Window Frame Tilt-Up Concrete Wall Forming Without Custom Fitting
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Solution Overview
Problem
Current methods for forming vertical walls around window frames in tilt-up or precast construction are inefficient, requiring custom fitting, excessive labor, materials, and create safety hazards and waste.
Innovation Solution
A method involving spraying a release on a flat surface, positioning a window assembly with a frame and bracing, securing it, pouring concrete around it, and then lifting the wall into a vertical position after curing, using reusable bracing to maintain assembly alignment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If boxes are placed between wall forms and concrete is poured around them, then window openings are formed in the wall, but the concrete opening dimensions are inconsistent requiring custom fitting
Solution Approach 1:
The window frame is installed in the wall form before concrete is poured, allowing the concrete to be formed around the pre-positioned frame. This preliminary action ensures consistent opening dimensions that match the frame, eliminating the need for custom fitting after concrete curing.
Solution Approach 2:
Instead of forming the concrete opening first and then installing the window frame, the invention inverts the sequence by installing the frame first and forming the concrete opening around it. This reversal ensures precise dimensional matching between the opening and frame.
2Ease of operation
If a third-party glazier is required to supply and install the window using a lift, then the window can be installed in the concrete opening, but the process is time consuming and creates safety issues
Solution Approach 1:
The window frame installation is merged with the wall forming process itself. The frame is positioned and secured during wall construction, and concrete is poured around it, combining two separate operations (frame installation and wall construction) into one integrated process, eliminating the need for separate glazier installation.
Solution Approach 2:
The window frame is pre-installed in the wall form before concrete pouring, allowing the opening to be formed precisely to fit the frame. This eliminates the need for subsequent measurement, custom fabrication, and installation by a glazier, significantly reducing time and safety risks.
3Manufacturing precision
If boxes are used to form window openings and are removed after concrete curing, then the openings are created, but job site waste is generated
Solution Approach 1:
The invention extracts and eliminates the need for removable boxes from the process. Instead of using boxes that must be removed after concrete curing, the window frame itself serves as the forming element, with concrete poured around it to create the opening, eliminating waste generation entirely.
Solution Approach 2:
The window frame serves a dual function: it acts as both the final window component and the forming tool for the concrete opening. The frame positions itself and defines the opening shape during concrete pouring, eliminating the need for separate forming boxes that would become waste.
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 reduces time, labor, and waste while ensuring consistent dimensions and safety by eliminating the need for custom fitting and third-party installation, and allows for safer, more efficient construction.
Implementation Method 1
spraying a flat surface with a release
Implementation Method 2
concrete is poured about the window assembly to form a wall. Once the concrete cures
Data Source
AI summary
The method for pouring concrete around a window frame begins by spraying a flat surface with a release, followed by positioning window assemblies on the flat surface. The window assemblies include at least a frame, and also possibly a sash, glazing and removable bracing. The window assemblies are secured to the flat surface and then concrete is poured around the window assembly to form a wall. Once the concrete cures around the frame, the bracing is removed, and the wall is tilted/lifted to a vertical position.