AU2004202126A1 - Construction components - Google Patents

Description

53988DIV2 KMC:PFB P/00/011 AUSTRALIA Regulation 3.2 Patents Act 1990 COMPLETE SPECIFICATION FOR A STANDARD PATENT

ORIGINAL

Name of Applicant: NICOLA LEONARDIS Actual Inventor: NICOLA LEONARDIS Address for Service: COLLISON CO.,117 King William Street, Adelaide, S.A. 5000 Invention Title: CONSTRUCTION

COMPONENTS

The following statement is a full description of this invention, including the best method of performing it known to me: -lA- "CONSTRUCTING

COMPONENTS"

This element relates to interlocking platform elements, and a method of construction using same.

This invention has particular but not exclusive application to those types of elements, blocks or so-called "pods" in the industry concerned, adapted to be locked abutting or at intervals to define a platform on which concrete may be poured and allowed to set in order to define a concrete slab for building, and channels between adjacent pods for forming reinforcing ribs extending below the slab. The slab may be a base slab case onto a level platform or footing assembly, or an upper level deck or floor structure suspended by supporting columns. Hereinafter, such elements are referred to as pods or platform elements.

It is common practice to use pods constructed from polystyrene foam and measuring for example 1.090 by 1.090 metres and being square or rectangular in plan view so that they can be located in abutting relationship to define a flat platform on which concrete may be poured, as for example when providing a concrete base slab of typically 85 mm thickness. Pods may be rafted together as a form voider in any number at any dimension in plan view. By using polystyrene or other foam plastics material of adequate equivalent strength, the pods will be light in weight and easily adjusted in position, using vertical or monolithic boxing or formwork so that the poured material will 25 set and be around the pods to form cavities in the set concrete with the pods permanently located, the edges of the structure being extended down to the ground or equivalent base so that the pods will be permanently enclosed and obscured from sight.

Where desired, there can be intermediate areas devoid of pods so that there will be additional strength at those locations derived from the greater thickness of set concrete, but at all other locations on the pods the concrete thickness can be restricted to the predetermined depth, such as 85 mm given by way of example above. Reinforcing systems can be employed according 35 to the standard procedures in the industry, such as for example, Australian Standard 2870.1 1988, so that the set concrete will be reinforced, using wire mesh and steel rods for example.

-2- The pods may be solid polystyrene foam, but commonly include hollow portions such that typical pod includes an upper wall and side walls, but are open on what, in use, is the under side of the pod. The pods generally define the shape of a square or rectangular prism.

While the pods and methods of using same have proved acceptable in the industry concerned, the main problem that arises is that the lightness that is, the relative buoyancy with respect to liquid concrete of the pods results in their separating from one another and then tending to float in the liquid concrete before it has set and so lose their intended levels, with resultant variation in thickness in the formed slab of concrete. In other words, a major disadvantage can arise when the pods are required to maintain themselves gravitationally in position when they can be displaced so easily because of their lack of weight, particularly through forces acting thereon as the concrete is poured.

Additionally, the weight of concrete between channels, though evenly distributed after the concrete has been poured, cannot be evenly applied about each pod during the pouring process, causing the pods to move horizontally so that they become out of alignment with one another and the desired location of the strengthening ribs of concrete in the finished slab.

The present invention aims to alleviate one or more of the above disadvantages and to provide a platform element which will be reliable and efficient in use.

With the foregoing in view, the invention in one aspect resides broadly in a platform element and a joining means for joining two or more platform elements in abutting or spaced apart, side-by-side relationship, wherein the platform element includes:engagement means operably associated with the platform element for engaging the joining means; "securing means operably associated with the engagement means 35 for securing the joining means whereby adjacent platform elements are operably prevented from being moved in relation to one another.

-3- In one preferred form, the engagement means includes channel means, such as a channel, groove or slot formed in one or more sides of the platform element, and the securing means includes a dovetail or the like cross-section to the channel, groove or slot. Suitably, the channel means includes an abutment surface permitting the engagement means to slide parallel to the side of the platform element, but preventing the engagement means from operable movement towards and away from the platform element.

