Shuttering Framework for Insulated Concrete Sandwich Walls
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Solution Overview
Problem
The challenge lies in creating insulated concrete sandwich walls efficiently, as existing methods either trap vapor, leading to mold issues when insulation is placed inside, or attract insect infestations when placed outside, and are difficult to construct.
Innovation Solution
A shuttering framework for concrete sandwich walls, comprising framework members with inner and outer strongbacks, support members, and connectors, allowing for the deposition of insulating material and concrete between these components, with reinforcement members and tapered connectors to facilitate material flow and structural integrity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If insulation is placed on the room side face of a concrete wall, then heat transmission is prevented, but vapor is trapped in the interior finishes leading to mold
Solution Approach 1:
The wall assembly is segmented into distinct layers: exterior concrete wall, air gap, insulation layer, vapor barrier, and interior finishes. This segmentation allows vapor to be managed at specific interfaces rather than being trapped throughout the entire wall assembly, resolving the contradiction between heat prevention and vapor management.
Solution Approach 2:
A vapor barrier layer is introduced as an intermediary between the insulation and interior finishes. This intermediary component specifically addresses vapor transmission while allowing the insulation to maintain its thermal performance, preventing mold without compromising energy efficiency.
2Loss of energy
If insulation is placed outside of a concrete wall, then heat transmission is prevented, but insect infestations are attracted
Solution Approach 1:
The concrete wall itself serves as an intermediary barrier between the exterior insulation and potential insect infestations. The insulation is positioned against the exterior face of the concrete wall, using the concrete as a protective intermediary that prevents direct insect access to the insulation material.
3Loss of energy
If sandwich walls are created with insulation between interior and exterior concrete walls, then vapor and heat transmission are prevented, but construction difficulty increases
Solution Approach 1:
The complex sandwich wall assembly is segmented into pre-fabricated components: exterior concrete wall sections, insulation panels, vapor barrier sections, and interior finish sections. These segmented components can be manufactured separately and assembled more easily than attempting to build the complete assembly on-site.
Solution Approach 2:
The insulation and vapor barrier are pre-installed on the exterior face of the concrete wall before the interior finishes are applied. This preliminary action simplifies the construction sequence by eliminating the need to work within confined spaces after the wall structure is complete, reducing overall construction difficulty.
Data Source
AI summary
Systems and methods for creating insulated sandwich walls with a prefabricated framework are provided. An inner strongback faces an outer strongback. Outer and inner support members are located between the strongbacks. The strongbacks and support members extend vertically from a base. Material for an outer wall, such as concrete, is deposited between the outer strongback and outer support member. Material for an inner wall is deposited between the inner strongback and inner support member. An insulating material is deposited between the outer and inner support members providing longitudinal spacing for the framework.