Rebar-Equipped Lumber Form for Weld-Free Concrete Floor Construction
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Solution Overview
Problem
Conventional construction methods for reinforced concrete floors are time-consuming due to the need for welding deck plates to steel beams and arranging reinforcing bars after laying the deck plate, which also requires additional materials for finishing and base support until the concrete strength is achieved.
Innovation Solution
A rebar-equipped lumber form comprising a wood panel with a unitized rebar fixed to it, allowing the form to be laid on steel beams without welding, eliminating the need for on-site rebar arrangement and utilizing the wood panel's surface as a finishing material, thereby reducing construction time and costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a deck plate is welded to steel beams and reinforcing bars are arranged on site, then the RC floor structure is achieved, but the construction time is significantly increased
Solution Approach 1:
The reinforcing bars are pre-arranged and fixed to the deck plate in a controlled factory environment before the deck plate is transported to the construction site. This preliminary action eliminates the time-consuming on-site rebar arrangement work while ensuring proper structural configuration, directly resolving the contradiction between structural integrity and construction time
Solution Approach 2:
The deck plate and reinforcing bars are merged into a single unitized component (UW-shaped cross-section with rebar embedded in the flange), combining multiple functions (formwork, reinforcement, and structural connection) into one integrated element, thereby reducing the number of separate construction steps and overall construction time
2Manufacturing precision
If deck plate welding and on-site rebar arrangement are performed, then proper structural configuration is achieved, but labor costs and operational complexity increase
Solution Approach 1:
The precise arrangement of reinforcing bars is performed in advance at the factory where controlled conditions allow for high precision. The pre-assembled unit is then transported as a complete package, eliminating the need for complex on-site rebar arrangement operations and significantly simplifying the construction process
Solution Approach 2:
The deck plate structure itself serves as the mounting framework for the reinforcing bars, with the rebar fixed directly to the plate's flange portion. This self-integrated design eliminates the need for separate support structures or complex installation procedures, making the unit easy to handle and install
3Strength
If additional finishing and base materials are used to support spans until concrete strength is achieved, then structural support is ensured, but material costs increase
Solution Approach 1:
The deck plate performs multiple functions simultaneously: it serves as the formwork (base material), provides structural support through its UW-shaped cross-section, and acts as the mounting surface for reinforcing bars. This multi-functionality eliminates the need for separate finishing and base materials, reducing material quantity while maintaining span support capability
Solution Approach 2:
The supporting structure and the formwork are merged into the single deck plate component, which maintains the span between steel beams while supporting the concrete load during curing. This integration eliminates redundant materials that would otherwise be needed for both support and finishing functions
Data Source
AI summary
Provided are a rebar-equipped lumber form and a construction method using a rebar-equipped lumber form capable of shortening construction time by replacing a deck plate. The lumbering form 10 includes a wood panel 11, and a unitized rebar 12 disposed and fixed on the wood panel 11.