AU2013203372A1 - Pod spacer, system and bar support - Google Patents

Abstract

A pod spacer 23 is of lattice construction being moulded in plastics and having a projection section 24 and a bridge section 25. The bridge section has two arms and a pod contact base 26 which is relatively wide and this section 25 tapers to a top edge 27. The base 26 joins the projection 24 and in this case tapers down as an inverted V with a vertical wall at 28 and 29 so that these surfaces are for a pod contact by reason of right angled pod contact surfaces 28 and 29 and likewise on the other side at 30 and 31. The surfaces 29 and 31 have spikes 32 and 33 so the spikes can be driven or pushed into the pod material, usually polystyrene foam. The spacer can be made with four arms to extend diagonally across corners at the intersection between four pods. Uj V .:P

Description

1 POD SPACER, SYSTEM AND BAR SUPPORT TECHNICAL FIELD [0001] THIS INVENTION relates to a spacer for positioning waffle pods in concrete flooring and and in particular but not limited to a pod placement system which at the same time aids pod placement and positioning of reinforcing steel. BACKGROUND [0002] It is known to provide spaced polystyrene blocks in a grid formation as lost formwork in concrete flooring. The polystyrene blocks are commonly known as "waffle pods" because they are hollow with a "waffle" like internal bracing. It will be appreciated that waffle pod or pod in this specification refers to any body or block made from any material. A basic rectangular floor is made using a peripheral formwork used to define an outer periphery of the floor. Pods are then placed in a defined distance from the peripheral form work to form an outer trench between the pods and the form. Further pods are then placed in a grid in fixed spaced relation, effectively, trenches of defined depth and width are formed between the pods. The outer formwork is deeper than the pod depth so that as concrete is poured it extends around and above the pods. Concrete is poured over and around the pods, flows into the spaces between the pods and into the outer trench. The flooring is reinforced using a single bar between the pods crossing at the intersection between the pods and three or more parallel spaced bars are used in the outer trench. Sheets of mesh are also applied over the top of the pods. These sheets are chaired just above the top of the pods. [0003] It is also well known to use cross shaped plastic spacers at the intersection between the pods. These spacers also support the reinforcing bars located between the pods. It is also known to use long narrow chairs which space and extend across the outer trench at spaced intervals to support the bars in the outer trench. [0004] The cross shaped spacer and the trench chair represent a solution to pod placement and steel reinforcement that has been used for many years.

