AU2015271923A1 - Mould - Google Patents

Abstract

Abstract The present invention provides a mould for a concrete foundation/suspended slab. The slab has a top surface, base and sides, wherein the top surface includes a plurality of channels arranged to receive reinforcing bars. The base includes at least once recess and the sides are chamfered into the base. 12 12 12 12 Figure 1 12 12 12 12 12 12 E 12 E 12 Figure 2 23 1t 13 12 nn . 23 21 7\ 21 1 5111 11 15 33 15 15 33 Figure 3

Description

Mould

TECHNICAL FIELD

[0001] The present invention generally relates to a mould. In particular the present invention relates to a mould for use as formwork in the preparation and pouring of a concrete slab.

BACKGROUND ART

[0002] Where a concrete slab is to be laid on soil containing clay, the risk of the ground moving underneath the laid concrete slab over time, causing the slab to crack is high. The soil movement is a seasonal effect and is caused by the swelling and contracting of the soil from season to season. The movement of the soil is greater at the perimeter of the slab as the centre of slab is not as effected by rain. When the clay is wet it can swell, while the centre remains stable causing an edge heave. Conversely when the clay is dry it contracts causing a centre heave.

[0003] Conventionally, to minimize the risk of the concrete cracking a variety of techniques have been employed. The use of reinforcing bars and post tensioning the reinforcing bars has been used to strengthen the concrete. This requires significant amounts of concrete.

[0004] As an alternative, waffle pods are used to effectively raise the concrete slab and minimize the amount of concrete used in the concrete slab. The waffle pods act as formwork and form a space between the ground and the slab. The pods also provide a flat surface on top to support the concrete slab. The space between the ground and the pod structure accommodates expansion and contraction of the soil underneath the pod, therefore minimizing stresses which may act on the concrete. Conventional waffle pods still require a reinforcing bar grid (which are available as a standard size mesh) to be placed above them before the concrete is poured. This requires significant labor to correctly place and tension the reinforcing bars before the concrete is poured.

[0005] The preceding discussion of the background art is intended to facilitate an understanding of the present invention only. The discussion is not an acknowledgement or admission that any of the material referred to is or was part of the common general knowledge as at the priority date of the application.

SUMMARY OF INVENTION

[0006] It is an object of this invention to provide a mould which ameliorates, mitigates or overcomes, at least one disadvantage of the prior art, or which will at least provide the public with a practical choice.

[0007] While the mould of the present invention has applications for on ground slabs the mould can be applied to suspended slab applications as well. Both applications, as well as other applications obvious to a person skilled in the art, are included in the scope of this invention.

[0008] In a first aspect, the present invention provides a mould for a concrete foundation including a top surface, base and sides, wherein the top surface includes a plurality of channels, the base includes at least one recess and the sides are chamfered into the base.

[0009] The purpose of the mould is to provide adequate strength and stiffness to ensure that the structure above the slab is not adversely effected by the soil movements, or the span of the slab in suspended slab applications. This is achieved while minimising the amount of concrete required. While this has obvious cost benfits it also reduces the weight of the slab, which is particularly important in suspended slab applications.

[0010] Preferably the base is in the form of an opening.

[0011] The plurality of channels may create a grid pattern.

[0012] The plurality of channels may create raised portions between them.

[0013] The plurality of channels may be located between raised portions of the top surface.

[0014] A formwork system comprising a plurality of moulds as hereinbefore described may be arranged with respect to each other to create a space between adjacent moulds.

[0015] The space between adjacent moulds allows concrete footing beams to be formed therebetween. The chamfered edges allow the base of the footing beams to be flanged and therefore have increased strength characteristics.

[0016] The plurality of moulds may be arranged with respect to each other so that a grid is formed by the moulds.

[0017] The plurality of moulds may be arranged with respect to each other so that the grid pattern formed by the raised portions on each mould aligns with the grid pattern formed on adjacent moulds.

