Permanent Rammed Earth Formwork-Facade for Faster Construction
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Solution Overview
Problem
Traditional formworks for rammed earth and concrete structures are time-consuming, costly, and environmentally harmful, requiring frequent replacement, and result in energy loss due to high thermal exchange, with concrete facades needing additional finishing and posing safety risks.
Innovation Solution
A permanent rammed earth formwork-facade system comprising two side panels with a mesh network, barbed wire reinforcement, and L-shaped anchor bolts, allowing for a durable, thermally insulated, and integrated facade that remains in place after construction, using materials like metal alloys and geosynthetic materials.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If traditional formworks are used for rammed earth and concrete structures, then construction can be completed, but the process is time-consuming and costly requiring frequent formwork replacement
Solution Approach 1:
The patent merges the formwork function with the permanent facade function into a single integrated system. The formwork panels are designed to remain in place after concrete pouring, serving as both the construction template and the building's exterior cladding, thereby eliminating the need for separate formwork removal and facade installation processes
Solution Approach 2:
The formwork system is designed to perform multiple functions: it serves as the temporary mold for concrete pouring, provides structural support during construction, and becomes the permanent facade of the building. This multi-functionality eliminates the need for separate formwork and facade components, directly addressing the time and cost issues
2Ease of manufacture
If traditional formworks are removed after construction, then the formwork can be reused, but this process entails spending a lot of time and money and the formworks become unusable after several uses
Solution Approach 1:
The formwork and permanent facade are merged into a single component that does not need to be removed or reused. The formwork is designed to be a permanent structure that remains attached to the building, eliminating the cyclical process of removal, collection, and recycling that consumes time and resources
3Strength
If concrete facades are used, then structural strength is achieved, but the facade looks cold and dry requiring additional facade working
Solution Approach 1:
The formwork panels are designed with an exterior surface that becomes the final facade finish. This surface is pre-finished during formwork manufacturing with textures, colors, or patterns that provide aesthetic appeal, eliminating the need for additional facade finishing work while maintaining the structural concrete behind it
4Strength
If concrete walls are used, then high structural strength is achieved, but thermal exchange is high causing energy losses
Solution Approach 1:
The patent applies different material properties to different parts of the wall system: the inner concrete layer provides structural strength while the outer formwork facade layer provides thermal insulation. This local differentiation of material qualities allows the structure to simultaneously achieve high strength and low thermal exchange
5Reliability
If facades are installed on concrete surfaces, then exterior protection is provided, but installation is difficult on smooth and tough surfaces and separation occurs
Solution Approach 1:
The formwork and facade are merged into a single integrated component that is poured together with the concrete structure. This eliminates the separate installation process that involves attaching facades to smooth concrete surfaces, thereby avoiding the difficulties and separation issues associated with post-construction facade installation
Data Source
AI summary
Disclosed herein is a permanent rammed earth formwork-façade, including two parallel side panels, a plurality of galleys and/or rebars fastened transversally between the two side panels interconnecting the two side panels to each other, and a plurality of Ω-shaped fasteners fastening the plurality of galleys between the two side panels and receiving rebars connecting side by side adjacent side panels of two or more of the permanent rammed earth formwork-facades in large formwork-facades. Each side panel includes a double-layered rammed earth wall reinforced by a mesh network there inside, a barbed wire woven into the mesh network, a plurality of rebars fastened to the mesh network, and a plurality of L-shaped anchor bolts fastened to the mesh network, a respective Ω-shaped fastener, and a respective rebar. Each side panel further includes a water-proof thermal insulator layer coated on an interior surface of the double-layered rammed earth wall.