Disposable V-Ribbed Mesh Formwork for Foundation Casting
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Solution Overview
Problem
Current formwork systems for constructing foundations, plinths, and construction elements are costly and time-consuming due to on-site assembly and removal, with high material waste and potential for incorrect alignment and damage during the casting process.
Innovation Solution
A disposable structure comprising bent and crossed reinforcing rods enclosed by a containment element with V-shaped ribs and a mesh construction, allowing for pre-assembled formwork and reinforcement fabrication at the factory, which can be easily transported and installed on-site, reducing the need for external supports and simplifying the casting process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If traditional formwork panels are used for making foundations and construction elements, then the casting can be formed with proper shape and reinforcement positioning, but the assembly and removal operations require significant time and labor on site
Solution Approach 1:
The formwork panels are pre-assembled with reinforcement cages and positioning elements at the factory before transport to site. This preliminary assembly eliminates time-consuming on-site construction operations and allows immediate installation of complete casting units upon arrival
Solution Approach 2:
The invention merges the formwork panels, reinforcement cages, positioning spacers, and casting material into a single integrated disposable unit. This combination eliminates the need for separate assembly and removal operations for each component, significantly reducing on-site time and labor
2Manufacturing precision
If expensive wooden panels are used for formwork, then proper casting shape can be achieved, but the panels are subject to breakage, damage, and require cutting on site to adapt to casting sizes
Solution Approach 1:
The formwork system is divided into standardized modular panels with fixed dimensions and integrated reinforcement cages. These segments can be selectively combined to match different casting size requirements, eliminating the need for on-site cutting and adaptation while maintaining precise shape control
Solution Approach 2:
The invention changes the formwork from reusable expensive wooden panels to disposable panels with integrated reinforcement made from affordable materials. The panels are manufactured with precise dimensions and reinforcement positioning built-in, ensuring casting accuracy without requiring expensive materials or complex on-site adjustments
3Strength
If galvanised sheet panels are used with pebble gravel for stiffening, then the panels can be fixed around reinforcing rods, but the system becomes complicated and requires adaptation to each cast product
Solution Approach 1:
The stiffening function previously requiring separate pebble gravel arrangements is merged into the panel structure itself through integrated V-shaped ribs and mesh constructions. This integration eliminates the need for additional stiffening materials and simplifies the overall system while maintaining required structural rigidity
Solution Approach 2:
The formwork panels utilize composite construction combining galvanised sheet with integrated reinforcement cages and mesh structures. This composite approach provides inherent stiffness and strength without requiring additional pebble gravel or complex support systems, reducing overall system complexity
4Manufacturing precision
If formwork and reinforcement are assembled on site, then the casting can be made with proper alignment, but alignment issues and incorrect positioning of parts occur
Solution Approach 1:
The reinforcement cages are pre-assembled and pre-positioned within the formwork panels at the factory with precise alignment. This preliminary positioning ensures correct reinforcement placement and formwork alignment are achieved without requiring complex on-site adjustment operations
Solution Approach 2:
The disposable panels are designed with self-aligning features and integrated reinforcement positioning elements that automatically ensure correct alignment during installation. The system serves itself by incorporating alignment mechanisms into the panel design, eliminating the need for separate alignment operations and reducing positioning errors
Data Source
AI summary
A disposable structure for making foundations, plinths and construction elements in general wherein there is provided an iron reinforcement (12, 13) arranged in at least one containment element (14) for receiving concrete (16), wherein the at least one containment element (14) comprises a metal sheet exhibiting a series of main V-shaped ribs (19), interspaced from one another and connected by a mesh construction (20), which realizes a beehive structure, and by further secondary ribs (21), also shaped as a V, in a central zone of the mesh construction, the series of main V-shaped ribs (19) being arranged against the iron reinforcement (12, 13) and having a height (h) between 1.5 and 3.0 cm.Such type of structure can be entirely made at the factory and installed in position at the yard.