Ratchet Insulation Fixing for Precast Panels Without Thermal Bridging
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Solution Overview
Problem
Conventional precast concrete panels face challenges such as high cost, complexity, and thermal bridging due to the manual fixing of insulation, which requires skilled labor and multiple layers, leading to slow construction and increased thermal bridging risks.
Innovation Solution
A two-part ratchet fixing system that securely attaches insulation to precast concrete panels, allowing for off-site manufacturing with minimal labor, by using flexible plastics that are independent of steel rebar and accommodate expansion, reducing thermal bridging and eliminating the need for drilling or fastening.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If manual fixing of insulation is used to precast concrete panels, then insulation can be attached to the panel, but labor requirements and construction time increase significantly
Solution Approach 1:
The fixing is pre-installed into the concrete panel during the pouring process, before insulation installation. This preliminary action eliminates the need for separate drilling and fastening operations at the construction site, significantly reducing labor requirements and construction time while ensuring reliable insulation attachment.
2Strength
If rigid anchors are used to support steel rebar and attach insulation, then structural support is provided, but thermal bridging occurs due to contact with steel rebar
Solution Approach 1:
The fixing is designed to be independent of the steel rebar, extracting the insulation attachment function from the structural reinforcement system. This separation eliminates the thermal bridging pathway that would occur if the same anchor contacted both the insulation and the steel rebar, while still providing adequate structural support for the insulation layer.
3Strength
If rigid anchors are used during concrete curing, then anchor strength is maintained, but the anchor fails due to concrete expansion and contraction
Solution Approach 1:
The fixing incorporates a flexible portion that can dynamically adjust to the expansion and contraction of concrete during curing. This dynamic flexibility prevents anchor failure while maintaining adequate holding strength, allowing the anchor to accommodate dimensional changes in the concrete without compromising either strength or reliability.
4Object-generated harmful factors
If sandwich panels with multiple concrete layers are used for insulation, then thermal insulation is achieved, but manufacturing cost and time increase
Solution Approach 1:
The fixing is pre-installed during concrete pouring, enabling subsequent rapid insulation installation without requiring multiple concrete casting cycles. This preliminary action achieves the desired thermal insulation performance while avoiding the time-consuming and expensive multi-layer concrete sandwich panel manufacturing process.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The ratchet fixing system enables fast, energy-efficient construction with minimal thermal bridging, reducing labor requirements and manufacturing costs, while ensuring structural integrity and optimal thermal characteristics.
Implementation Method 1
the flexible tie can offer room for expansion and contraction of the concrete during curing
Implementation Method 2
The insulation penetrating portion includes a ratchet which is engageable by the pawl
Data Source
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AI summary
A ratchet fixing 5 for connecting an insulation layer 4 to a precast concrete panel 2, a precast concrete panel system 1 comprising the fixing 5 and a method for forming an insulated precast concrete panel system 1 comprising fixing an insulation layer 4 to a concrete panel 2 with fixings 5 in which the fixing 5 is made up of an insulation layer penetrating portion 18 and a concrete penetrating portion 19 contiguous with the insulating layer penetrating portion 18, the insulation layer penetrating portion 18 having a disc-like tension head 20 for abutting against the outer surface of the insulation layer 4 and a pawl 22 and ratchet 25 for securing the tension head 20 to the insulation layer penetrating portion 18.