Precast Concrete Wall Insulating Layer with Embedded Fasteners
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Solution Overview
Problem
Existing precast concrete wall structures face challenges in maintaining the desired configuration of insulating foam blocks during concrete pouring and securing the walls to building structures, leading to quality control issues and labor-intensive on-site installation processes.
Innovation Solution
A precast concrete wall structure with an insulating layer featuring integrally-formed rectangular protrusions and embedded fasteners, including hollow channels and tabbed portions, to maintain the configuration and secure the walls to support structures without adhesives or destructive modifications.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If insulating foam blocks are placed in the casting bed to define void channels, then thermal insulation is improved, but the blocks flex and shift during concrete pouring, worsening manufacturing precision
Solution Approach 1:
The insulating foam blocks are pre-positioned within a rigid frame structure before concrete pouring. The frame acts as a preliminary support system that maintains the blocks' positions during the concrete pouring and curing process, preventing the flexing and shifting that would otherwise occur.
Solution Approach 2:
The rigid frame structure serves as an intermediary element between the insulating foam blocks and the concrete. It provides a stable framework that holds the blocks in their desired configuration while allowing the concrete to be poured around them without causing displacement.
2Strength
If conventional precast walls are installed using adhesives or fasteners requiring hole boring, then structural attachment is achieved, but labor time and installation complexity increase
Solution Approach 1:
The fastener embedding holes and the fasteners themselves are incorporated into the wall structure during the precasting process, before the wall leaves the factory. This preliminary preparation eliminates the need for on-site hole boring and fastener installation, significantly reducing installation time and labor requirements.
Solution Approach 2:
The manufacturing of the wall structure and the integration of attachment features are merged into a single precasting process. The holes for fasteners and the fasteners themselves are embedded during concrete pouring, combining structural formation and attachment preparation into one operation.
3Ease of manufacture
If insulating foam blocks are used without a rigid frame, then material cost is reduced, but quality control deteriorates due to block shifting and flexing
Solution Approach 1:
The rigid frame acts as an intermediary structure that supports the insulating foam blocks without requiring complex modifications to the blocks themselves. It provides the necessary stability and configuration control while maintaining relative simplicity in the overall manufacturing process.
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 solution ensures precise alignment and secure attachment of precast concrete walls, enhancing quality control and simplifying installation by eliminating the need for adhesives and fasteners, thereby reducing labor and material costs.
Implementation Method 1
the blocks may be prone to shift vertically due to buoyancy of the blocks in the more dense unfinished concrete
Implementation Method 2
each rib may be keyed to and disposed within a respective channel of the insulating layer
Data Source
AI summary
A precast concrete wall structure and method for forming a wall structure are disclosed. A forming member is positioned within a casting bed. The forming member comprises a layer of insulating material defining a plurality of integrally-formed rectangular protrusions extending in a parallel and spaced-apart relationship to one another to define a plurality of rectangular-shaped channels therebetween. The forming member also defines at least one cutout for defining a first portion of a fastener for securing the wall structure to a support structure. A second portion of the fastening member is positioned within the cutout. Uncured concrete is placed within the casting bed and allowed to cure.