Prefabricated Composite Wall Element with Connecting Profiles
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Solution Overview
Problem
The construction of building walls using prefabricated wall elements made of wood chip shuttering blocks is hindered by the need for on-site assembly by professionals, leading to increased labor costs, weather dependency, and variability in quality and dimensional accuracy.
Innovation Solution
A transportable, prefabricated composite wall element comprising formwork blocks connected by a bending and warping-resistant profile, combined with modular elements like insulation or cladding, which can be easily assembled and ensures consistent quality and reduced construction time by allowing off-site prefabrication.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If wall elements are prefabricated outside the construction site, then construction time and labor costs are reduced, but the flexural strength and stability of the composite wall element during transport and concrete filling are compromised
Solution Approach 1:
The connecting profiles are pre-installed on the formwork blocks during factory prefabrication, establishing the structural framework before the wall element is transported to the construction site. This preliminary action ensures that the flexural strength is already in place to withstand transport loads and subsequent concrete filling operations
Solution Approach 2:
The wall element combines formwork blocks (wood chip shuttering blocks) with connecting profiles (metal or rigid material) to create a composite structure. The metal connecting profiles provide the necessary flexural strength and rigidity, while the formwork blocks provide the formwork function, creating a synergistic composite wall element that meets both strength and prefabrication requirements
2Manufacturing precision
If traditional on-site assembly methods are used, then quality and dimensional accuracy can be controlled, but labor costs and weather dependency increase
Solution Approach 1:
The formwork blocks are pre-assembled into complete wall panels with connecting profiles during factory production, allowing precise manufacturing under controlled conditions. This preliminary assembly ensures high dimensional accuracy and quality control while eliminating weather dependency, as all assembly work is completed in the factory before transport to the construction site
Solution Approach 2:
The wall structure is divided into modular wall panels that can be independently manufactured, quality-checked, and transported. Each panel is a complete, self-contained unit with integrated formwork blocks and connecting profiles, allowing for standardized production processes that ensure consistent dimensional accuracy across all wall elements
3Stability of the object's composition
If connecting profiles are added to increase flexural strength, then structural stability is improved, but device complexity increases
Solution Approach 1:
The connecting profiles serve as intermediary elements that join the formwork blocks together to create a structurally stable composite wall element. These profiles act as mediators between the individual formwork blocks, providing the necessary flexural strength and rigidity while maintaining a relatively simple overall structure that is easy to manufacture and assemble
Data Source
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AI summary
The invention relates to a transportable prefabricated composite wall element (1) comprising at least a first wall panel (2, 2.1, 2.2, 2.3) composed of interconnected shuttering blocks (4), in particular wood chip shuttering blocks, stacked on top of one another in rows, these blocks having hollows (6) and cavities (8) for through filling the wall panel (2, 2.1, 2.2, 2.3) with concrete and the side walls (10) thereof forming a first and second planar wall panel surface (12, 14), wherein at least the first wall panel surface (12) is connected to at least one plate-shaped module element (16), in particular an insulating or wall cladding element, and wherein there is provided at least one connecting profile (18, 20) which, at least in certain sections, extends along the lower or the upper row of shuttering blocks (4) and which interconnects at least some of the shuttering blocks (4) so as to increase the bending rigidity of the composite wall element (1).