Pneumatic Underlayment Delivery System for Rapid Floor Installation
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Solution Overview
Problem
Current methods for delivering and installing building materials, such as concrete, are inefficient, costly, and pose environmental and safety hazards, particularly in terms of dust exposure and prolonged construction times, while also requiring extensive preparation and finishing processes.
Innovation Solution
A system comprising a silo, pump, crane, and distribution hose, utilizing a premixed cementitious underlayment compound with fly ash and a high-solids styrene acrylic polymer primer to create a durable, environmentally friendly underlayment that can be installed quickly and efficiently, reducing the need for mechanical preparation and allowing for rapid access to the concrete floor.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If traditional concrete delivery and installation methods are used, then construction processes are completed, but the processes are inefficient, costly, and pose environmental and safety hazards including dust exposure and prolonged construction times
Solution Approach 1:
The cementitious underlayment compound is premixed at the plant with precise proportions of binder, aggregate, water, and admixtures before delivery. This preliminary preparation eliminates on-site mixing time and ensures consistent quality, directly improving installation speed and reducing overall construction time
Solution Approach 2:
The system uses pneumatic conveying through distribution hoses to deliver the premixed underlayment compound directly to the installation location. This hydraulic/pneumatic delivery method enables rapid material transport and placement, significantly increasing productivity while reducing the time required compared to traditional delivery methods
2Ease of manufacture
If traditional underlayment installation methods are used, then flooring can be installed, but extensive preparation and finishing processes are required, increasing construction time and cost
Solution Approach 1:
The underlayment compound is formulated with specific rheological parameters (flowability, setting time, compressive strength) that allow it to be pumped through hoses and self-level upon placement. These parameter optimizations eliminate the need for extensive mechanical preparation and manual finishing, reducing preparation time while maintaining ease of installation
Solution Approach 2:
The cementitious underlayment is a composite material combining binder, aggregate, and specialized admixtures that provide both structural integrity and workability. This composite formulation allows the material to be delivered in a pumpable state and achieve final strength without extensive on-site processing, simplifying preparation while reducing time
3Strength
If traditional cementitious materials are used, then structural strength is achieved, but environmental hazards and occupational safety risks increase due to dust and packaging waste
Solution Approach 1:
The system extracts and eliminates the harmful packaging materials traditionally associated with bagged cementitious products. By using bulk premixed delivery through pneumatic conveying, the need for individual bags and their packaging waste is removed, reducing environmental hazards and occupational safety risks associated with handling packaging materials
Solution Approach 2:
The pneumatic conveying system delivers the underlayment compound through sealed hoses, containing the material during transport and placement. This enclosed delivery method minimizes dust generation and exposure to workers, reducing occupational safety hazards while maintaining the compressive strength properties of the cementitious material
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The system enables rapid installation of a durable underlayment compatible with various flooring types, reduces occupational hazards, and lowers construction costs by minimizing material waste and preparation time, while ensuring compliance with environmental standards like LEED certification.
Implementation Method 1
at least one pump
Implementation Method 2
acts as an adhesive intermediary between the new material and the concrete slab
Implementation Method 3
penetrates the surface of the concrete slab floor
Implementation Method 4
curing it to a minimum of strength such as up to 4,000 PSI
Data Source
AI summary
There is disclosed a system for depositing building materials comprising a motor vehicle, a container comprising a material depositing system and at least one device for removing the container from the motor vehicle. The device can comprise one or more outriggers which are adapted to remove the container from the motor vehicle and which can be used to deposit the container on a job site, There is also disclosed a process as well, which includes at least one of the following steps providing a base slab floor; bull floating the base slab floor, inspecting the base slab floor for debris, utilizing a measuring device to survey height dimensions, applying an adhesive intermediary, inserting plastic pins with respect to survey measured points, mixing a self leveling compound, pumping the mixed compound through a conveying system, and smoothing the mixed compound to create a uniform surface and floor which is cured.