Variable Assembly PC Member Hollow Modules

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Solution Overview

Problem

Conventional precast concrete (PC) construction methods face challenges in reducing construction time, managing quality, and achieving structural integration and watertightness, especially in large structures and applications requiring load transfer in multiple directions, due to weight and labor constraints.

Innovation Solution

A variable assembly PC member system comprising hollow PC modules with upper and lower flanges and webs, connected by steel bars and connectors, allowing for post-tensioning and non-shrinkage mortar filling, which facilitates modular assembly and integration in both width and length directions, and includes features like shim plates and water stops for enhanced stability and watertightness.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If precast concrete members are used for large-sized structures, then construction quality and speed are improved, but the weight of members becomes too heavy for carrying and assembly in the field

Engineering Contradiction:

Improveconstruction speedVSAvoidweight of PC member

Core Design Contradiction:

ProductivityVSWeight of moving object

Solution Approach 1:

The PC member is divided into multiple hollow modules that can be assembled together. Each module has a hollow cross-section formed by upper and lower flanges with webs connecting them, creating lightweight yet structurally sound segments that can be easily transported and assembled on-site while maintaining overall structural integrity

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The PC member incorporates hollow spaces within its structure through the use of hollow modules. These hollow sections reduce the overall weight of the member while maintaining sufficient structural strength, enabling easier handling and assembly of large-sized structures without compromising construction quality or speed

Inventive Principle:

Principle #31Porous materials

2Weight of moving object

If half PC members with cast-in-place concrete are used, then weight is reduced, but construction time cannot be sufficiently reduced due to required concrete placement

Engineering Contradiction:

Improveweight of PC memberVSAvoidconstruction period

Core Design Contradiction:

Weight of moving objectVSLoss of time

Solution Approach 1:

The member is segmented into hollow modules that are completely precast in factories. This segmentation allows the entire member to be manufactured off-site without requiring any cast-in-place concrete operations, eliminating the time-consuming concrete placement and curing processes while maintaining reduced weight through the hollow structure

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

All concrete work is performed in advance during factory precasting of the hollow modules. The modules are completely prepared with all structural elements in place before being transported to the construction site, eliminating any on-site concrete placement activities and significantly reducing the construction period

Inventive Principle:

Principle #10Preliminary action

3Weight of moving object

If conventional PC members are used, then weight reduction is achieved, but structural integration in the width direction cannot be accomplished

Engineering Contradiction:

Improveweight of PC memberVSAvoidstructural integration

Core Design Contradiction:

Weight of moving objectVSStability of the object's composition

Solution Approach 1:

Multiple hollow modules are merged together through connectors that join the steel bars of adjacent modules. The connectors include couplers, headed bars with expanded heads, sockets, and fixing caps that securely bind the modules in the width direction, achieving complete structural integration while preserving the weight benefits of the hollow configuration

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The PC member combines concrete hollow modules with steel bar connectors to create a composite structure. The concrete provides compression strength while the steel connectors provide tensile strength and structural integration, achieving both weight reduction and complete structural integration in the width direction

Inventive Principle:

Principle #40Composite materials

4Ease of manufacture

If fastening bolts are used to combine PC plates and concrete ribs, then assembly is achieved, but watertightness cannot be secured at portions connected with neighboring structures

Engineering Contradiction:

Improveassembly capabilityVSAvoidwatertightness

Core Design Contradiction:

Ease of manufactureVSReliability

Solution Approach 1:

The connection method is extracted from traditional bolt-based assembly to a integrated steel bar connector system. The connectors use couplers, headed bars, sockets, and fixing caps to create continuous structural connections that maintain watertightness while enabling assembly, eliminating the need for fastening bolts that compromise watertightness

Inventive Principle:

Principle #2Taking out (Extraction)

Data Source

PatentUS12129653B2Variable assembly PC member

Publication Date: 2024.10.29 SEOUL NATIONAL UNIVERSITY R&DB FOUNDATION

AI summary

A variable assembly PC member includes: a plurality of hollow PC modules, each of which has an upper flange and a lower flange spaced apart from each other, and a pair of webs connecting both ends of the upper flange and the lower flange to form a hollow therein; and connectors connecting the plurality of hollow PC modules with each other in the width direction.