Precast Road Repair Panel With Leveling Plate System
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Solution Overview
Problem
Current concrete road repair methods are inefficient and time-consuming, leading to traffic congestion and safety issues due to the lengthy process of removing and replacing sections of concrete, as temporary patches often disintegrate quickly.
Innovation Solution
A pre-fabricated or pre-cast road repair panel with textured underside for grout fixation, incorporating dowels or rebar for anchoring, and a leveling plate system for precise adjustment and quick installation, allowing for rapid setting and load-bearing capabilities.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional concrete removal and replacement process is used, then road repair can be achieved, but the repair process is lengthy and causes traffic congestion
Solution Approach 1:
The repair panel is pre-fabricated with all necessary components (leveling plates, grout holes, textured underside for adhesion) before installation. This preliminary preparation allows the panel to be quickly installed and immediately bear loads, eliminating the lengthy curing time required for traditional concrete repairs.
Solution Approach 2:
The road repair system uses a modular panel that can be independently installed in the damaged section. The panel is segmented into functional components (leveling plates, grout injection holes, textured base) that work together to achieve rapid, durable repair without affecting surrounding areas.
2Productivity
If traditional patching method is used, then temporary repair can be achieved, but the patch disintegrates quickly
Solution Approach 1:
The repair panel combines multiple materials and features: a rigid base structure with textured underside for mechanical interlocking, grout injection holes for chemical bonding, and leveling plates for precise positioning. This composite approach creates a durable repair that resists disintegration while enabling quick installation.
Solution Approach 2:
The panel is pre-prepared with adhesion-promoting textures and grout injection channels before installation. This preliminary action ensures that when the panel is installed and grouted, it achieves maximum bonding strength immediately, preventing quick disintegration that plagues traditional patches.
3Strength
If concrete must be completely set before traffic, then strong bonding is achieved, but lane restrictions and traffic congestion occur
Solution Approach 1:
The panel is pre-fabricated with all bonding and leveling components in place before installation. The textured underside and grout holes are prepared in advance, allowing the panel to achieve full bonding strength through pre-installed features rather than requiring extended in-situ setting time, thus maintaining road availability.
Solution Approach 2:
The system replaces the traditional reliance on prolonged chemical setting of concrete with a mechanical solution: pre-installed leveling plates provide immediate structural support and precise positioning, while grout injection through pre-formed holes provides rapid chemical bonding. This dual mechanism achieves strong bonding without lengthy lane closures.
Data Source
AI summary
A precast concrete road repair panel is configured to be received in a prepared portion of an existing road under repair. Openings are provided throughout the panel for introducing grout or other similar composition to fix the precast panel in place on the road sub-base. The panel is further provided with a leveling plate system that includes one or more sleeves embedded within corresponding openings in the panel and accessible at the upper surface of the panel. The leveling plate system includes a base plate for positioning on the road sub-base, the base plate including a post telescopingly disposed within the sleeve. A power cylinder engages the sleeve and includes a piston operable to bear against the post to adjust the height and level of the panel.