Textile-Reinforced Concrete Folded Structure for Lightweight Walls
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Solution Overview
Problem
Prefabricated building elements in lightweight construction face challenges such as low load-bearing capacity, short service life, poor sound and heat insulation, and fire safety compared to solid construction elements, while also being difficult to recycle.
Innovation Solution
A prefabricated building element featuring a prestressed planar structure element made of textile-reinforced concrete with a folded design and concrete layers on top and bottom, providing high load-bearing capacity, extended service life, improved insulation, and enhanced fire safety, while maintaining low material thickness and weight.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of stationary object
If prefabricated building elements are made in lightweight construction, then weight is reduced and environmental friendliness is improved, but load-bearing capacity, service life, sound and heat insulation, and fire safety deteriorate
Solution Approach 1:
The invention uses a composite structure combining a textile-reinforced concrete core layer with metal profile frames. The textile-reinforced concrete provides compressive strength and fire resistance, while the metal profiles provide tensile strength and structural rigidity. This composite approach allows the element to achieve high load-bearing capacity despite using lightweight materials, resolving the contradiction between weight reduction and strength maintenance.
Solution Approach 2:
The building element is segmented into distinct functional layers: a textile-reinforced concrete core, metal profile frames at edges and intersections, and optional insulation layers. This segmentation allows each component to be optimized for its specific function - the textile concrete for compression and fire resistance, the metal profiles for tensile strength and structural integrity - while working together to achieve both lightweight construction and high load-bearing capacity.
2Weight of stationary object
If prefabricated building elements are made in lightweight construction, then weight is reduced, but service life deteriorates
Solution Approach 1:
The combination of textile-reinforced concrete and metal profiles creates a durable composite structure. The textile reinforcement (steel fibers or mesh) embedded in the concrete matrix prevents cracking and enhances tensile strength, while the metal profiles provide additional structural support and protection at critical locations. This composite construction significantly extends the service life compared to conventional lightweight materials alone.
Solution Approach 2:
The invention changes the material parameters by using high-strength textile reinforcement with specific fiber orientations and densities within the concrete matrix. This parameter optimization enhances the overall durability and service life of the lightweight element while maintaining its weight advantage.
3Weight of stationary object
If prefabricated building elements are made in lightweight construction, then weight is reduced, but sound and heat insulation deteriorate
Solution Approach 1:
The invention implements a nested structure where insulation materials are placed within the cavity formed by the metal profile frame and the textile-reinforced concrete layers. This nested arrangement allows insulation materials to be efficiently positioned within the structural element itself, providing superior thermal and acoustic insulation without significantly increasing the overall weight or external dimensions of the building element.
4Weight of stationary object
If prefabricated building elements are made in lightweight construction, then weight is reduced, but fire safety deteriorates
Solution Approach 1:
The textile-reinforced concrete material itself provides excellent fire resistance due to the non-combustible nature of concrete and the high-temperature stability of properly treated textile reinforcements. The metal profiles are protected by the concrete cover, which acts as a thermal barrier during fire exposure. This composite construction maintains fire safety performance while achieving weight reduction compared to traditional solid concrete elements.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution achieves a high load-bearing capacity, long service life, superior sound and heat insulation, and high fire safety with reduced material usage and weight, making it suitable for large-format wall and ceiling elements, and allows for easy recycling and reuse.
Implementation Method 1
a prestressed planar structure element made of textile-reinforced concrete... The prestressed surface structure element is designed as a folded structure... Textile-reinforced concrete, which is prestressed with a tensile stress, can be used to form prestressed planar structure elements which, despite their low dead weight, give the prefabricated element a high load-bearing capacity due to their prestressing
Implementation Method 2
an improved load-bearing capacity can also be achieved by folding the surface structure element and the top or bottom concrete layer. The folding of the surface structure element causes a folding reinforcement of the surface structure element, with which the compressive and bending strength of the prefabricated element can be increased
Implementation Method 3
The top concrete or bottom concrete layer can also have a positive effect on the service life of the prefabricated component, since they protect the textile concrete of the surface structure element from detaching the concrete cover of the textile reinforcement
Implementation Method 4
the surface structure element and the top concrete or sub-concrete layer can interlock in a form-fitting manner due to the folding in such a way that a shear bond can be formed between the surface structure element and the top concrete or sub-concrete layer, through which the rigidity of the prefabricated element can be additionally increased
Data Source
Figure 1
Figure 2~3
Figure 4~5
AI summary
The prefabricated element comprises a prestressed surface structural element (1) made of textile-reinforced concrete, a topping layer (2), and/or a base layer (3). The prestressed surface structural element (1) is designed as a folded structure, exhibiting folds formed by protrusions and/or depressions within the prestressed surface structural element (1). The topping layer (2) is formed on a surface of the prestressed surface structural element (1) in the depressions and/or between the protrusions of the fold such that the topping layer (2) forms a flat surface that is parallel to the prestressed surface structural element (1).The sub-concrete layer (3) is formed on a surface of the prestressed surface structural element (1) opposite the super-concrete layer (2) in such a way that the sub-concrete layer (3) forms a flat surface which is aligned parallel to the prestressed surface structural element (1).