It will be appreciated that a T-section or base level recess may be provided in the channel, groove or slot. Suitably, the joining means includes a spline or the like having a complementary cross-section to the channel, groove or slot.

The joining means may be integral with the platform element, but preferably, the joining means is separate from the platform element and engages in like manner with the platform elements to be joined. For arranging adjacent platform elements in spaced apart relationships, the joining means includes a spacing means such as a frame or panel separating the two complementary spline portions. For arranging adjacent platform elements in abutting relationship, the joining means includes one or more complementary spline portions in close relationship to one another.

It is also preferred that the channel, groove or slot is tapered with the narrower dimensions of the channel, groove or 25 slot downward, with the spline portions being of substantially constant cross section such that a spline portion may be firmly engaged in a tapered channel, groove or slot, although it will be appreciated that the spline portions may also be tapered to achieve a tight engagement between the slot and the spline portion.

•In another preferred form, the engagement means includes S. edge securing strips along each of the two adjacent side in each platform element, the respective edge securing strips being held spacedly by uppermost connecting webs to constitute depending 35 hook-like edge securing strips, while the other two adjacent sides include edge channels each defined between an upstanding edge strip and the element wall to which it is connected by a -4lowermost connecting web, the parts being so made and arranged that an element may be secured to an assembly of elements by engaging its hook-like strips at adjacent sides into the corresponding edge channels of precedingly placed elements, with predetermined widths of channels and hook-like strips ensuring desired degree of rigidity.

Preferably, adequate rigidity is achieved by tapering the thicknesses of the hook-like strips and receiving channels as later described, while the hook-like strips naturally terminate short of the lower extremity of the element so as to engage the lower webs in the respective channel, the free outer strip of the channel similarly terminating short of the upper extremity of the element so that it can bear against the upper connecting web of the hook member of the next interlocking element.

The underneath pattern of each element can be of any desired form without restricting the scope of the invention. While the "top skin" is of plain square or rectangular form to provide an adequate platform, the total height of the element or block may be as desired from 175 mm up to 525 numm for example, in which case the element can be hollowed underneath in order to conserve material without lack of strength, while a system of strengthening webs may be provided within a peripheral wall arrangement of edge flanges.

In another aspect, this invention resides broadly in a 25 methos of producing a formwork for concrete casting, the method S"including:providing a plurality of platform elements and a joining means as hereinbefore defined; joining two or more platform elements in abutting or spaced apart, side-by-side relationships; providing concrete reinforcing above said platform elements S and between such pairs of said platform elements as are in spaced apart relationship, and placing the reinforcing between adjacent platform elements 35 in association with the joining means as to operably ballast the platform elements.

In order that the invention may be more readily understood and put into practical effect, reference will now be made to the accompanying drawings which illustrate one or more preferred embodiments of the invention, wherein:- Figure 1 shows in isometric view a platform element according to the invention, but given by way of illustrative example only; Figure 2 shows diagrammatically in isometric view the platform element of Figure 1 from the underside, with two of the sides shown partly in phantom outline for clarity; Figure 3 shows diagrammatically in isometric view the platform element of Figure 1 with an alternative form engagement means; Figure 4 shows diagrammatically a side view of the platform element of Figure 3; Figure 5 shows diagrammatically an alternative construction for the underside of a platform element; Figure 6 shows in isometric view an extended joiner for joining two platform elements of Figures 1 and 2 in spaced apart relationship; Figure 7 shows in isometric view a link joiner for joining two platform elements of Figures 1 and 2 in abutting o relationship; o* Figures 8, 9 and 10 show respective alternative forms extended joiners to that shown in Figure 6; Figure 11 shows a side view of the extended joiner of Figure 9; "Figure 12 shows in isometric view an edge spacer for use with the platform element of Figures 1 and 2; Figure 13 shows an elevation view a top spacer together with a sectional detail plan view of a portion thereof; Figure 14 shows a further alternative extended joiner; Figure 15 shows in perspective view, from above, a typical form of an alternative embodiment of an interlocking S. 35 platform element, block or pod, according to the invention, but given by way of illustrative example only; -6- Figure 16 shows the block of Figure 7 in plan view but turned through 1800 as viewed; Figure 17 is a sectional side elevation taken on the line A-A of Figure 16; Figure 18 is a sectional end elevation taken on the line B- B of Figure 16; Figure 19 is an inverted plan view of the block or element of Figures 16 to 18, with section lines A-A and B-B corresponding to the same lines in Figure 16, and Figure 20 shows in perspective view, from below, the same platform element or block, but drawn to illustrate details and not being drawii to scale.