2 [0005] While these are effective, there is a potential for pod movement as workers move about the site and also while concrete is being poured. SUMMARY [0006] It is an object of the present invention to inhibit pod movement by using a pod spacer located on the upper horizontal surface of the pods, bridging across adjacent pods and projecting above the upper surface of the pods to preferably support reinforcing steel at the same time a stabilising the pods. [0007] In one preferred embodiment the spacer is generally T-shaped, having in use a vertical section and a horizontal section, the vertical section being adapted for location between adjacent pods in a region near the top of the pods, the horizontal section extending bilaterally from the vertical section and being adapted in use to be located on top of the adjacent pods while the vertical section is between the pods. In another embodiment, the spacer extends diagonally across the juncture or intersection of four pods in a corner-to-corner configuration. In this case the spacer may have four diagonally extending arms. The arms are typically set at 90 degrees forming an X-shape in plan. [0008] In one embodiment the spacer is moulded and has a lattice structure. In another embodiment the spacer is formed as a cellular structure of polygonal prismatic cells, typically identical cells. This may be a "honeycombed" structure of polygonal prisms stacked horizontally having regard to the pod surface in use. [0009] The spacer may include spikes or other means to positively engage the pods or the spacer may be wide enough to be non-invasive and simply be supported by the pods. Preferably the spacer has one or more projections that project down between adjacent pods to hold the pods in predetermined spaced relation These projections may be shaped to engage a side, edge or a corner of a pod. In the case of a corner-to-corner configuration the spacer preferably has bilateral angle projections fitting the corner of diagonally opposed pods. The spacers may be employed in a system having upper and lower pod spacers to stabilise both top and bottom 3 regions of the pods. In this regard the lower pod spacer may comprise a cross shaped spacer adapted to be located between four adjacent pods. Typically, the lower pod spacer has a length so that it may be used in the outer trench as a steel support well as between pods. BRIEF DESCRIPTION OF THE DRAWINGS [0010] In order that the present invention may be more readily understood and be put into practical effect reference will now be made the accompanying drawings and wherein: Figure 1 is a schematic drawing of a typical pod layout for a floor and building footings; Figure 2 is a perspective view of one embodiment of a spacer according to the present invention; Figure 3 is a section through a concrete construction employing the pod spacer according to Figure 2; Figure 4 is a drawing illustrating a second embodiment employing a cellular structure; and Figure 5 is a drawing similar to Figure 3 but using the spacer as used in Figure 4; Figure 6 is a cut-away perspective view illustrating a further embodiment employing a diagonal corner-to-corner arrangement; Figure 7 is a top plan view showing a corner-to-corner spacer; Figure 8 is an underside view of the corner-to-corner spacer 4 way spacer; and Figure 9 is a drawing illustrating form above a further embodiment of a 4 way spacer (pods omitted). DESCRIPTION OF EMBODIMENTS [0011] Referring to the drawings and initially to Figure 1 there is illustrated in part cut away a formwork layout 10 for a floor having an outer timber form 11, 12 defining an outer trench and a grid of pods 13 there being 10 pods, shown in whole or part shown in Figure 1. [0012] The pods closest to the timber form are spaced from the timber form by spacers 14 and in the case shown the same spacers 14 are used between the pods and at each 4 way junction 15. As illustrated these spacers engage the region near the bottom of the pods. The upper horizontal surfaces of the pods support spacers 17 according to the spacer aspect and these 4 bridge between the adjacent pods. These spacers 17 are located at spaced intervals across the grid of pods. It will be appreciated that in combination the upper and lower pods represent a system to stabilise the pods. In a further preferred form the spacers also stabilise steel reinforcement. [0013] Reinforcing mesh 18 is in turn supported by the spacers 17. Additional steel supports or chairs may be used elsewhere on top of the pods as required to fully stabilise the mesh 18, further steel bars are usually placed between and around the pods. These are typically supported on the spacers 14 as shown at 19 and 20 in broken outline. This reinforcing steel has been omitted from the drawings for clarity purposes but it is understood that appropriate steel extends throughout the gaps 21 between the pods and the outer trench 22. [0014] The pod spacers 17 may be of any suitable structure to both separate the pods using a projection between the pods as well as a bridging section above the pods to support the steel. In this regard a general T-shaped structure is preferred as a convenient configuration. Two versions are described below. [0015] Referring to Figures 2 and 3 a spacer 23 is shown, the spacer is of lattice construction being moulded in plastics and having a projection section 24 and a bridge section 25. The bridge section has a pod contact base 26 which is relatively wide and this section 25 tapers to a top edge 27. The base 26 joins the projection 24 and in this case tapers down as an inverted V with a vertical wall at 28 and 29 so that these surfaces are for a pod contact by reason of right angled pod contact surfaces 28 and 29 and likewise on the other side at 30 and 31. The surfaces 29 and 31 have spikes 32 and 33 so the spikes can be driven or pushed into the pod material, usually polystyrene foam. [0016] The top edge 27 supports steel as shown in Figure 3. Figure 3 shows the spacer 23 in position with part of the concrete cut away. [0017] Referring to Figures 4 and 5 there is illustrated use of a second embodiment being of a spacer 34 two being shown in Figure 4. In this case the spacer is again generally T-shaped having a main bridge section 35 and two projections 36 and 37 again providing general right 5 angle corners at 38 and 39 to match the pods surfaces at or adjacent corners of the pods as shown. [0018] As can be seen the spacers 34 have a cellular structure which may be moulded or extruded. Each cell is a polygonal prism which may be pentagonal, hexagonal etc. This embodiment is wide enough so that it does not need the spikes of the previous embodiment. [0019] Referring to Figures 6-8 a third embodiment of the present invention is illustrated where in this case an X-shaped spacer 40 is positioned at the intersection between four pods 41, 42, 43 and 44. Parts of the pods are shown in cut-away and a bottom spacer 45 is shown in phantom at the lower region of the intersection between the pods. Directly above this is the spacer 40 and it has four arms 46, 47, 48 and 49. The arms 46 and 47 form a diagonal across the intersection from opposite pod corner-to-corner as shown best in Figure 7. Arms 48 and 49 form a diagonal for the other pod corners. Each arm has an angle projection 50 on the underside which sets the pod spacing by locating at the corners. The projections 50 in this case are right angled to match the pod corner but any suitable arrangement may be employed. For example, the pods may be moulded to have a keyway and the spacer may have corresponding keys. [0020] The lattice moulded arrangement shown in Figures 6-8 is similar to Figures 2 and 3 but it will be appreciated that the cellular arrangement may also be employed as could any other workable structure. The arms 46-49 also support the steel shown at 51 in Figure 6. Thus it operates in the same way as the other embodiments. Indeed they could be used together as well as with the lower spacer. [0021] Figure 9 illustrate a still further embodiment showing a spacer which also has four arms 51, 52, 53 and 54 and a central circular support arrangement 55 from which the arms depend. The central support has an outer upper ring 56 and an inner conical central section 57 and circumferentially spaced spokes 58 extending from the base of the cone to the outer upper ring with wider spokes being aligned with each arm. Each arm extends radially and includes a relatively wide flat pod contacting base and a relatively narrow top for steel support. Bracing is formed between the base and the top. The base tapers toward the centre and pod penetrating 6 prongs or pod corner abutments 59 depend in pairs downwardly from each arm such that the arms in use extend diagonally across a set of four pods in the same fashion as depicted in Figures 6 and 7. [0021] Whilst the above has been given by way of illustrative example many variations and modifications will be apparent to those skilled in the art without departing from the broad ambit and scope of the invention as set out in the appended claims.

