AU2017100083A4

AU2017100083A4 - Reinforced panel mold for concrete structures

Info

Publication number: AU2017100083A4
Application number: AU2017100083A
Authority: AU
Inventors: Christian Ian HILLIER; Sunderaj A. L. Nagalingam; Danny James ZARB
Original assignee: Dscaff Eng Sdn Bhd
Current assignee: Dscaff Engineering Sdn Bhd
Priority date: 2014-06-24
Filing date: 2017-01-24
Publication date: 2017-03-02
Anticipated expiration: 2023-06-18

Abstract

REINFORCED PANEL MOLD FOR CONCRETE STRUCTURES 5 Disclosed reinforced panel mold (100) for constructing a plurality of concrete structural components is assembled using a plurality of panel structures (102) . The panel structures (102) have a base portion (104) and a plurality of sides (106). At least one reinforcement beam (108) is molded to the 10 plurality of sides (106) of the panel structures for providing improved loadbearing capacity. Each of the panel structures (102) is spliced to the next panel structures (102), when assembling the reinforced panel mold. The splice plate (110) is inserted through the predesigned pocket at the top and 15 bottom of the panel structures (102) and fixed using at least one mechanical attachment means (114) . The splice plate (110) maintains the loadbearing capacity of a single panel structure (102) throughout the reinforced panel mold (100). 20 Most illustrative figure: FIG. 2

Description

1

REINFORCED PANEL MOLD FOR CONCRETE STRUCTURES

FIELD OF INVENTION

The present invention relates generally to a reinforced mold for forming concrete structural units, in particular, to lightweight reinforced molds assembled from individual panels offering improved loadbearing capacity.

BACKGROUND

At present, with the rapid economical growth and acceleration of urban construction, precast and on-site cast concrete structures are widely constructed in desired shape and size using molds assembled from smaller individual parts. This improves the speed of construction with faster assembling and/or disassembling of the molds, which in turn reduces the work hours and labor cost. Traditional casting molds are generally made from steel, steel and plywood, alloy, alloy and plywood or a type of plastic. In each situation these casting molds each have inherent disadvantages. Conventional panel or a series of panels used to create a casting mold used for forming concrete employs plywood attached together using nails and supported using wooden or metallic support beams. The wooden molds for forming concrete structural units such as walls, roofs and floors suffer from the main disadvantage of weight and portability. These traditional forming molds mostly require the use of heavy plant and equipment such as cranes to assist in the maneuverability and resetting for the next cast. These traditional plywood based forms have reduced durability when considering their reuses. The plywood molds are arranged in vertical, horizontal or angled planes manually and are very 2 labor intensive, requiring a lot of time to assemble and disassemble the mold. This contributes to a major element of the overall cost of the work. In addition, plywood molds require large number of wooden or metallic support beams to support the high pressures of concrete during concrete placement. Further, the plywood molds cannot be reused many times, it can become easily damaged while assembling or disassembling and during the concrete placement process. Once the top protective layer is compromised by scratching of the top layer, the presence of moisture during the concrete placement process begins to affect the plywood panel. The molds made with plywood faced casting surfaces are extremely labor intensive relating to the ongoing maintenance in keeping the products fit for purpose. This traditional method is seen and accepted as having a very high labor content to ensure continued use.

Yet another traditional casting mold for reinforced concrete includes the use of plastic molds. Current plastic casting molds have inherent disadvantages that they are very weak when compared to the conventional plywood panels. The plastic molds may get easily deformed or bend when used as a mold for forming the concrete structures such as walls, roofs, beams etc. This may affect the shape and dimension and sometimes strength of the concrete structures formed using the plastic molds. However they offer several advantages over the conventional plywood panels as they can be easily assembled and dissembled, cheap and the estimated life span of the panels greatly exceeds plywood. However for providing sufficient loadbearing capability to the plastic molds additional supports need to be provided. 3

Hence the above said traditional plastic molds are very weak when compared to steel, or steel and plywood molds, and require a large secondary support. This secondary support is usually steel or timber sections and / or form ties at close spacing to compensate for this weakness.

