layered boards (such as fiberboard, particle board, or OSB) that provide both structural integrity and effective sealing properties, eliminating the need for separate net and frame assemblies.
5Ease of manufacture
If nets clamped in frames are used for intermediate formwork, then the structure can be assembled, but a large number of stable frames and mounts or additional struts with small mutual spacings are required
Solution Approach 1:
The formwork system uses standardized modular panels that can be assembled in segments, reducing the need for numerous individual frames and mounts. Each panel is self-supporting and can be quickly connected to adjacent panels, simplifying the overall assembly process.
Data Source
Figure 1~2
Figure 3~4
Figure 5
AI summary
The device has a formwork plate (5) with areas formed as weak spots, where the formwork plate has maximum layers for limiting a viscous concrete mass. The maximum layers of the formwork plate are provided at the areas of the weak spots. The layers of the formwork plate exhibit a homogenous material composition in the areas of the weak spots. The formwork plate has a main plate manufactured from foam or pressable and hardening material and/or form-stable material such as fiber-reinforced concrete, wood product, metal or plastic.