Installation Method for Reducing Workload During Carport Foundation Excavation

In the construction industry, personnel shortages caused by factors such as the aging of skilled installation technicians have become a serious problem. Carport installation, in particular, involves physically demanding tasks such as foundation work and lifting heavy objects. Furthermore, conventional installation methods were prone to variations in finish quality depending on the skill level of the technician, presenting the challenge of maintaining quality regardless of who performs the installation. To address these challenges, YKK AP has developed the "Easy Plate," a new-concept column base plate for foundation construction.

The foundation plays the most important role in supporting the carport. Foundations must withstand downward loads from snow buildup, upward loads from wind uplift, and horizontal overturning forces from snow and wind. As such, the size of the foundation must be determined based on these conditions. However, the larger the foundation, the greater the workload during excavation and the greater the amount of soil to be removed.
This led to the development of a new installation method, in which the concrete floor itself serves as the foundation. This method involves installing the "Easy Plate" specialized column base plate onto the bottom of the carport’s posts, then pouring and setting the concrete floor on top. This transfers the vertical, horizontal, and lateral loads acting on the base to the floor itself. This allows sufficient strength to be achieved even with shallow excavation.
Because this is an innovative foundation construction method, we repeatedly conducted analysis-based simulations and experiments using full-scale models, while also obtaining evaluations from external experts. After this extensive testing process, practical application was finally achieved.

Installation using the "Easy Plate" offers significant benefits in terms of labor saving. First, because it allows the size of the foundation itself to be reduced, it cuts down on the effort required for excavation and the disposal of excavated soil. Compared to conventional methods, foundation excavation and soil disposal time is reduced from 148 minutes to 31 minutes, and foundation pouring time is reduced from 29 minutes to 0 minutes—a total reduction of 146 minutes. This also reduces excavation volume and leftover soil volume by approximately 80%.*

* Comparison based on installation of "G Port Pro" 3000 Type, Size 5555, 4-post configuration

Additionally, there are advantages for customers in terms of utilizing their land. With conventional installation methods, the posts were positioned at the center of the foundation, making it necessary to leave a gap between the posts and the border with the neighboring property. Conversely, the new method is not constrained by the size of the foundation, allowing the posts to be placed right up to the property line, providing greater flexibility in adapting to the site.

We will continue to pursue technological development that reduces the burden on installation technicians while delivering reliable quality to our customers.