As mentioned above, it is generally recognized within the construction industry that forming systems made with plywood faced casting surfaces can be extremely labor intensive relating to the ongoing maintenance in keeping the products fit for purpose. Although several other inventors have proposed various prefabricated molds for concrete walls, none shows the combination of plastic and steel for molds as having the combination of strength and lightweight provided by the present invention. Hence there exists a need for an improved mold that would provide improved loadbearing capacity over existing plastic only molds, durability and lightweight. This mold for reinforced concrete would be lightweight and can be used in vertical, horizontal or angled planes. This mold would require almost zero structural maintenance of the casting surface and the estimated life span of the product would greatly exceed the existing timber plywood faced systems and methods. These plastic/steel combination panels would be easily assembled at site or can be preassembled and transported to the site for forming precast structural units such as walls, floors, etc. When utilizing these plastic/steel combination panels for assembling concrete molds the benefits are very lightweight providing portability, a reduction in labor when stripping and resetting of the molds, and high durability compared to current product offerings. 4

The plastic/steel combination panels when used for assembling the molds would have the durability of both a plastic surface mold and the loadbearing capacity of metallic molds.

SUMMARY

The present invention is a reinforced panel mold for use in constructing the plurality of concrete structural components. Assembling a plurality of panel structures in horizontal, vertical or angled directions forms the reinforced panel mold. The individual panel structures have a base portion and a plurality of sides that forms a frame of the panel structure. The plurality of sides of the panel structure includes a top edge, a bottom edge and a cavity extending throughout the length of the sides of the panel structure. At least one reinforcement beam is passed through the cavity on the at least one of the plurality of sides of the panel structure. When assembled, the reinforcement beams in the plurality of sides of the panel structures become arranged in parallel to each other at a predetermined distance apart. The reinforcement beams are injection molded to the plurality of sides of the panel structures. The reinforcement beam improves the loadbearing capacity of the reinforced panel mold formed from the plurality of panel structures. At least one splice plate is used to strengthen the joints formed when assembling a pair of panel structures to form the reinforced panel mold. The reinforced panel mold employs a series of reinforcement beams of varying thickness to some of the longitudinal ribs or the sides of the plastic panel structures. Each of the panel structures is spliced to the next panel structures, when assembling the reinforced panel mold. The splice plate is inserted through the preformed pockets on panel structure and attached at top 5 and bottom of the panel structure using at least one mechanical attachment means. This enables the reinforced panel mold via the use of the splice plate, to maintain the loadbearing capacity of a single panel structure throughout the multiple panel configurations. The reinforced panel mold thus formed has effectively zero structural maintenance, other than cleaning after use while using the strength advantages of steel, and the low maintenance and weight advantages of plastics.

Other objects and advantages of the embodiments herein will become readily apparent from the following detailed description taken in conjunction with the accompanying drawings.

BRIEF DESCRIPTIONS OF THE DRAWINGS FIG. 1 illustrates a perspective view of a reinforced panel mold for use in constructing a plurality of concrete structural components according to a preferred embodiment of the present invention; FIG. 2 illustrates an enlarged perspective view of the reinforced panel mold showing a plurality of reinforcement beams molded within the plurality of sides of the panel structures forming the reinforced panel mold and a plurality of splice plates connecting the panel structures according to the preferred embodiment of the present invention; FIG. 3 illustrates a perspective view of the reinforced panel mold showing a method of connecting the splice plates at a top and bottom of the panel structures, according to the preferred embodiment of the present invention; and 6 FIG. 4 illustrates a flowchart showing the process of assembling the reinforced panel mold from the panel structures and using the splice plates at the top and bottom of the panel structures for use in constructing the plurality of concrete structural components, according to the preferred embodiment of the present invention.

DETAILED DESCRIPTION

In the following detailed description, a reference is made to the accompanying drawings that form a part hereof, and in which the specific embodiments that may be practiced is shown by way of illustration. These embodiments are described in sufficient detail to enable those skilled in the art to practice the embodiments and it is to be understood that the logical, mechanical and other changes may be made without departing from the scope of the embodiments. The following detailed description is therefore not to be taken in a limiting sense.

In this document, the terms "a" or "an" are used, as is common in patent documents, to include one or more than one. In this document, the term "or" is used to refer to a nonexclusive "or," such that "A or B" includes "A but not B," "B but not A," and "A and B," unless otherwise indicated. Furthermore, all publications, patents, and patent documents referred to in this document are incorporated by reference herein in their entirety, as though individually incorporated by reference. In the event of inconsistent usages between this document and those documents so incorporated by reference, the usage in the incorporated reference(s) should be considered supplementary to 7 that of this document; for irreconcilable inconsistencies, the usage in this document controls.