Referring to Figures 1 to 14, a platform element 10 includes an upper wall 11, and four side walls 12 depending downwardly from the side edges of the upper wall 11.

In each side wall 12 there is provided two respective engagement slots shown typically at 13 and a half-depth slot 14 as shown in Figure 1. The engagement slots 13 and the halfslots 14 have been removed from Figure 2 for clarity, and the embodiment shown in Figures 3 and 4 has no half-depth slot 14.

Each engagement slot 13 and each half-slot 14 includes an abutment surface 15 the purpose of which will be described hereinafter.

251 Referring in particular to Figure 2, the platform element 10 includes a reinforcing rib structure as shown. The reinforcing rib structure includes two or four respective diagonal ribs 16 extending across from the respective corners of the platform element 10 and two respective bisecting ribs 17 extending laterally across the platform element 10 between one of the bisecting ribs 17 and respective side walls 12.

In the embodiment shown in Figure 2, the diagonal ribs 16 and bisecting ribs 17 each extend down to the same base level as the respective side walls 12, but the stiffening ribs 18 extend a lesser amount and are also provided with gussets next to their 35 engagement with the side walls 12 for added strength. In the embodiment shown in Figure 5, the stiffening ribs 18 each extend down to the same base level as the respective side walls 12.

Referring in particular to Figure 6, a spacer-joiner includes two respective locking elements 21 spaced apart by a spacer portion 23. The spacer portion 23 also includes a saddle portion 24 upon which steel reinforcing may be placed or alternatively, for supporting a chair upon which steel reinforcing may be placed.

The locking elements 21 include two respective complementary abutment surfaces 22 for engagement with the abutment surface in the engagement slots 13 and half-depth slots 14, the engagement slots 13 and locking elements 21 forming a dove-tail construction to prevent the spacer-joiner 20 from being removed laterally from the engagement slots 13. The locking element 21 also includes a compression surface 27 for engagement with a rear surface 19 on the respective engagement slot 13.

Referring to Figure 7 in particular, an abutting joiner includes a compound locking element 31 having two dove-tail portions in juxtaposition such that the complementary abutment surfaces 22 may be engaged with respective engagement slots 13 in two adjacent platform elements 10 to join them in abutting relationship. The compound locking element 31 is in the form of two elements of trapezoidal cross-section having the shorter V side of each trapezium joined to form an element having a butterfly cross section.

Referring to Figures 8, 9 and 10 in particular, three 25 alternative spacer joiners 25 have a similar effect to the spacer joiner 20. However, in the form shown if figure 8, the spacer joiner 25 has two hollow locking elements 26 spaced from each other by an alternative spacer portion 28 having a frame-like construction, but including an alternative saddle portion 29.

Where the engagement slots 13 are in T-section, the locking element 21 is likewise in the form of a complementary T-section in order to engage with the engagement slots 13 as shown in Figure 3. It will also be appreciated that the spacer portion 23 may be used in association with the hollow locking elements 35 26 or the alternative spacer portion 28 may be used with the locking elements 21 of the spacer joiner 20 shown in Figure 6.

-8- Referring to Figure 12, an edge element 32 includes an extension portion 33 extending laterally from the locking element 21 of the same form as that shown in respect of Figure 6. The extension portion 33 includes four supporting saddles shown typically at 34 and three overlaying saddles shown typically at Referring to Figure 13, a top spacer 70 includes two side portions 71 being T-section in plan view. The body of the top spacer 70 comprises a frame portion 72 receiving a reinforcing bar support 73. Two support surfaces 74 laterally of the frame portion 72 engage with complementary support platforms 75 on the spacer joiners 20, particularly as shown in Figures 9 to 11.

