UHPC Shell Formwork for Concrete Construction
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Solution Overview
Problem
The on-site manufacture of concrete beams and other elements is hindered by the need for time-consuming and expensive formwork removal, as well as the difficulty and cost of transporting heavy, cured concrete elements.
Innovation Solution
The use of Ultra-High Performance Concrete (UHPC) shells formed using 3D printing or shell formworks, which allow for the incorporation of Normal Strength Concrete (NSC) into the UHPC shell, eliminating the need for formwork removal and reducing transportation challenges due to the lighter weight of the UHPC shell.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If traditional formwork is used to manufacture concrete beams on-site, then the concrete elements can be produced with required strength, but the formwork removal process is time-consuming and expensive
Solution Approach 1:
The patent merges the formwork function with the final structural element by creating a double-shell concrete construct where the outer shell serves as both formwork and permanent structural component. The UHPC outer shell and NSC inner core are combined into a single integrated element that eliminates the need for separate formwork removal, directly resolving the time loss contradiction.
Solution Approach 2:
The patent uses composite materials by combining Ultra-High Performance Concrete (UHPC) for the outer shell with Normal Strength Concrete (NSC) for the inner core. This composite construction allows the outer shell to function as permanent formwork while providing superior strength and durability, thereby eliminating formwork removal time and improving construction productivity.
2Ease of manufacture
If normal strength concrete is used for complete concrete elements, then the elements can be manufactured on-site, but the weight and size make transport difficult and costly
Solution Approach 1:
The patent segments the concrete element into two distinct parts: an outer UHPC shell and an inner NSC core. The UHPC shell provides high strength-to-weight ratio and can be manufactured with thinner sections, reducing overall weight while maintaining structural integrity. The NSC core fills the interior space, providing bulk volume without the full weight penalty of traditional concrete elements, thus easing transportation.
Solution Approach 2:
The patent applies local quality by using UHPC specifically for the outer shell where high strength and durability are most needed, while using NSC for the inner core where lower strength requirements allow for cost-effective material usage. This localized material optimization reduces overall weight compared to using UHPC throughout, while still achieving the desired on-site manufacturing capability.
3Productivity
If traditional formwork is used, then concrete elements can be manufactured, but multiple formworks must be constructed and removed on-site increasing cost
Solution Approach 1:
The patent merges the formwork function with the final structural element by creating a double-shell concrete construct where the outer shell serves as both formwork and permanent structural component. The UHPC outer shell and NSC inner core are combined into a single integrated element that eliminates the need for separate formwork removal, directly resolving the time loss contradiction.
Solution Approach 2:
The outer UHPC shell serves multiple functions: it acts as the outer structural layer, provides the formwork for the inner NSC core, and becomes a permanent load-bearing element in the final structure. This multi-functionality eliminates the need for separate temporary formwork systems, reducing device complexity and improving construction efficiency.
4Weight of moving object
If UHPC shell is used instead of traditional formwork, then the shell has less weight and can be transported more easily, but requires precise manufacturing to ensure durability and moisture-resistance
Solution Approach 1:
The patent uses composite materials by combining Ultra-High Performance Concrete (UHPC) for the outer shell with Normal Strength Concrete (NSC) for the inner core. This composite construction allows the outer shell to function as permanent formwork while providing superior strength and durability, thereby eliminating formwork removal time and improving construction productivity.
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
This method accelerates construction, reduces costs, and results in a longer-lasting, durable structure as the UHPC shell is exceptionally durable and moisture-resistant, protecting the inner NSC core.
Implementation Method 1
the UHPC shell is exceptionally durable and moisture-resistant, which provides a longer-lasting structure
Data Source
AI summary
Methods for manufacturing a composite concrete structure are provided. A method can include utilizing a shell formwork with a displacement piece positioned therein. A first type of concrete can be placed in the shell formwork around the displacement piece. The displacement piece, when removed, leaves a void that is fillable with a second type of concrete for form the composite concrete structure. A reinforcement cage or reinforcement rods can be incorporated into the void prior to placement of the second type of concrete.