Stair Formwork Carriers with Self-Aligning Positioning Assembly
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Solution Overview
Problem
The construction of stairs in multi-storey buildings is time-consuming and costly due to the need for skilled tradespeople to accurately set the stair angle, depth of treads, and height of risers, often resulting in delays and potential penalties for project managers.
Innovation Solution
A stairway forming system comprising stacked, elongate riser form carriers with a positioning assembly that allows for longitudinal displacement and adjustment to achieve a staggered configuration, along with an anchoring unit for secure placement and levelling, enabling the formation of stairs without requiring skilled labor.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If skilled tradespeople are used to construct formwork, then manufacturing precision of stair components is improved, but labor cost and project time increase
Solution Approach 1:
The formwork system is designed to be self-positioning through the interconnected carrier units that automatically align themselves at the correct angles and positions. The carriers are disposed at predetermined angles and the positioning assembly ensures proper alignment without requiring skilled labor for measurement and adjustment, allowing unskilled workers to assemble the system quickly while maintaining manufacturing precision.
Solution Approach 2:
The formwork system is divided into multiple modular carrier units, each capable of independent positioning and adjustment. These segmented carriers can be individually positioned and then locked into place, allowing for precise stair component formation while enabling quick assembly and disassembly by unskilled workers, thus reducing construction time without sacrificing precision.
2Manufacturing precision
If skilled tradespeople are used to set stair angle and dimensions, then manufacturing precision is improved, but project cost increases
Solution Approach 1:
The system eliminates the need for skilled tradespeople by designing a self-aligning formwork structure. The carriers are positioned at predetermined angles and the positioning assembly automatically ensures correct alignment of all stair components. The system serves itself by maintaining precise geometry through its inherent structural design rather than requiring skilled labor for measurement and adjustment.
Solution Approach 2:
The carriers are pre-configured at predetermined angles and the positioning assembly is pre-designed to automatically align all components. This preliminary configuration of the system geometry allows unskilled workers to simply assemble the pre-positioned components without needing to perform complex measurements or calculations, reducing labor requirements while maintaining manufacturing precision.
3Manufacturing precision
If independent contractor tradespeople are used, then manufacturing precision is maintained, but project schedule reliability decreases
Solution Approach 1:
The formwork system is designed to be self-positioning and self-aligning, eliminating dependency on skilled independent contractors. The carriers automatically position themselves at correct angles and the positioning assembly ensures proper alignment without requiring skilled labor. This self-service capability allows any worker to assemble the system quickly and accurately, improving schedule reliability while maintaining manufacturing precision.
Solution Approach 2:
The modular carrier units can be independently positioned and locked into place by any worker, eliminating the need for skilled tradespeople. Each carrier is self-sufficient in its positioning capability, and the interlocking mechanism ensures proper alignment. This segmentation allows for rapid assembly by unskilled workers, improving project schedule reliability while maintaining the manufacturing precision required for accurate stair construction.
Data Source
AI summary
A stairway forming system includes a plurality of stacked, elongate stair riser form carriers, the carriers being longitudinally displaceable relative to one another. An anchoring unit anchors at least a lowermost riser form carrier in position relative to a substrate. A positioning assembly is attached to at least one of the riser form carriers and cooperates with the remaining riser form carriers for displacing the carriers in unison relative to one other to adopt a staggered operative configuration approximating an angle of the stairway to be formed.