[0018] The plurality of moulds may be arranged to receive reinforcing bar in the channel between the raised portions.

[0019] The grid formed by the raised portions allows commercially available mesh style reinforcing bars to be placed directly in the channels between the raised portions. This improves the efficiency with which reinforcement mesh/bars can be placed against the moulds.

[0020] Concrete may be poured over the plurality of moulds to form a foundation slab wherein concrete pours into the space between moulds to form beam footings.

[0021] A barrier may be placed between adjacent moulds to cover the space between moulds. The barrier may stop concrete pouring into the space between moulds. The moulds may include a barrier receiving recess to receive the barrier.

[0022] The moulds may be placed side by side such that at least one side of one mould is in contact abutment with at least one side of another mould.

[0023] The moulds may be formed of any size, for example the moulds may have a footprint of 2 meter by 2.5 meter.

[0024] The moulds may be easily cut to size. This may be done at site so that the mould can be readily altered to provide the requisite size.

[0025] The mould may be formed from one or more mould portions, wherein the mould portions may co-operate with each other to form the mould. When in a side by side abutting arrangement adjacent mould portions may defined the mould recess.

[0026] The mould or mould portions may be configured so that they may be easily stacked.

[0027] The moulds may be made from polystyrene.

[0028] The moulds may be made from polyurethane.

[0029] The moulds may be made from cardboard [0030] Each mould may have a plurality of internal walls extending from the top surface into the recess. Preferably the internal walls terminate at the base. The internal wall may take the same form as one of the sides of the mould. The internal walls may be arranged such that the mould can be cut whereby an internal wall becomes a side of the mould.

[0031] In a second aspect, the present invention provides formwork for pouring a concrete slab onto a base surface, the formwork including a plurality of moulds arranged to rest on the base surface and a reinforcing mesh arranged to rest on the plurality of moulds, wherein the plurality of moulds are spaced apart from each other to form a grid pattern for receiving concrete within the space apart region between the moulds and wherein the moulds include recesses arranged to receive portions of the reinforcing mesh.

[0032] The moulds may include a recessed base.

[0033] The recesses may be profiled to conform to at least a portion of the surface of the reinforcing mesh.

[0034] The recesses may include a chamfered portion to minimize the space between the recesses and the reinforcing mesh.

[0035] The concrete received within the spaced apart regions may be set to form a footwork beam.

[0036] The footwork beam may include a flanged base that is arranged to rest on the base surface.

[0037] Sides of the moulds may chamfer into a base of the moulds to provide an enlarged space for forming the flanged base.

[0038] The sides of the mould may be shaped to provide a footwork beam having a predetermined profile.

[0039] A barrier may be placed between at least one of the spaced apart moulds to stop concrete flowing into the spaced apart area.

[0040] The moulds may include a barrier receiving recess to receive the barrier.

[0041] In a third aspect, the present invention provides a concrete slab on a base surface wherein the concrete slab includes a plurality of internal moulds and footing beams between the internal moulds.

[0042] The concrete slab may also include reinforcing beams on the internal moulds.

[0043] The footing beams may be formed in channels provided between the internal moulds.

[0044] The footing beams may have reinforcement means therein. The reinforcement means may be in the form of reinforcement bar.

[0045] The footing beams may include a flanged base.

[0046] The reinforcing beams may be located in channels in the upper surface of the internal moulds. The reinforcing beams may be in the form of a mesh.

[0047] The channels in the upper surface of the internal moulds may be profiled to conform to the reinforcing beams.