Thus, the weight of reinforcing is supported by the spacer joiners 20, rather than the platform elements Typically, the locking elements 21 taper as shown in Figure 11, such as for example, from 30 mm to 26 mm over a distance of 225 mm.

Referring to Figures 15 to 20, an interlocking platform element 40 comprise a rectangular top skin or platform 41 which is plain and flat, this skin 41 having a longer longitudinal length slightly less than 1200 mm and a width slightly less than 000 mm, with peripheral flanges giving a constant "height" of up to 550 mm though it could be less, such as down to 250 mm. The side edges of the top skin 41 are identified by the numerals 42, 25 43, 44 and 45 viewed in plan and taken in clockwise order.

Adjacent sides 42 and 43 each have hook-like securing strips or flanges 46 and 47 spaced from adjacent wall sections 48 and 49 by uppermost connecting webs 50 and 51, while the lower ends of the hook-like flanges 46 and 47 terminate in bottom edges 52 and 53 spaced from the bottom extremity of the element.

S. On the other hand, the other two adjacent sides 44 and have recessed channels 54 and 55 defined by upstanding flanges 56 and 57 spaced from wall sections 58 and 59 by lowermost connecting webs 60 and 61, while the upper ends of the upstanding 35 flanges 56 and 57 terminate in top edges 62 and 63 spaced from the top extremity of the top skin 41. In the space beneath the top skin 41 and within the wall sections 48, 49, 58 and 59, there -9are integrally moulded transverse strengthening ribs 64 and having end gussets 66, limited to the location of the top skin 41, as well as criss-cross webs 67 and longitudinal webs 68, all extending to the lower extremity face 69 of the interlocking platform element 40. Various tapers are provided for ease in removing the element from the mould, while all internal corners have a chamfer for practical purposes in moulding, as shown on the drawings. The tapers of the hook-like flanges and receiving channels therefor will also ensure a firm fit when one element is interlocked with another.

In use, an array of platform elements 10 may be constructed by joining them in spaced apart relationship using the spacer joiners 20 or alternative spacer joiners 25. Where a larger pod in required, two or more platform elements 10 may be joined in abutting relationship by inserting respective abutting joiners into the respective engagement slots 13 of the platform elements which are to be abutted together.

Preferably, the engagement slots 13 are tapered so that the joiners 20, 25, 30 and 32 may be firmly engaged into the engagement slots thereby enabling any weight of reinforcing provided on the spacer joiners 20 or 25 or the edge elements 32 to be transferred to the respective platform elements 10 and prevent them from rising against the buoyancy effects when surrounded by liquid concrete.

Additionally, one or more platform elements 10 may be cut alongside either the diagonal ribs 16 or bisecting ribs 17 to form a half platform element. The half platform element may be *used in places where the dimensions of a full size, or rectilinear shape platform element 10 are not appropriate. For example, a platform element 10 may be cut alongside one of the diagonal ribs 16 for use in an area of a concrete slab at 450 to the remainder of the slab, such as in a bay window or such like.

Additionally, the edge element 32 may be used in association with the platform element 10 which has be-en cut alongside one of S: 35 the bisecting ribs by inserting the locking element 21 behind the exposed bisecting rib and having the extension portion 13 extending through a base slot 36 provided in the underneath surface of the bisecting rib 17.

The assembled array of platform elements may thus be used to form a concrete base slab by providing reinforcing bars between each respective spaced apart side wall 12 and above the top upper wall 11 and pouring liquid concrete around the platform elements and reinforcing bars. The pouring of concrete between platform elements places a force tending to separate platform elements 10, but spaced apart platform elements 10 joined by respective spacer joiners 20 or 25 are constrained against moving further apart engagement of the complementary abutment surfaces 22 with the abutment surfaces 15 on the engagement slots 13.

Additionally, where the tendency is to move one pod laterally, respective spacers may be placed in compression and the compression is accommodated by abutting the compression surface 27 on respective locking elements 21 against the rear surfaces 19 of respective engagement slots 13.