Molds or supporting structures are used in a variety of applications for easy and fast construction of a desired shape from any material using the mold. For example, in construction industry molds or supporting structures are used to construct concrete structures such as, but not limited to, walls, concrete floors, roofing, beams etc. The molds can be employed at the construction site to construct the above said concrete structures or the molds can be used at any remote place for prefabricating the plurality of concrete structures that can be transported to the construction site and can be installed easily for fast completion of the structure. The molds are available in a plurality of sizes and shapes and the concrete is poured into the mold for forming the desired structure. After the concrete has set forming a solid concrete structure, the mold can be disassembled and prepared for reuse. Currently available molds for use in construction industry are made from a plurality of materials, such as, but not limited to, steel, steel and plywood, alloy, alloy and plywood etc., or a combination of any of these an can be used for the construction of structural units such as, but not limited to, walls, floors, beams etc. of different sizes and shapes. The molds made from these kinds of materials can be either heavy or difficult to transport or both, , can be very labor intensive to assemble and disassemble the individual units. The present invention employs special metallic reinforcement bars that are integrated into the molds and these molds can be used in horizontal, vertical or angled configurations to support the casting of concrete structures such as, but not limited to, the walls, 8 floors beams or roofing. The metallic reinforcement bars provides additional strength to the molds which are made from lightweight plastic materials and improves the loadbearing capacity of the mold. Further, the individual modular units having the metallic reinforced bars are interconnected using a plurality of splice plates at a top and bottom of the panel structures that extends the loadbearing capacity of the individual mold units to the entire panel structure created by assembling the individual modular mold units. FIG. 1 illustrates a perspective view of a reinforced panel mold 100 for use in constructing the plurality of concrete structural components according to a preferred embodiment of the present invention. The reinforced panel mold 100 comprises a plurality of panel structures 102 and assembling the plurality of individual panel structures 102 in horizontal, vertical or any angled directions can form the reinforced panel mold 100. The individual panel structures 102 are available in a plurality of dimensions and a plurality of shapes such as, but not limited to, rectangular, square, triangular, etc. In a preferred embodiment of the present invention, the rectangular or square shaped panel structures 102 are assembled to form the reinforced panel mold 100. Each of the individual panel structure 102 have a base portion 104 and a plurality of sides 106 that forms a frame of the panel structure 102. The plurality of sides 106 of the panel structure 102 includes a top edge, a bottom edge and a cavity extending throughout the length of the sides 106 of the panel structure 102. In some instances, the cavity may have a width extending between the top edge and the bottom edge of the sides 106 of the panel structure 102. The reinforced panel mold 100 further comprises 9 at least one reinforcement beam 108, which is passed through the cavity on at least one of the plurality of sides 106 forming the frame of the panel structure 102. The reinforcement beam 108 is an elongated metallic plate 108 having a plurality of holes 112 and is passed through the cavity on the plurality of sides 106 of the panel structures 102. When the plurality of panel structures 102 are assembled in vertical, horizontal and/or in any other angular configuration to form the reinforced panel mold 100 of desired shape, the elongated metallic plates 108 will become arranged in parallel to each other at a certain space apart. The reinforcement beam 108 or the elongated metallic plates 108 are injection molded to the plurality of sides 106 of the panel structures 102. Thus the elongated metallic plates 108 forms a part of the frame structure for the panel structures 102 and prevents the bending or deforming of the reinforced panel mold 100 while in use. The elongated metallic plates 108 improves the strength of the reinforced panel mold 100 by distributing the load of the concrete structure which in turn improves the loadbearing capacity of the reinforced panel mold 100. FIG. 2 illustrates an enlarged perspective view of the reinforced panel mold 100 showing a plurality of reinforcement beams 108 molded within the plurality of sides 106 of the panel structures 102 forming the reinforced panel mold 100 and a plurality of splice plates 110 connecting at the top and bottom of the panel structures 102, according to the preferred embodiment of the present invention. The plurality of panel structures 102 having the reinforcement beams 108 can be assembled further by arranging the plurality of panel structures 102 in vertical, horizontal and/or in any other angular configuration and tightly connecting using at least one 10 splice plate 110 at the top and bottom of the panel structures 102. The splice plates 110 can only be attached at the top and bottom of the panel structures 102, where the loads may be higher. Thus the excessive loads can be distributed throughout the reinforced panel mold 100 by connecting the pair of panel structures 102 using the splice plate 110. The splice plate 110 is a metallic plate having high strength of a predetermined thickness and having a plurality of holes 116 on its surface. The splice plate 110 can only be attached at the top and bottom of the panel structures 102 and by aligning the plurality of holes 112 of the reinforcement beam 108 with the holes 116 on the splice plate 110 and locking together tightly using a plurality of mechanical attachment means 114 such as, but not limited to, nuts and bolts, rivets, locking pins, attachment plates, screws etc. In some embodiments, the plurality of holes 116 on the splice plate 110 and the plurality of holes 112 on the reinforcement beams 108 are provided with threads for easy attachment using the plurality of screws. It also ensures tight coupling between the splice plate 110 and the top and bottom of the panel structures 102. The splice plates 110 helps to maintaining the loadbearing capacity of the reinforced panel mold 100 formed by assembling individual panel structures 102. The splice plates 110 also allow the users to increase length and width of the reinforced panel mold 100 formed by assembling individual panel structures 102 in any direction without losing its strength and loadbearing capacity. Thus larger molds can be formed using the plurality of panel structures 102 as the splice plates 110 attached at the top and bottom of the panel structures 102 distributes the load evenly on to the reinforced panel mold 100 to reduce bending or deforming. 11

