Prefabricated Concrete Stair Step with Integrated Reinforcement
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Solution Overview
Problem
Existing outdoor concrete stair solutions require high installation effort and are prone to connection issues due to thermal expansion, leading to instability and aging over time.
Innovation Solution
A prefabricated concrete stair step part with a one-piece design featuring a foundation section and a step section, both with elongated reinforcing elements, allowing for easy installation and resistance to environmental influences, where the step section projects beyond the foundation section laterally to create a stable and aesthetically appealing structure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If individual foundation sections are constructed from cast-in-place concrete or precast elements with treads attached on-site, then the staircase structure can be assembled, but the connection between foundation and tread ages due to thermal expansion differences causing loosening and instability
Solution Approach 1:
The patent merges the foundation section and tread section into a single monolithic precast concrete element with integrated reinforcement. The reinforcement elements extend continuously through both sections, creating a unified structural unit that eliminates the connection interface between separate foundation and tread components, thereby preventing thermal expansion-related loosening and ensuring long-term stability.
Solution Approach 2:
The patent uses composite reinforcement elements consisting of metal reinforcement bars embedded in concrete matrix. These reinforcement elements extend through both the foundation and tread sections, creating a composite structure that combines the advantages of both materials while maintaining structural integrity across the entire element.
2Ease of manufacture
If multiple individual elements (foundation sections and treads) are assembled on-site with bolts or screws, then the staircase can be constructed, but the installation cost and effort increase significantly
Solution Approach 1:
The patent segments the staircase into multiple individual precast elements, each comprising an integrated foundation-tread unit. These standardized segments can be manufactured off-site and quickly assembled on-site by simply placing them in position, eliminating the need for complex on-site connections while maintaining the ability to construct longer staircases by repeating the basic unit.
Solution Approach 2:
The foundation section and tread section are pre-assembled and reinforced as a single unit in the precast plant before delivery to the construction site. This preliminary action of combining and reinforcing the elements off-site eliminates time-consuming on-site assembly and connection work, significantly improving installation speed and reducing labor costs.
3Stability of the object's composition
If the vertical extent of the foundation section is increased to at least 40 cm to provide stable anchoring, then the anchoring stability improves, but the amount of concrete and reinforcement material required increases
Solution Approach 1:
The patent optimizes the vertical extent parameter of the foundation section to be at least 40 cm, which provides sufficient anchoring stability in the substrate while controlling the quantity of concrete and reinforcement materials used. This parameter change balances the competing requirements of stability and material efficiency.
Data Source
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AI summary
A precast concrete stair tread element T is described, comprising a foundation section F and a tread section S, wherein the foundation section F is designed and configured for anchoring the precast concrete stair tread element T in the subsoil. The foundation section F has a base area Fg intended for bearing on the subsoil and a surface area. The tread section S has a top surface Sd intended as a tread, a base surface Sg opposite the top surface Sd, and a surface area. The tread section S projects beyond the foundation section F, at least in a portion of its surface area.The precast concrete stair tread element T has elongated reinforcement elements A, wherein at least one of the elongated reinforcement elements A has a foundation reinforcement section FA arranged in the foundation section F and a step reinforcement section SA arranged in the step section S.