Prefabricated Wall Element With Inner Formwork Cavity
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Solution Overview
Problem
Existing construction methods for prefabricated buildings, such as lost formwork and skeleton construction, face challenges in efficiency, economic viability, and aesthetic appeal, particularly due to the need for extensive manual and mechanical effort, bulky formwork, and the use of plastic formwork which does not contribute to structural stability.
Innovation Solution
A prefabricated wall element comprising two boundary walls connected by reinforcement components with an inner formwork cavity, allowing for variable installation of utilities and featuring an installation matrix with pre-installed pipe and channel elements, and optional insulation, which simplifies assembly, reduces concrete usage, and enhances structural stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If permanent plastic formwork is used as inner or outer wall, then the surface quality is improved, but the structural stability deteriorates
Solution Approach 1:
The wall element is divided into two functional parts: permanent plastic formwork providing the inner surface and separate reinforcement components providing structural stability. This segmentation allows each component to fulfill its specific function without compromise.
Solution Approach 2:
Reinforcement components act as intermediaries between the permanent plastic formwork and the concrete filling, providing structural stability while allowing the plastic formwork to maintain its surface quality function.
2Strength
If self-supporting formwork is used, then the structural stability is improved, but the device complexity and bulkiness worsen
Solution Approach 1:
The formwork system is segmented into permanent plastic formwork for surface quality and separate reinforcement components for structural stability, avoiding the need for complex self-supporting formwork structures.
Solution Approach 2:
The permanent plastic formwork serves itself as the inner wall surface, eliminating the need for separate support devices that would be required for non-self-supporting formwork.
3Strength
If conventional reusable formwork is used, then the structural stability is maintained, but the productivity and economic efficiency deteriorate
Solution Approach 1:
The permanent plastic formwork and reinforcement components are prepared in advance as separate elements, allowing for faster assembly on site compared to conventional formwork that requires erection and dismantling cycles.
Solution Approach 2:
The permanent plastic formwork remains as part of the final structure (inner wall), eliminating the need for dismantling and storage operations required by conventional reusable formwork systems.
4Productivity
If skeleton construction with prefabricated parts is used, then the productivity is improved, but the loss of substance and transport costs worsen
Solution Approach 1:
Instead of fully prefabricating entire wall components, the invention uses partial prefabrication with permanent plastic formwork and separate reinforcement components, reducing concrete consumption while maintaining assembly efficiency.
Solution Approach 2:
The invention changes the parameter of material distribution by using permanent plastic formwork that defines the exact concrete filling volume, reducing concrete consumption compared to traditional skeleton construction.
Data Source
Figure 1
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Figure 3
AI summary
The invention relates to a constructional element for prefabricated edifices, particularly a wall element (3), comprising two boundary walls (6, 7) which are interconnected by means of reinforcement parts (5) and/or joining elements. At least one insert (8) is disposed between the internal surfaces of the boundary walls (6, 7) in order to form at least one space (9) that contains no cast material.