Sprayable Concrete Artificial Reef with Cinder Block Formwork

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Solution Overview

Problem

Existing artificial reefs are costly, time-consuming to produce, and prone to degradation due to metal infrastructure corrosion, lack of suitable surfaces for marine organisms to attach, and inadequate design for water circulation and turtle escape hatches.

Innovation Solution

A process using sprayable concrete and cinder blocks with openings to form a pyramid-shaped artificial reef, minimizing steel usage, avoiding welding, and incorporating limestone surfaces for marine growth, with a design that allows water circulation and turtle escape routes.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If metal infrastructure is used in artificial reef construction, then structural strength is improved, but the reef degrades over time due to saltwater corrosion

Engineering Contradiction:

Improvestructural strengthVSAvoidreef durability

Core Design Contradiction:

StrengthVSReliability

Solution Approach 1:

The patent changes the material parameter from metal to concrete, fundamentally altering the chemical composition and properties of the infrastructure. Concrete does not corrode in saltwater like metal, thereby maintaining structural integrity and reliability over time while still providing the necessary strength for reef construction.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent uses concrete as a composite material (cement, sand, aggregate) to replace metal infrastructure. This composite material provides both the structural strength needed for reef construction and the corrosion resistance required for long-term durability in marine environments.

Inventive Principle:

Principle #40Composite materials

2Strength

If conventional concrete is used for artificial reef, then structural integrity is improved, but marine organisms cannot attach due to incorrect pH and hardness

Engineering Contradiction:

Improvestructural integrityVSAvoidbiological compatibility

Core Design Contradiction:

StrengthVSEase of manufacture

Solution Approach 1:

The patent applies limestone surfaces specifically to the exterior surfaces of the concrete reef structure where marine organisms need to attach. This local modification provides the correct pH and texture for biological attachment while maintaining the overall structural integrity of the concrete body.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The patent creates a composite structure combining concrete (for structural integrity) with limestone surfaces (for biological compatibility). This multi-material approach allows each material to fulfill its optimal function: concrete provides strength and durability, while limestone provides the chemically suitable surface for marine organism attachment.

Inventive Principle:

Principle #40Composite materials

3Productivity

If sprayable concrete is used instead of traditional concrete pouring, then production time is reduced, but manufacturing precision may be affected

Engineering Contradiction:

Improveproduction speedVSAvoidconcrete application precision

Core Design Contradiction:

ProductivityVSManufacturing precision

Solution Approach 1:

The patent employs forms and blockouts as preliminary structures before applying the sprayable concrete. These pre-positioned elements guide the concrete application process, ensuring that the sprayed concrete is deposited precisely where needed and maintains the desired geometric shape and dimensions of the artificial reef.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The patent uses forms and blockouts as intermediary structures that facilitate the sprayable concrete application. These intermediaries provide a framework that directs the concrete spray, ensuring precision in the final product while allowing the benefits of sprayable concrete (speed and flexibility) to be realized.

Inventive Principle:

Principle #24Intermediary (Mediator)

4Stability of the object's composition

If solid concrete blocks are used for artificial reef, then structural stability is improved, but water circulation and turtle escape routes are blocked

Engineering Contradiction:

Improvestructural stabilityVSAvoidhabitat functionality

Core Design Contradiction:

Stability of the object's compositionVSAdaptability or versatility

Solution Approach 1:

The patent incorporates blockouts with openings that create a porous or permeable structure within the solid concrete reef. This allows water to circulate through the reef interior and provides passage ways for marine organisms including turtles, while the overall solid concrete structure maintains structural stability and resistance to wave forces.

Inventive Principle:

Principle #31Porous materials

Data Source

PatentUS10138610B2Artificial reef and process for forming such an artificial reef

Publication Date: 2018.11.27 ATLANTIS MARINE HABITATS LLC

AI summary

A process for forming an artificial reef includes forming a form having a geometric shape, applying at least one blockout onto a surface of the form such that the blockout extends outwardly of the surface of the form, applying a sprayable concrete over the form and over a portion of the blockout, curing the sprayable concrete on the form for a period of time so that the sprayable concrete adheres to the blockout, and removing the cured sprayable concrete and the adhered blockout together from the surface of the form. The sprayable concrete is applied over the form until the depth of the sprayable concrete is approximately equal to a depth of the blockout. The blockout is a cinder block.