BRIEF DESCRIPTION OF THE DRAWINGS

[0048] Further features of the present invention are more fully described in the following description of several non-limiting embodiments thereof. This description is included solely for the purposes of exemplifying the present invention. It should not be understood as a restriction on the broad summary, disclosure or description of the invention as set out above. The description will be made with reference to the accompanying drawings in which:

Figure 1 is a side view of a mould according to a first aspect of the present invention;

Figure 2 is a top view of the mould of Figure 1;

Figure 3 is a side view of a plurality of the moulds of Figure 1 in use;

Figure 4 is a top view the mould of Figure 1 with reinforcing mesh;

Figure 5 is a perspective cross sectional view of a mould according to a second aspect of the present invention;

Figure 6 is a perspective cross sectional view of the mould of Figure 5;

Figure 7 is an end view of a plurality of the moulds of Figure 5 stacked: [0049] In the drawings like structures are referred to by like numerals throughout the several views. The drawings shown are not necessarily to scale, with emphasis instead generally being placed upon illustrating the principles of the present invention.

DESCRIPTION OF EMBODIMENTS

[0050] Broadly, the present invention relates to moulds for use as formwork in the pouring of concrete slabs/foundations/suspended concrete slabs. The moulds are profiled to facilitate easy placement of reinforcing bars/mesh, allow easy placement and set-out, minimise labour required and provide channels between adjacent moulds for the creation of concrete footing beams. The easy placement of reinforcing bars or mesh is enabled by incorporating spaced apart channels in the top surface of the moulds. These channels match the sizing of reinforcement bars that come as a mesh. The arrangement of the channels is such that when a plurality of moulds are placed together a common spacing between moulds is created to form a grid. This results in the formation of a grid pattern in the top surface across the collection of moulds due to alignment of the channels in the top surface and spaces formed between the adjacent moulds.

[0051] Referring to figures 1 to 4, the invention according to the first embodiment is in the form of a mould 11 which provides formwork for pouring and setting a concrete slab/foundation. The mould includes a top surface 10, sides 23 and a base 33. The base of the moulds include at least one recess in the form of a void so that when the base is sitting on a supporting surface (such as the ground), a region of space is available between the base and the supporting surface.

[0052] The top surface 10 of the mould 11 includes channels 13 that run along the length and width of the surface to form a grid pattern as best illustrated in Figures 2 and 4. The channels 13 form a grid pattern that matches the grid pattern of reinforcing bar mesh 14 that is commonly available. The channels create raised portions 12 between them as part of the formed grid pattern. The cross sectional profile of the channels 13 is curved to match the curvature of the reinforcing bar mesh 14. The channels 13 are positioned such that, when reinforcing bar mesh 14 is placed against moulds 11 in channels 13, adjacent moulds 11 have parallel sides 23, creating straight channel portion 23 and a grid pattern between the moulds 11.

[0053] Alternatively the profile of the channels 13 includes chamfered bases to minimise any space created between the channels 13 and the reinforcing bar mesh 14 when it is inserted.

[0054] Referring to Figure 3, the sides 23 of the mould 11 run generally square to the top surface with a chamfered angled surface 15 at its lower region that runs into the base 33. When a plurality of moulds 11 are arranged together with spaces between them creating a grid pattern as discussed above, a straight channel portion 22 is created. At the base of the straight channel portion the angled surfaces 15 create a flanged channel portion 17. When concrete is poured over a number of moulds 11 in the above described grid arrangement to form a concrete slab/foundation a concrete footing beam is created in straight channel portion 22 and flanged portion 17. The flanged footing of the concrete footing beam maximizes the stiffness of the footing beam and adds to its strength.

[0055] Referring to Figure 3, in areas of the concrete slab/foundation that additional reinforcement will not be required a concrete footing beam may be unnecessary. In this scenario a barrier 19 can be inserted in the upper region of the straight channel portion 22 along the entire length of the straight channel portion 22 or with vertical additions (not shown) to stop concrete entering these areas.

[0056] The moulds can be made from polystyrene, polyurethane, wood, composite materials, plastic or otherwise as would be understood by the skilled addressee.

[0057] The moulds may have a rectangular footprint.

[0058] The moulds may have a footprint of 2 meter by 2.5 meter or any other suitable rectangular dimension as understood by the skilled addressee.

