Prefabricated Panelization System for Floor and Roof Construction
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Solution Overview
Problem
Traditional building construction methods face challenges in balancing cost, safety, and architectural flexibility, particularly in high-rise structures, as they require labor-intensive and time-consuming piece-by-piece assembly of floor or roof components, which increases safety risks and construction costs.
Innovation Solution
A panelization system that uses prefabricated frames and deck pans with horizontal support beams attached to columns on the sides, allowing for preassembly at ground level and easy installation at elevated levels, creating space for mechanical, electrical, and plumbing components, and incorporating a spandrel beam system for lateral support without increasing beam thickness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If traditional piece-by-piece assembly methods are used for floor or roof components, then structural integrity can be maintained, but labor costs and construction time increase significantly
Solution Approach 1:
The floor or roof structure is divided into modular panels that are pre-assembled on the ground and then lifted into position. Each panel consists of discrete components (beams, decking, connectors) that can be manufactured separately and assembled into complete modules before installation, dramatically reducing on-site assembly time while maintaining structural integrity.
Solution Approach 2:
Complete floor or roof panels are pre-assembled on the ground level before being lifted into their final positions. This preliminary assembly includes attaching decking to beams, installing connectors, and preparing all components in advance, which eliminates the need for complex high-altitude assembly operations and significantly improves construction efficiency.
2Reliability
If prefabricated modules are used for floor or roof construction, then worker safety is improved by reducing elevated work, but initial manufacturing complexity increases
Solution Approach 1:
The construction system is segmented into ground-level manufacturing operations and elevated installation operations. By completing all complex assembly tasks at ground level and only performing simple lifting and positioning at height, worker safety is dramatically improved while the prefabrication system manages complexity through clear separation of manufacturing and installation phases.
Solution Approach 2:
The panelized system is designed to be self-contained with all necessary components (beams, decking, connectors) integrated into complete modules that require minimal on-site assembly. The modules are engineered to be lifted and positioned as complete units, eliminating the need for workers to perform complex assembly tasks at elevated heights and thereby improving safety.
3Strength
If horizontal support beams are attached to column centerlines, then structural support is optimized, but space for mechanical and electrical components is reduced
Solution Approach 1:
Instead of symmetrically attaching beams to column centerlines, the system uses asymmetric attachment where beams are connected to column faces or edges. This asymmetric positioning creates asymmetric space distribution that deliberately reserves central column areas for mechanical, electrical, and plumbing components while maintaining adequate structural support through properly positioned beam connections.
Solution Approach 2:
The system resolves the spatial conflict by utilizing the third dimension (vertical space). Beams are attached to column faces at optimized heights, creating horizontal support while vertical clearance around column centerlines is preserved for MEP routing. This dimensional approach allows structural support and component space to coexist by exploiting different spatial zones.
4Strength
If traditional framing systems are used, then structural support is provided, but additional construction steps are required for MEP components
Solution Approach 1:
The structural framing system and MEP routing system are merged into a unified panelized design. Beam attachment locations are coordinated with MEP component positions, and panel configurations are optimized to accommodate both structural requirements and mechanical/electrical/plumbing routing needs simultaneously, eliminating the need for separate construction steps and improving overall construction efficiency.
Data Source
AI summary
A prefabricated panelization system having a floor or roof component and a frame component. In particular, the floor or roof component includes a deck member, which can be made of deck sections, profiles, or panels. For example, the deck member can be made of continuous panels that cover the desired width and length of the floor or roof component without intermediate beams between supporting elements. Alternatively, the deck members can be made of individual or panelized sections that are combined in juxtaposed relation to form the desired width and length. The frame component includes opposing horizontal support channels that are attached to opposing columns, respectfully.