The manner of using the interlocking platform element will be clear from the drawings, particularly Figure 15 which shows receiving channels at the front left side 44 and the extreme left side 45, while hook-like flanges are shown at the right side 43 and at the right rear side 42. The hook-like flanges can be engaged over the channels of previously placed elements, while the receiving channels can receive the 25 appropriate hook-like flanges of identical elements brought to the element and pushed downward.

At all times the upper surfaces of the top skins 41 will be maintained coplanar because the hook-like flanges and channeldefining flanges terminate short of the upper extremities of the element and bear against the respective upper connecting webs and 51 or the lower connecting webs 60 and 61. The underneath pattern of strengthening webs will be found efficient while acting to conserve material, but any alternative pattern could be used.

35 It is believed that the platform elements of the present invention may be formed to desired sizes and strengths using polystyrene or other equivalent foam plastics materials. Any -11peripheral boxing or formwork is able to be used if an however required.

It will be appreciated that the principles illustrated may also be applied to other types of building blocks or elements, including those made of other materials and usable for purposes other than supporting concrete, the elements being usable in any application where hollow interlocking platform units are required.

It will of course be realised that the above has been given only by way of illustrative example of the invention and that all such modifications and variations thereto as would be apparent to persons skilled in the art are deemed to fall within the broad scope and ambit of the invention as claimed in the following claims.

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Claims (8)

1. A platform element and a joining means for joining two or more platform elements in abutting or spaced apart, side-by-side relationship, wherein said platform element includes: engagement means operably associated with said platform element for engaging said joining means; securing means operably associated with said engagement means for securing said joining means whereby adjacent platforn elements are operably prevented from being moved in relation to one another; wherein said engagement means includes channel means formed in one or more sides of said platform element, and said channel means includes an abutment surface permitting said joining means to slide parallel to the side of the platform element, but preventing said joining means from operable movement towards and away from the platform member.

2. A platform element and a joining means as claimed in claim 1, wherein said joining means includes a spline or the like and having a complementary cross-section to said channel means.

3. A platform element and a joining means as claimed in any one of the preceding claims, wherein, for arranging adjacent said platform elements in spaced apart relationship, said joining means includes a spacing means for separating two complementary spline portions.

4. A platform element and a joining means as claimed in any one of claims 1 or 2, wherein, for arranging adjacent said platform elements in abutting relationship, said joining means includes one or more complementary spline portions in close relationship to one another.

A platform element and a joining means as claimed in any one of the preceding claims, said channel means is tapered whereby said respective spline portions are firmly engageable therein.

6. A platform element as claimed in claim 1, wherein said engagement means includes edge securing strips along each of two adjacent sides of each platform element, respective said edge securing strips being held spacedly by uppermost connecting webs to constitute depending hook-like edge securing strips, while the other two adjacent sides include edge channels each defined by an upstanding edge strip and the element wall to which it is connected by a lowermost connecting web, the parts being so made and arranged that an element may be secured to an assembly of elements by engaging its hook-like strips at adjacent sides into the corresponding edge channels of precedingly placed elements, with predetermined widths of channels and hook-like strips ensuring desired degree of rigidity.

7. A platform element as claimed in claim 6, wherein said hook-like strips terminate short of the lower extremity of said platform element so as to engage the lower webs in the respective channel, and the free outer strip of the channel similarly terminating short of the upper extremity of said platform element so that it can bear against the upper connecting web of the hook member of the next interlocking said platform element.

8. A method of producing a formwork for concrete casting, the method including: providing a plurality of platform elements and a joining means as claimed in any one of claims 1 to 7; joining two or more said platform elements in abutting or spaced apart, side-by- side relationship; providing concrete reinforcing above said platform elements and between such pairs of said platform elements as are joined in spaced apart relationship, and 14 placing said reinforcing between adjacent platform elements in association with the joining means as to operably ballast the platform elements. Dated this 20 day of May 2004 NICOLA LEONARDIS By his Patent Attorneys COLLISON CO