[0059] With a plurality of moulds in place as formwork, concrete can be poured over the moulds so that no concrete fills the space occupied by the mould. This reduces the amount of concrete required. Where a barrier 19 has been used, the concrete amount is even further reduced. As there are multiple concrete footing beams running between moulds 11 with a flanged base, the strength of the concrete slab/foundation increases.

[0060] Referring to Figures 5 to 7 a second embodiment of the invention is illustrated. For convenience features of the second embodiment that are similar or correspond to features of the first embodiment have been referenced with the same reference numerals.

[0061] Moulds 31 are formed with attachment 25 covering the chamfered angled section 15. The attachment 25 causes the side 23 to run perpendicular to the top 10, from the top 10 to the base 33. This further reduces concrete required to form the concrete footing beam. If further strengthened concrete footing beams are required, the attachment 25 can be removed manually to allow flanged channel portion 17 to be created with adjacent moulds.

[0062] Referring to Figure 6, the internal region of the mould 31 includes reinforcement beams 27. The bases of reinforcement beams 27 form part of base 33. The reinforcement beams 27 strengthen the moulds 27 to allow workers to walk on the moulds in addition to providing additional strength to the set concrete slab/foundation. The space between the reinforcement beams 27 and the bottom of angled surface 15 allows the base surface to expand and contract into the space and minimise the forces imparted to set concrete.

Method of Laying Concrete Slab/Foundation [0063] To further illustrate the use of the moulds 11,31 of the present invention the use of them in pouring a concrete slab/foundation will be described.

[0064] The base surface for a concrete slab/foundation is cleared and leveled ready for pouring of concrete. Moulds 11,31 are laid on the base surface in an approximate grid pattern.

[0065] Alternatively in suspended slab applications the moulds use the plywood formwork scaffolding to provide additional support.

[0066] Barriers 19 are placed over spaces between moulds where beams are not needed, and attachments 25 in moulds 31 are removed where additional strength is desired.

[0067] Reinforcing bar mesh 14 is placed over the moulds 11,31 and the channels 13 in the moulds are aligned with the reinforcing bar mesh 14. When aligned, the reinforcing bar mesh is placed within the channels 13 in all the moulds 11,31.

[0068] If required, reinforcement means in the form of reinforcement bars may be positioned between adjacent moulds.

[0069] Concrete is poured over the moulds 11,31 to a height above them as desired and left to set.

[0070] Modifications and variations such as would be apparent to the skilled addressee are considered to fall within the scope of the present invention. The present invention is not to be limited in scope by any of the specific embodiments described herein. These embodiments are intended for the purpose of exemplification only. Functionally equivalent products, formulations and methods are clearly within the scope of the invention as described herein.

[0071] Reference to positional descriptions, such as lower and upper, are to be taken in context of the embodiments depicted in the figures, and are not to be taken as limiting the invention to the literal interpretation of the term but rather as would be understood by the skilled addressee.

[0072] Throughout this specification, unless the context requires otherwise, the word "comprise" or variations such as "comprises" or "comprising", will be understood to imply the inclusion of a stated integer or group of integers but not the exclusion of any other integer or group of integers.

Claims (34)

1. A mould for a concrete foundation including a top surface, base and sides, wherein the top surface includes a plurality of channels, the base includes at least one recess and the sides are chamfered into the base.

2. The mould according to claim 1 wherein the base is in the form of an opening.

3. The mould according to claim 1 or 2 wherein the plurality of channels creates a grid pattern.

4. The mould according to claim 1, 2 or 3 wherein the plurality of channels creates raised portions between them.

5. The mould according to any one of the preceding claims wherein the plurality of channels is located between raised portions of the top surface.

6. A formwork system comprising a plurality of moulds arranged with respect to each other to create a space between adjacent moulds, the mould being in accordance with any one of the preceding claims.

7. The formwork system of claim 6 wherein the plurality of moulds is arranged with respect to each other so that a grid is formed by the moulds.

