Roller Bracket for Tunnel Form Positioning and Removal
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Solution Overview
Problem
The use of tunnel forms in construction is labor-intensive and expensive due to the need for manual sealing and removal processes, which puts stress on lower taper ties and requires the use of cranes, making it inefficient and costly to form concrete walls and ceilings of varying heights.
Innovation Solution
A roller bracket system that allows for easier positioning, sealing, and removal of tunnel forms by using a raising and lowering mechanism with horizontal and vertical rollers to support the forms during concrete pouring and curing, reducing the need for cranes and minimizing stress on taper ties, enabling the formation of concrete walls of desired heights without the need for multiple tunnel form sizes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If manual sealing and removal processes are used for tunnel forms, then the forms can be positioned and removed, but the process becomes labor-intensive and expensive
Solution Approach 1:
A roller bracket system is introduced as an intermediary device between the tunnel form and the support structure. The bracket includes rollers that facilitate easy positioning and removal of the tunnel form, converting manual labor into a mechanical assistance system that reduces effort and time requirements
Solution Approach 2:
The roller bracket system transforms the static support process into a dynamic one. The rollers allow the tunnel form to be easily moved into position and removed by rolling, converting what would be heavy lifting and manual handling into simple rolling motions that require minimal effort
2Reliability
If conventional support methods are used, then tunnel forms can be retained during concrete pouring, but significant stress is placed on lower taper ties
Solution Approach 1:
The support function is segmented between the roller bracket system and the taper ties. The roller brackets bear the primary load and support weight during positioning and removal, while the taper ties only need to provide minimal retention force during concrete pouring, significantly reducing their stress and the risk of failure
Solution Approach 2:
The roller brackets act as intermediary support elements that take over the primary load-bearing function during critical operations. This intermediary system protects the taper ties from excessive stress by handling the mechanical support requirements separately
3Ease of operation
If cranes are used for removing tunnel forms, then the forms can be lifted and repositioned, but the process becomes costly and time-consuming
Solution Approach 1:
The roller bracket system serves as a mechanical intermediary that replaces the need for expensive crane equipment. The brackets with rollers enable workers to manually roll and reposition tunnel forms without requiring heavy lifting machinery, significantly reducing both cost and time
Solution Approach 2:
The roller bracket system enables the tunnel forms to essentially service themselves during removal and repositioning. The rollers allow the forms to be easily maneuvered and relocated with minimal human effort, eliminating the need for external heavy equipment assistance
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
Substantially reduces labor costs and improves safety by automating the removal process of tunnel forms, relieving stress on lower taper ties, and allowing for flexible height adjustments without the need for extensive crane usage or multiple tunnel form sizes, enhancing the efficiency of concrete wall and ceiling construction.
Implementation Method 1
a horizontal roller having an inner end and an outer end separated by more than the bottom edge thickness, rollably mounted on the platform
Implementation Method 2
a vertical roller perpendicular to the horizontal roller, rollably mounted on the platform outward from and above the outer end of the horizontal roller
Data Source
AI summary
A roller bracket having a base, a raising and lowering mechanism, a platform, and horizontal and vertical rollers. The base is attached to the vertical face of a starter wall at a level to provide a desired height for a concrete ceiling. With the platform in the raised position, the bottom edge of a tunnel form is lowered between the vertical roller and the starter wall onto the horizontal rollers. A wedge is driven between the vertical roller and the tunnel form to seal the tunnel form against the starter wall. After concrete has been poured, retained by the seal, and cured to form the concrete walls and ceiling, the mechanism can lower the platform to strip the tunnel form from the tunnel. The tunnel form can then be rolled away on the horizontal rollers while being retained on the horizontal rollers by the vertical roller and the starter wall.