Claims (20)

1. A pod spacer locatable on the upper horizontal surface of spaced pods, the pod spacer being adapted to bridge across adjacent pods and projecting above the upper surface of the pods to support reinforcing steel at the same time a stabilising the pods.

2. A pod spacer according to claim 1 wherein the spacer is generally T-shaped, having in use a vertical section and a horizontal section, the vertical section being adapted for location between adjacent pods in a region near the top of the pods, the horizontal section extending bilaterally from the vertical section and being adapted in use to be located on top of the adjacent pods while the vertical section is between the pods.

3. A pod spacer according to any one of the preceding claims wherein the spacer extends diagonally across an intersection of four pods in a corner-to-corner configuration.

4. A pod spacer according to any one of the preceding claims wherein the spacer has four arms.

5. A pod spacer according to any one of the preceding claims wherein the spacer is moulded and has a lattice structure.

6. A pod spacer according to any one of the preceding claims wherein the spacer is formed as a cellular structure of polygonal prismatic cells.

7. A pod spacer according to any one of the preceding claims wherein the spacer includes spikes or other means to positively engage the pods.

8. A pod spacer according to any one of the preceding claims wherein the spacer has one or more projections that project down between adjacent pods to hold the pods in predetermined spaced relation.

9. A pod spacer according to claim 8 wherein the projections are adapted to engage a side, 8 edge or a corner of a pod.

10. A pod spacer according to claim 9 wherein, in the case of a spacer used for diagonal corner-to-corner pod bridging configuration, the spacer has bilateral downward projections fitting against pods at or adjacent the opposite corners of diagonally opposed pods.

11. A pod spacer according to any one of the preceding claims wherein the spacer is a X-shaped spacer positionable at the intersection between four equally spaced pods, the spacer having four arms forming diagonals across the intersection from opposite pods corner-to-corner each arm having an underside and at least one downward projection from the underside which sets the pod spacing by locating at or adjacent the corners of the pods in abutment with the pods.

12. A pod spacer according to claim 11 wherein the projections on each arm are adapted to locate against a pod on either side of a pod corner to frame the corner.

13. A pod spacer according to claim 11 or 12 wherein the spacer has four arms depending from a central circular support arrangement having an outer upper ring and an inner conical central section having a base and circular top with circumferentially spaced spokes extending from the base of the cone to the outer upper ring.

14. A pod spacer according to claim 13 wherein the spokes include narrow and wider spokes with wider spokes being aligned with each arm.

15. A pod spacer according to claim 14 wherein each arm extends radially and includes a relatively wide flat pod contacting base and a relatively narrow top for steel support.

16. A pod spacer according to claim 15 wherein lattice bracing extends between the base and the top and the base tapers toward the centre and pod penetrating prongs or pod corner abutments depend in pairs downwardly from each arm such that the arms in use extend diagonally across a set of four pods with the prongs or abutments extending into or between the pods. 9

17. A system of pod spacing having upper and lower pod spacers to stabilise both top and bottom regions of the pods.

18. A system of pod spacing according to claim 11 wherein each lower pod spacer comprises a cross shaped spacer adapted to be located between four adjacent pods.

19. A system of pod spacing according to claim 11 or claim 12 wherein each upper pod spacer comprises a pod spacer according to any one of claims 1-10.

20. A pod spacer according to any one of claims 1-16 and substantially as described with reference to any one of the accompanying drawings.