Sacrificial Concrete Void Form for Modular Construction
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Solution Overview
Problem
Current concrete forming methods in modular construction are time-consuming, wasteful, and hazardous, particularly in situations requiring rapid construction of concrete superstructures after disasters, and fail to meet the industry's needs for efficiency and speed.
Innovation Solution
A sacrificial concrete void form comprising a steel frame with corrugated steel decking, which allows for the construction of permanent formwork without the need for conventional forming, stripping, and reshoring, enabling faster and safer on-site assembly by pouring concrete over or adjacent to the void form.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional concrete forming methods are used, then structural requirements are met, but construction time is excessive and labor costs increase
Solution Approach 1:
The concrete void forms are constructed off-site in advance using modular steel frames and corrugated steel decking, allowing the forming process to be completed before arrival at the construction site. This preliminary construction eliminates the need for time-consuming on-site form assembly, stripping, and reshoring operations.
Solution Approach 2:
The patent employs sacrificial concrete void forms made from steel frames and corrugated steel decking that are designed to be temporary and disposable. These forms are installed, concrete is poured, and then the forms are removed and discarded, eliminating the need for complex form stripping and reshoring processes required by conventional reusable forms.
2Reliability
If conventional concrete forming is used, then structural integrity is achieved, but material waste and cost increase
Solution Approach 1:
The concrete void forms utilize a composite structure combining steel frames with corrugated steel decking. This composite construction provides the necessary structural integrity and strength to support wet concrete while using materials that are readily available and cost-effective, reducing overall material costs without compromising reliability.
Solution Approach 2:
The sacrificial nature of the concrete void forms allows for the use of simpler, less expensive materials that would not be suitable for reusable forms. The steel frames and corrugated steel decking are inexpensive compared to conventional reusable formwork systems, and their temporary use eliminates the need for expensive, durable materials.
3Reliability
If conventional forming methods are used, then code requirements are met, but construction safety hazards increase
Solution Approach 1:
By constructing the concrete void forms off-site in a controlled environment, workers are removed from hazardous on-site conditions during the form assembly phase. The pre-constructed modular units are then simply installed at the site, significantly reducing exposure to dangerous working conditions while maintaining code compliance through proper design and installation.
Data Source
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AI summary
The present specification relates generally to modular construction and more specifically to a sacrificial concrete void form and method of modular construction therewith. The concrete void form includes a steel frame having a top face, a bottom face, and four side faces, wherein at least one of the four side faces and the top face are covered with at least one sheet of corrugated steel decking. The method of modular construction includes constructing at least one concrete void form, the at least one concrete void form comprising a steel frame having a top face, bottom face and four side faces, wherein at least one of the four side faces and the top face are covered with at least one sheet of corrugated steel decking, installing the at least one concrete void form at a construction site, and pouring concrete over or adjacent to the at least one concrete void form.