Waffle Slab Formwork Using Self-Compacting Concrete
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Solution Overview
Problem
Conventional methods for forming waffle slabs require polishing, which is labor-intensive, time-consuming, and can be delayed by weather conditions, leading to inefficiencies and increased costs.
Innovation Solution
The method involves using Self-Compacting Concrete (SCC) or self-leveling cement to form waffle slabs without the need for polishing, by providing steel molds with air holes and disposing steel bar cages, allowing the concrete to fill and set without vibration, or using a layer of self-leveling cement to create a smooth surface.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional concrete pouring and polishing methods are used, then the concrete surface can be formed, but additional labor and time are required for polishing, and the process is delayed by weather conditions
Solution Approach 1:
The patent changes the material parameter from conventional concrete to Self-Compacting Concrete (SCC), which has different flowability and compaction properties. SCC automatically fills the mold and consolidates without vibration, eliminating the need for polishing while maintaining surface quality, thus resolving the contradiction between surface quality and construction efficiency
Solution Approach 2:
The patent extracts and removes the polishing step from the construction process by using SCC that produces a finishable surface directly upon consolidation. This eliminates the additional labor and time required for polishing while still achieving the desired concrete surface quality
2Strength
If conventional concrete vibration and consolidation methods are used, then the concrete can be compacted, but vibration equipment and additional processing steps are required
Solution Approach 1:
The patent employs Self-Compacting Concrete (SCC) that performs its own consolidation and compaction without external vibration or mechanical intervention. The SCC flows automatically into all spaces and consolidates under its own weight, eliminating the need for vibration equipment and simplifying the processing steps while achieving proper concrete consolidation
Solution Approach 2:
The patent replaces the mechanical vibration system with a material-based solution. Instead of using external mechanical force to compact the concrete, the SCC's inherent rheological properties enable self-compaction, substituting a mechanical consolidation system with a material property-based approach
3Manufacturing precision
If polishing is performed to achieve smooth concrete surfaces, then surface quality is improved, but labor costs and time consumption increase
Solution Approach 1:
The patent incorporates surface finish requirements into the initial concrete mix design of the SCC. The self-compacting properties and composition are predetermined to produce a surface that meets finish specifications directly upon placement and consolidation, eliminating the need for subsequent polishing operations and reducing completion time
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 approach reduces labor and overtime, eliminates the need for additional processing steps, and ensures consistent quality and durability of the concrete surfaces, even in adverse weather conditions, thereby enhancing construction efficiency and reducing costs.
Implementation Method 1
pouring Self-Compacting Concrete (SCC) into the space from the hole of the at least one of the steel molds such that the SCC fills the space to form the waffle slab
Implementation Method 2
disposing a steel plate on top surfaces of the steel molds, wherein the steel plate comprises separately distributed air holes
Implementation Method 3
forming a layer of self-leveling cement on a surface of the concrete
Data Source
AI summary
The present disclosure relates to a method of forming a waffle slab with concrete surfaces that do not require polishing, the method comprising: providing steel molds connected to each other, and forming a space in the steel molds, wherein at least one of the steel molds has a hole; disposing a plurality of inner molds in the space formed by the steel molds; disposing predetermined steel bar cages between the plurality of inner molds, and between the plurality of inner molds and the steel molds; disposing a steel plate on top surfaces of the steel molds, wherein the steel plate comprises separate air holes; and pouring a Self-Compacting Concrete (SCC) into the space from the hole of the at least one of the steel molds such that the SCC fills the space to form the waffle slab.