Prefabricated Lintel Form Assembly Eliminates On-Site Welding
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Solution Overview
Problem
Conventional methods for securing structural lintels to concrete floors are time-consuming, costly, and hazardous due to the need for on-site welding and alignment corrections, requiring specialized workers and potentially hazardous procedures.
Innovation Solution
A prefabricated form assembly comprising an elongated form plate and a substantially L-shaped lintel with anchor elements, allowing for quick and ergonomic anchoring of structural lintels to concrete slabs without welding, enabling a single class of workers to perform the task.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional welding methods are used to secure lintels to concrete floors, then structural strength is achieved, but construction time increases and safety risks arise
Solution Approach 1:
The lintel assembly is pre-assembled with the bearing plate and anchor elements attached before arrival at the construction site. This preliminary assembly eliminates on-site welding operations, reducing construction time while maintaining structural integrity through factory-controlled precision assembly.
Solution Approach 2:
The invention replaces the welding process (thermal/mechanical system) with a mechanical anchor element system. The anchor elements physically secure the bearing plate to the concrete floor through threaded engagement, substituting the welding process with a purely mechanical fastening system that is faster and safer.
2Manufacturing precision
If on-site welding and alignment corrections are performed, then proper lintel installation is achieved, but construction costs increase
Solution Approach 1:
Alignment and positioning are performed in advance during factory assembly of the lintel unit. The bearing plate and anchor elements are pre-positioned with precise alignment, eliminating the need for on-site alignment corrections and reducing installation complexity to simple mechanical assembly.
Solution Approach 2:
The pre-assembled lintel unit is self-aligning through its integrated design. The bearing plate geometry and anchor element positioning automatically ensure proper alignment when installed, eliminating the need for external alignment tools or corrective operations during construction.
3Reliability
If specialized steel workers perform welding operations, then lintel security is achieved, but labor complexity and safety hazards increase
Solution Approach 1:
The welding operation requiring specialized steel workers is replaced with a mechanical fastening system using anchor elements and bearing plates. This substitution allows general construction workers to perform the installation without specialized welding training, improving accessibility while maintaining lintel security through the mechanical anchor system.
Solution Approach 2:
The invention uses consumable anchor elements (such as threaded rods or expansion anchors) that are inexpensive and easily replaced if needed. These simple mechanical components can be installed by any construction worker, eliminating the need for expensive specialized welding services while ensuring reliable lintel attachment.
Data Source
AI summary
A prefabricated form assembly for making a concrete floor is disclosed. The form comprises an elongated form plate having a front for forming and retaining a flowable concrete material before it sets, anchor elements extending from the back face of the form plate, and being destined to be embedded into the concrete floor; and an L-shaped lintel having a back wall connected to the front face of the form plate and a bearing wall for supporting a masonry wall. Advantageously the construction of a concrete floor adapted to structurally retain a masonry wall using prefabricated form assemblies according to the invention no more requires the use of different groups of workers from different building trades as in the prior art, only one group of workers is required.