Prefabricated Beam Units With Gravity-Assisted Interlocking Connectors
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Solution Overview
Problem
The process of erecting multistorey building structures using prefabricated components is costly and cumbersome, requiring skilled labor and specialized machinery, and often results in components that are either too heavy or complex for efficient on-site assembly.
Innovation Solution
The development of prefabricated structural beam units, column units, and deck units with integrated structural engagement connectors and reinforcing frameworks, allowing for efficient interlocking and assembly under gravity assistance, and the use of composite materials to enhance strength and reduce weight.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of time
If prefabricated components are manufactured off-site, then construction time and cost are reduced, but the components become too heavy and complex for efficient on-site assembly
Solution Approach 1:
The building structure is divided into modular prefabricated components (beam units, column units, deck units) that can be manufactured off-site and assembled on-site. Each component is designed as a discrete module with standardized connection interfaces, enabling efficient transportation and assembly while maintaining structural integrity.
Solution Approach 2:
Structural engagement connectors serve as intermediary elements between prefabricated components. These connectors include engagement formations that facilitate the interlocking of beam units with column units and deck units, simplifying the assembly process and reducing the need for heavy lifting and complex on-site manufacturing.
2Strength
If components are designed for heavy load-bearing applications, then structural strength is improved, but the components become too heavy and complex for rapid on-site deployment
Solution Approach 1:
The prefabricated components utilize composite materials consisting of a composite material body (such as concrete or metal) combined with reinforcement frameworks. This composite construction provides high structural strength while controlling the overall weight, making the components suitable for both load-bearing applications and rapid on-site assembly.
Solution Approach 2:
The reinforcement frameworks and structural engagement connectors are pre-integrated into the prefabricated components during off-site manufacturing. This preliminary action ensures that the components arrive at the construction site ready for assembly, eliminating the need for additional on-site manufacturing and reducing the weight that needs to be handled during deployment.
3Ease of manufacture
If prefabricated components are used, then on-site manufacturing is reduced, but skilled labor and specialized machinery are still required for assembly
Solution Approach 1:
The structural engagement connectors are designed to enable self-alignment and self-assembly of the prefabricated components. The engagement formations include features such as tapered surfaces, interlocking geometries, and gravity-assisted positioning that allow components to automatically align and connect without requiring highly skilled labor or complex specialized machinery.
4Productivity
If components are made modular and prefabricated, then assembly speed is improved, but the structural integrity may be compromised
Solution Approach 1:
The reinforcement frameworks are merged with the composite material bodies during the prefabrication process, creating an integrated composite structure. This merging ensures that the structural integrity is maintained throughout the component, and when components are assembled on-site, the connection between modules is as strong as monolithic construction while allowing for rapid assembly.
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
This solution enables faster and more cost-effective construction of multistorey buildings by reducing the need for on-site manufacturing and skilled labor, while maintaining structural integrity and allowing for quick assembly of multiple storeys.
Implementation Method 1
one or more structural engagement connectors dimensioned to engage with, or interlock, under gravity assistance with one or more complementary structural engagement connectors forming part of a further prefabricated building unit
Data Source
AI summary
Embodiments of the present invention relate to a prefabricated structural beam unit for a building structure. The beam unit includes a planar sole, two laterally spaced, elongate sidewall sections, and two longitudinally spaced endwall sections. The sole, sidewall sections and endwall sections combine to define a cuboid cavity at least partially filled with a composite material, wherein at least one endwall section includes one or more structural engagement connectors dimensioned to engage with, or interlock, under gravity assistance with one or more complementary structural engagement connectors forming part of a further prefabricated building unit of the building structure. Other embodiments relate to a prefabricated structural column unit.