8. The formwork system of claim 6 or 7 wherein the plurality of moulds is arranged with respect to each other so that the grid pattern formed by the raised portions on each mould aligns with the grid pattern formed on adjacent moulds, the plurality of moulds is arranged to receive reinforcing bar in the channel between the raised portions.

9. The formwork system of claim 6, 7 or 8 wherein a barrier is placed between adjacent moulds to cover the space between moulds, wherein barrier prevents concrete flowing into the space between moulds.

10. The formwork system of claim 9 wherein the moulds include a barrier receiving recess to receive the barrier.

11. The formwork system of any one of claims 6 to 10 wherein the moulds are placed side by side such that at least one side of one mould is in contact abutment with at least one side of another mould.

12. The formwork system of any one of claims 6 to 11 wherein the moulds are made form a material which is easy to cut.

13. The formwork system of any one of claims 6 to 12 wherein the moulds are formed from one or more mould portions, wherein the mould portions co-operate with each other to form the mould, wherein when arranged in a side by side abutting arrangement adjacent mould portions define the mould recess.

14. The formwork system of any one of claims 6 to 13 wherein the mould or mould portions are configured to be stacked.

15. The formwork system of any one of claims 6 to 14 wherein the moulds are made from polystyrene, polyurethane, or cardboard.

16. The formwork system of any one of claims 6 to 15 wherein each mould has a plurality of internal walls extending from the top surface into the recess, wherein the internal walls terminate at the base.

17. The formwork system of claim 16 wherein the internal wall takes the same form as one of the sides of the mould.

18. The formwork system of claim 16 wherein the internal walls is arranged such that the mould can be cut upon which an internal wall becomes a side of the mould.

19. A formwork system for forming a concrete slab on a base surface, the formwork including a plurality of moulds arranged to rest on the base surface and a reinforcing mesh arranged to rest on the plurality of moulds, wherein the plurality of moulds are spaced apart from each other to form a grid pattern for receiving concrete within the space apart region between the moulds and wherein the moulds include recesses arranged to receive portions of the reinforcing mesh.

20. The formwork system of claim 19 wherein the moulds include a recessed base.

21. The formwork system of claim 20 wherein the recesses are profiled to conform to at least a portion of the surface of the reinforcing mesh.

22. The formwork system of claim 20 or 21 wherein the recesses include a chamfered portion to minimize the space between the recesses and the reinforcing mesh.

23. The formwork system of any one of claims 19 to 22 wherein the concrete received within the spaced apart regions forms a footwork beam.

24. The formwork system of claim 23 wherein the footwork beam includes a flanged base that is arranged to rest on the base surface.

25. The formwork system of any one of claims 19 to 24 wherein the sides of the moulds are chamfered into a base of the moulds to provide an enlarged space for forming the flanged base.

26. The formwork system of any one of claims 19 to 25 wherein the sides of the mould are shaped to provide a footwork beam having a predetermined profile.

27. The formwork system of any one of claims 19 to 26 wherein a barrier is placed between at least one of the spaced apart moulds to stop concrete flowing into the spaced apart area.

28. The formwork system of claim 27 wherein the moulds include a barrier receiving recess to receive the barrier.

29. A concrete slab on a base surface wherein the concrete slab includes a plurality of internal moulds, footing beams between the internal moulds and reinforcing beams on the internal moulds.

30. The concrete slab of claim 29 wherein the footing beams is formed in channels provided between the internal moulds.

31. The concrete slab of claim 30 wherein the footing beams has reinforcement means therein, the reinforcement means is in the form of reinforcement bar.

32. The concrete slab of claim 29, 30 or 31 wherein the footing beams include a flanged base.

33. The concrete slab of any one of claims 29 to 32 wherein reinforcing beams is located in channels in the upper surface of the internal moulds. The reinforcing beams is in the form of a mesh.

34. The concrete slab of claims 33 wherein channels in the upper surface of the internal moulds are profiled to conform to the reinforcing beams.