Standoff Cladding Repair System for Corroded Structures
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Solution Overview
Problem
Existing structures, particularly those made of concrete or metal, face challenges in repair and reinforcement due to corrosion, harsh environmental exposure, and access constraints, leading to degradation and structural integrity issues.
Innovation Solution
A method and apparatus using formworks with standoff retainers, standoffs, and cladding panels to create a repair structure by introducing curable material between the panels and the existing structure, which cures to provide a reinforced and protected surface, while allowing for access and structural enhancement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional repair methods are used on structures with constrained access, then the repair process becomes difficult or impossible, but the structural integrity cannot be restored
Solution Approach 1:
The repair system transitions from requiring lateral access (parallel to surface) to accessing the surface from a normal direction (perpendicular approach). Standoffs extend outward from the structure surface, allowing panels to be positioned and curable material to be introduced through the normal direction rather than requiring access from the sides.
Solution Approach 2:
Standoffs act as intermediary elements that bridge the gap between the existing structure and the repair panels. These standoffs provide a mounting mechanism that allows the repair system to be attached to and work on surfaces that would otherwise be inaccessible due to tight spaces or structural constraints.
2Strength
If reinforcement is added to existing structures, then structural integrity is improved, but the device complexity and installation difficulty increase
Solution Approach 1:
The repair system is divided into discrete, modular components: individual standoffs, panel sections, and curable material compartments. This segmentation allows each component to be independently manufactured, installed, and adjusted, reducing overall system complexity while providing reinforcement.
Solution Approach 2:
The standoffs serve multiple functions: they act as mounting structures for panels, provide spacing to create voids for curable material, and can be configured in various patterns to address different structural needs. This multi-functionality reduces the number of separate components needed, simplifying the overall system.
3Reliability
If protective coating is applied to existing structures, then durability against environmental damage is improved, but the manufacturing precision and surface preparation requirements increase
Solution Approach 1:
The system uses panels that form a protective shell or cladding over the existing structure. These panels provide environmental protection while being tolerant of surface irregularities, eliminating the need for high-precision surface preparation that would be required for traditional coating applications.
Solution Approach 2:
The standoffs are pre-installed on the existing structure surface, creating a framework that holds the protective panels in position. This preliminary action establishes the protection system before final panel installation, allowing for adjustment and ensuring proper spacing without requiring perfect surface conditions.
Data Source
Figure 1A~1C
Figure 2A~2C
Figure 3
AI summary
Methods and apparatus are provided for repairing existing structures. A portion of the existing structure is covered with the repair structure. One or more standoffs are coupled to the existing structure to project outwardly away from a surface of the existing structure. One or more cladding panels are coupled to the standoffs by forcing the one or more panels in a direction normal to the surface of the existing structure and into engagement with a standoff connector component of the standoff at a location spaced apart from the existing structure. Curable construction material and/or insulation may be introduced into the space between the cladding panels and the existing structure to provide a repair structure.