Ventilated Reinforced-Concrete Wall Module with Metal Rib Trusses
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Solution Overview
Problem
Conventional prefabricated concrete wall systems face challenges such as difficulty in transportation and assembly due to heavy weight, limited architectural flexibility, thermal discomfort, and the need for skilled labor for perfect solidarization and installation of accessory parts, leading to increased costs and rework.
Innovation Solution
A ventilated reinforced-concrete wall module system comprising a pair of vertically produced panels interconnected by metal rib trusses, manufactured using automated robotic equipment, allowing for flexible dimensions and on-site assembly with pre-installed electrical and hydraulic installations, reducing labor and material waste, and providing thermal comfort through internal voids and air pockets.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional prefabricated concrete wall systems are used, then structural strength is achieved, but transportation and assembly become difficult due to heavy weight
Solution Approach 1:
The wall system is divided into multiple panels that are connected through dry joints with mechanical fasteners. Each panel can be independently manufactured, transported, and assembled, reducing the weight burden during transportation while maintaining overall structural strength through the interconnected panel system
Solution Approach 2:
The wall panels utilize composite construction combining concrete with steel framing and insulation materials. This composite structure achieves required structural strength while reducing overall weight compared to solid concrete walls, facilitating easier transportation and assembly
2Ease of manufacture
If vertically-concreted walls with metal forms are produced, then structural elements can be reused, but architectural flexibility is limited
Solution Approach 1:
The wall system employs standardized modular panels that can be configured in various arrangements to create different architectural designs. The modular nature allows the same metal forms to be reused for producing different panel types while maintaining architectural flexibility through varied panel configurations
Solution Approach 2:
The metal forms are designed as universal templates that can produce multiple types of wall panels with different dimensions, openings, and configurations. This multi-functional form system enables both economical reuse and architectural versatility through standardized modular components
3Strength
If conventional concrete wall systems are used, then structural integrity is maintained, but thermal comfort is poor in extreme temperatures
Solution Approach 1:
The wall panels incorporate composite construction with concrete exterior shells, insulation layers, and interior finishes. This composite structure maintains structural integrity of the concrete while adding thermal insulation layers that provide thermal comfort in extreme temperatures
Solution Approach 2:
The wall system applies different materials with specific properties to different zones: concrete for structural integrity and exterior durability, insulation materials for thermal performance, and finishes for interior quality. This localized material assignment optimizes both structural and thermal performance
4Ease of manufacture
If accessory parts are installed before concreting, then installation is simplified, but changes require costly rework
Solution Approach 1:
The wall panels are manufactured as complete modular units with accessory parts pre-installed during panel production. This segmentation allows standardized installation while enabling easy modification by simply replacing entire panels rather than performing costly rework on site
Solution Approach 2:
Accessory parts such as electrical conduits, window frames, and door openings are pre-installed during the panel manufacturing process before final assembly. This preliminary action simplifies on-site installation while allowing flexible modifications through panel replacement rather than destructive rework
5Reliability
If skilled labor is used for perfect solidarization, then connection reliability is improved, but labor costs and complexity increase
Solution Approach 1:
The connection system is segmented into standardized mechanical fasteners and pre-fabricated connection details that can be installed using simple tools. This segmentation maintains connection reliability through proven mechanical designs while reducing assembly complexity to tasks that require minimal skill and training
Solution Approach 2:
The panel connection system incorporates self-aligning features, pre-drilled holes, and standardized fastening mechanisms that enable workers to achieve reliable connections through simple repetitive actions rather than requiring skilled judgment. The system performs much of the alignment and positioning automatically during assembly
Data Source
AI summary
A ventilated wall module (10) of the type used in civil construction for a range of buildings using pre-fabricated components, such as one-story homes, large houses, houses, schools, hospitals, industrial sheds, inter alia; the wall module (10) includes a pair of panels (20A) and (30A) that are produced independently of one another by automated, robotic equipment (E1), based on large moving metal surfaces (M1) that slide on rails (T1); said mechanized method (M1) developed for the production of the panels (20A) and (30A) includes an industrialized construction system (SC) for producing each wall module (10) comprising the combination of the coordination and compatibilization of the designs to be implemented with the pre-installation of the complementary components such as electrical boxes (c1) or other necessary elements.