Reinforcement Device with Openings for Prefabricated Concrete
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Solution Overview
Problem
Existing reinforcement devices for prefabricated components are costly to manufacture, require a large amount of steel, and can lead to nesting issues during concrete pouring due to full-surface designs, which results in incomplete filling and material flow blockages.
Innovation Solution
A reinforcement device with a V-shaped arrangement of longitudinal elements and zigzag-reinforced transverse elements, allowing for independent setup and insertion into free spaces within reinforcement mats, minimizing formwork concrete and preventing nesting by creating openings between transverse elements for complete concrete coverage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional full-surface reinforcement devices are used, then structural strength is provided, but nesting issues occur during concrete pouring and material flow is blocked
Solution Approach 1:
The transverse elements are designed with openings instead of solid full-surface structures. These openings allow concrete to flow through during pouring, preventing nesting and blockage while the surrounding steel structure maintains structural strength. The porous/open design solves the contradiction between providing structural integrity and enabling material flow.
Solution Approach 2:
The reinforcement device is segmented into longitudinal elements and transverse elements with openings. This segmentation creates spaces within the structure that facilitate concrete flow while distributing structural loads. The segmented design prevents the nesting issues that occur with solid, continuous reinforcement surfaces.
2Strength
If conventional reinforcement devices are used, then side walls are connected, but a large amount of formwork concrete is required
Solution Approach 1:
The reinforcement device is extracted from the traditional embedded-in-concrete design to a standalone structure that connects side walls through mechanical means. The longitudinal elements extend outward from the side walls, allowing connection without requiring large volumes of formwork concrete for integration. This extraction reduces the quantity of formwork concrete needed while maintaining connection strength.
3Stability of the object's composition
If traditional reinforcement devices are used, then structural stability is provided, but manufacturing cost and steel usage are high
Solution Approach 1:
The reinforcement device uses composite construction with longitudinal elements made of steel for tensile strength and transverse elements with openings that may use alternative materials or reduced steel sections. This composite approach maintains structural stability while reducing overall steel consumption and manufacturing cost compared to traditional all-steel reinforcement devices.
Solution Approach 2:
Instead of providing full steel reinforcement throughout the entire structure, the invention uses partial reinforcement with openings in transverse elements. This partial action approach provides sufficient structural stability for the application while significantly reducing steel usage and associated manufacturing costs.
Data Source
Figure 1~2
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Figure 5~6
AI summary
The invention relates to a reinforcement device (1) for prefabricated components, comprising several longitudinal elements (2), in particular longitudinal bars, and one or more transverse elements (3) which connect the longitudinal elements (2) to one another. According to the invention, the reinforcement device (1) can be independently erected on the ends (4, 5) of the longitudinal elements (2) and the transverse element(s) (3) defines at least one opening (6) in or between the transverse elements (3), wherein the longitudinal elements (2) can be inserted into spaces between one or more reinforcement elements for side parts of a prefabricated component. Furthermore, the invention relates to a method for manufacturing a prefabricated component with two spaced-apart concrete side walls.