U-Shaped Steel-Concrete Modular Elements with Venting
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Solution Overview
Problem
Current reinforced modular structures for buildings, particularly in nuclear power plants, face challenges such as high labor costs, complex assembly processes, and potential structural weaknesses due to trapped air pockets when filled with concrete, which limits flexibility and efficiency in construction.
Innovation Solution
The design features a U-shaped construction element with panel openings for reinforcement and a vent to prevent air pockets, along with diaphragm support plates and tensioning ducts for secure assembly and concrete filling, allowing for efficient and flexible construction without extensive on-site welding or mechanical fastening.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If traditional layered steel plates with internal lattice reinforcement are used, then structural strength is improved, but device complexity and labor costs increase
Solution Approach 1:
The structure is divided into modular U-shaped elements that can be independently manufactured and assembled. Each element is a self-contained unit with integrated reinforcement features, eliminating the need for complex on-site assembly of multiple separate components while maintaining structural integrity.
Solution Approach 2:
The U-shaped elements combine multiple functions into a single component: structural support, reinforcement anchoring, and concrete formwork. This integration eliminates the need for separate internal lattice structures and reduces the number of parts required, simplifying both manufacturing and assembly.
2Productivity
If modular U-shaped elements are assembled on-site, then construction speed is improved, but structural integrity may be compromised due to fastening requirements
Solution Approach 1:
Critical reinforcement features, including welded steel plates and anchoring points, are pre-installed on the U-shaped elements during manufacturing. This preliminary action ensures structural integrity is established before on-site assembly, allowing rapid construction without compromising strength.
Solution Approach 2:
The design replaces complex mechanical fastening systems with a simplified assembly approach where elements interlock and are secured with minimal fasteners. The pre-welded reinforcement plates provide mechanical strength without requiring extensive on-site welding or complex mechanical connections.
3Strength
If concrete is poured into enclosed U-shaped elements, then structural strength is improved, but air pockets may form causing weakened portions
Solution Approach 1:
Vent openings are incorporated into the U-shaped elements to extract trapped air during the concrete pouring process. These vents allow air to escape from the enclosed space, preventing the formation of air pockets that would weaken the concrete structure.
Solution Approach 2:
The vent openings act as intermediary channels that facilitate the removal of air during concrete filling. By providing a controlled escape path for air, the vents ensure complete concrete consolidation without introducing harmful voids into the final structure.
4Strength
If extensive welding and mechanical fastening are performed on-site, then structural connection strength is improved, but labor costs and construction time increase
Solution Approach 1:
All critical welding and reinforcement work is completed during off-site manufacturing of the U-shaped elements. This preliminary action transfers complex fabrication to controlled manufacturing environments, allowing rapid on-site assembly with minimal welding or fastening required.
Solution Approach 2:
The structure is segmented into pre-assembled modules that connect through simple interfaces. This segmentation reduces the number of connections requiring welding or mechanical fastening, significantly reducing on-site labor time while maintaining connection strength through the modular design.
Data Source
AI summary
A construction element is provided. The construction element comprises a base panel and two substantially perpendicular sidewall panels which together define a U-shaped channel having an internal cavity. At least one of the panels includes at least one panel opening dimensioned to allow the passage of a reinforcement or stabilising material into the internal cavity. The construction element further comprises at least one support plate (70) having first and second ends fixed to respective sidewall panels and extending substantially perpendicular to the sidewall panels across the channel so as to provide support to the sidewall panels.