Precast Plug System for Fire-Rated Concrete Floor Repair

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Solution Overview

Problem

Current methods for repairing holes in concrete floors are inefficient, often require access from below, result in protruding surfaces, and may not meet fire and water resistance standards, posing challenges in maintaining the integrity and safety of the flooring assembly.

Innovation Solution

A precast plug system comprising a concrete housing with protruding rods that register with grooves on the floor surface, allowing for easy installation and sealing of holes to create a flush, fire-resistant, and water-resistant repair.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If expandable metal plugs or caps are installed through the bottom of the hole, then the fire break properties are restored, but access from below is required which is disruptive and expensive

Engineering Contradiction:

Improvefire break propertiesVSAvoidaccess requirement

Core Design Contradiction:

ReliabilityVSEase of operation

Solution Approach 1:

The patent inverts the traditional installation approach by providing access from above instead of from below. The plug is inserted through the top opening of the hole and secured using a expansion mechanism that engages with the floor assembly from the upper side, eliminating the need for access from the bottom.

Inventive Principle:

Principle #13The other way round (Inversion)

Solution Approach 2:

The plug is pre-formed with an expansion mechanism and securing features before installation. The plug includes pre-configured elements that allow it to be inserted and then expanded to the proper size within the hole, eliminating the need for complex on-site assembly or access from below.

Inventive Principle:

Principle #10Preliminary action

2Ease of manufacture

If traditional repair materials like plaster are used to fill holes, then the holes are sealed, but the repair is insufficient and does not meet fire code requirements

Engineering Contradiction:

Improverepair simplicityVSAvoidfire code compliance

Core Design Contradiction:

Ease of manufactureVSReliability

Solution Approach 1:

The patent uses a composite construction for the plug combining fire-resistant materials suitable for meeting fire code requirements. The plug is formed from materials that provide both structural integrity and fire resistance, eliminating the need for additional fire-blocking materials like plaster.

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The patent employs a disposable pre-formed plug that is inserted, expanded, and left in place as a permanent solution. This eliminates the need for temporary or insufficient repairs using materials like plaster that would require further work to meet code requirements.

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

3Productivity

If holes are left open after tenant vacancy, then no repair work is needed, but the fire control properties of the flooring assembly are compromised

Engineering Contradiction:

Improvetenant vacancy speedVSAvoidfire control properties

Core Design Contradiction:

ProductivityVSReliability

Solution Approach 1:

The plug is designed to be installed quickly from above as a preliminary action to restore fire control properties before the next tenant moves in. The pre-formed nature of the plug allows for rapid installation without requiring access from below or complex construction work.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The plug is designed to be self-contained with all necessary features for installation and securing built-in. The expansion mechanism and securing elements are integrated into the plug itself, allowing for quick self-contained installation that restores fire control properties without requiring additional materials or complex procedures.

Inventive Principle:

Principle #25Self-service

4Reliability

If mechanical closure products are used to restore fire break properties, then the holes are sealed, but the parts and labor associated are expensive

Engineering Contradiction:

Improvefire break restorationVSAvoidinstallation cost

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The patent divides the plug into separable components including the main body, expansion mechanism, and securing elements. This segmentation allows for easier manufacturing and installation, reducing labor costs while maintaining the fire break restoration function.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The plug incorporates self-contained features including built-in expansion mechanisms and securing elements that eliminate the need for additional parts and complex installation procedures. The self-service design reduces both parts and labor costs while effectively restoring fire break properties.

Inventive Principle:

Principle #25Self-service

Data Source

PatentUS9765541B2Method and apparatus to fill and fire proof holes in concrete floors

Publication Date: 2017.09.19 GRAY GERALD R

AI summary

The present apparatus and method relates in general to sealing a hole in a floor with a precast plug. A precast plug is created by pouring a wet aggregate mix into a form mold and thereafter inserting a pre formed rod into the uncured mixture, positioning it such that the center of the rod rests in the center of the form mold and the ends of the rod extend outward near the top of the form mold. The mix is then cured. The precast plug may then be transported to the hole that it is destined to fix. Grooves may be carved on either side of the hole to accommodate the rod' s ends. The interior of the hole and the exterior of the plug may then be covered with a sealant, after which the plug may be inserted into the hole. Once the sealant cures, the hole is fully repaired.