Porous Concrete Formwork Studs for Efficient Flow
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Solution Overview
Problem
Conventional concrete formwork systems are aesthetically unpleasing, time-consuming to erect, and can be difficult to obtain in busy construction markets, especially when space between buildings is limited, and they do not allow for efficient concrete flow, leading to structural inefficiencies.
Innovation Solution
A formwork stud system comprising roll-formed steel members with a web and flanges, featuring a high percentage of web material removal to create spaced holes for concrete flow and divots for reinforcing bars, allowing for off-site construction and reduced on-site labor needs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional formwork systems are used with solid web studs, then structural strength is maintained, but concrete flow efficiency deteriorates
Solution Approach 1:
The stud web is designed with a porous structure containing multiple holes of varying sizes (circles, squares, rectangles, triangles) that allow concrete to flow through while the remaining web material maintains structural strength. The holes are distributed throughout the web to optimize both concrete permeability and structural integrity.
Solution Approach 2:
The continuous web material is segmented into discrete sections by removing portions to create holes. This segmentation allows concrete to pass through the web while the remaining web segments maintain structural support functions.
2Ease of manufacture
If conventional solid web studs are used, then manufacturing simplicity is maintained, but rebar integration efficiency deteriorates
Solution Approach 1:
Divots are pre-formed in the web structure at strategic locations where rebars need to be integrated. These divots serve as ready-made receptacles that simplify rebar placement and integration during construction, eliminating the need for additional drilling or modification steps.
3Productivity
If conventional formwork systems are used, then structural functionality is achieved, but construction time increases
Solution Approach 1:
Multiple functions are merged into the stud assembly: the web provides structural support, the holes enable concrete flow, the divots integrate rebars, and the flanges provide mounting surfaces. This consolidation reduces the number of separate components and assembly steps required on-site.
Solution Approach 2:
The stud design serves multiple purposes simultaneously: structural support through the web, concrete flow channels through the holes, rebar integration through divots, and assembly facilitation through flanges with attachment features. This multi-functionality reduces construction time by eliminating sequential installation steps.
4Strength
If conventional formwork is left in place, then structural support is provided, but aesthetic quality deteriorates
Solution Approach 1:
The web is designed with non-uniform properties: holes and divots are strategically positioned in specific locations to provide functional benefits (concrete flow, rebar integration) while maintaining structural strength where needed. This localized variation in web properties optimizes both structural and aesthetic outcomes.
Data Source
AI summary
A formwork stud system includes a plurality of studs, a top channel, a bottom channel and a plurality of horizontal and vertical rebars. At least one of the plurality of studs is a formwork stud. The formwork stud includes a web and a pair of flanges. The web has opposed side portions extending from the top of the formwork stud to the bottom of the formwork stud and a plurality of lateral spaced apart connectors extending between the opposed side portions. The opposed side portions and the lateral spaced apart connectors define a plurality of spaced apart holes. The holes are configured to allow concrete to flow therethrough. The pair of flanges extend generally orthogonally from the opposed side portions of the web.