Reusable Plastic Masonry Form System Modular Assembly
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Solution Overview
Problem
Conventional masonry forms, such as wooden forms, are often destructive and not reusable, while steel forms are heavy and difficult to handle, store, and transport, necessitating more efficient and cost-effective solutions for constructing and deconstructing masonry forms in building projects.
Innovation Solution
A masonry form system comprising plastic reusable masonry form members, including thermoplastic materials with connector mechanisms, anti-spread clips, and structural foam, which can be configured to form various shapes and securely hold concrete, allowing for easy assembly, concrete pouring, and disassembly without damage, enabling reuse.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If wooden forms are used for masonry construction, then the forms can be easily constructed on site, but the forms are destructive and not reusable after concrete setting
Solution Approach 1:
The form system is divided into multiple modular plastic form members (straight members, corner members, spacer members) that can be individually assembled and disassembled. Each member is a separate component that can be reused independently, eliminating the destructive nature of traditional wooden forms while maintaining ease of construction through simple modular assembly.
Solution Approach 2:
The plastic form members are designed to be non-destructive and recoverable after concrete setting. Unlike wooden forms that are destroyed during form removal, the plastic members maintain their structural integrity and can be recovered, cleaned, and reused for subsequent construction projects, directly addressing the reusability issue.
2Reliability
If steel forms are used for masonry construction, then the forms are durable and reusable, but the forms are heavy and difficult to handle, store, and transport
Solution Approach 1:
The material parameter is changed from steel (high density, high weight) to plastic (low density, low weight). The plastic form members maintain sufficient structural durability for formwork applications while dramatically reducing the weight, making them easier to handle, store, and transport compared to steel forms.
Solution Approach 2:
The form members utilize plastic material properties that combine durability with lightweight characteristics. The plastic material provides sufficient strength and rigidity for formwork applications while inherently offering weight advantages over steel, achieving both reliability and ease of handling through material selection.
3Adaptability or versatility
If custom built wooden forms are used for each element, then the forms can be tailored to specific dimensions and shapes, but the construction and deconstruction process is time-consuming and not cost-effective
Solution Approach 1:
The system uses standardized modular plastic form members with consistent dimensions and connection mechanisms. These modules can be quickly assembled in various configurations to create custom-shaped forms for different elements (footings, walls, columns), eliminating time-consuming custom carpentry while maintaining design flexibility through modular arrangement.
Solution Approach 2:
The plastic form members are designed as universal components that can be used for multiple different construction elements and configurations. The same basic form members can be assembled to create various shapes and sizes for footings, walls, columns, and other structural elements, providing versatility without requiring custom-built forms for each application.
Data Source
AI summary
A masonry form system including a plurality of masonry form members, wherein the plurality of masonry form members may include opposing vertical side walls; and a connector mechanism on at least one end of each of the plurality of masonry form members; and wherein, the plurality of masonry form members may be configured to be connected together via the connector mechanisms. A method of using a masonry form system including providing a masonry form system, selecting and positioning the selected plurality of masonry form members based on a pre-determined plan to form a desired masonry form; and connecting the selected and positioned plurality of masonry form members together.