In a preferred embodiment, the plurality of panel structures 102 are made from strong plastic materials and the plurality of sides 106 of the panel structures 102 are reinforced using the plurality of metallic plates or the reinforcement beams 108. The reinforcement beams 108 or the splice plates 110 can be manufactured from a plurality of metals such as, but not limited to, steel and alloys. The plastic panel structures 102 are lightweight and are easy to transport to the construction site and can be easily handled by the workers to assemble molds for a plurality of structural components such as walls, roofing, beams etc. In addition, the panel structures 102 are durable and can be reused several times for molding a variety of structural components. In some embodiments, multiple reinforcement beams 108 of same thickness or different thicknesses can be molded to the plurality of sides 106 of the panel structure 102 for achieving further improvement in the loadbearing capacity of the reinforced panel mold 100. The reinforcement beams 108 allows the use of larger panel structures 102 for construction since it offers much better strength and loadbearing capacity. The use of larger panel structures 102 reduces the time-consuming labor tasks of assembling the panel structures 102 for use in construction purposes. This in turn saves time and makes it even more economical to use the reinforced panel mold 100 assembled from the larger panel structures 102. FIG. 3 illustrates a perspective view of the reinforced panel mold 100 showing a method of connecting the splice plates 110 to the panel structures 102. The splice plates 110 are used to strengthen the joints formed when assembling a pair of panel structures 102. The splice plates 110 can be inserted through 12 small pockets provided on the sides 106 of the panel structures 102 and can be used to support weak positions on the reinforced panel mold 100 formed by assembling the plurality of panel structures 102. The plurality of holes 116 on the splice plates 110, which are inserted through small pockets provided on the sides 106 of the panel structures 102, are made to align with the plurality of holes 112 of the reinforcement beams 108 accessible from the sides 106 of the panel structures 102 and then connected using the mechanical attachment means 114 such as, but not limited to, nuts and bolts, rivets, locking pins, attachment plates, etc. The final assembled reinforced panel mold 100, which is formed by connecting the plurality of panel structures 102 using the splice plates 110, includes parallel, spaced apart reinforcement beams 108. Thus the reinforced panel mold 100 assembled from the panel structures 102 can directly used to form the mold for concrete structural components without having much additional supports to the base portion 104 and to the plurality of sides 106. The splice plates 110 enable the reinforced panel mold 100 formed by assembling the panel structures 102 to retain its loadbearing capacity and prevents excessive bending when concrete is added to the reinforced panel mold. In some embodiments, connecting the adjacent panel structures 102 using the mechanical attachment means 114 such as screws or pins and the splice plates 110 at weak points, such as, at the top and bottom of the panel structures 102, assembles the reinforced panel mold 100. The reinforced panel mold 100 of the present invention has effectively zero structural maintenance of the casting surface or the base portion 104 as the estimated life span of the reinforced panel mold 100 greatly exceeds the like including plywood. The reinforced panel mold 100 of the present invention uses the strength advantages of steel, and the maintenance and weight 13 advantages of plastics and is lightweight and easy to maintain. In some instances, reinforced panel mold 100 employs a series of steel strips of varying thickness as reinforcement beams 108 to some of the longitudinal ribs of the plastic reinforced panel mold 100. After inserting reinforcement beams 108 they are injection molded with the plastic to encapsulate the steel strips or the reinforcement beams 108 making the reinforcement beams 108 an integral part of the reinforced panel mold 100. Each of the panel structures 102 are spliced to the next panel structures 102, when forming the reinforced panel mold 100, by adding the splice plate 108 at the top and bottom of the panel structures 102 into the preformed pockets on panel structure 102. This enables the reinforced panel mold 100 to achieve further strength and the splice plate 110 maintains the loadbearing capacity of a single panel structure 102 throughout the multiple panel configurations. FIG. 4 illustrates a flowchart showing the process of assembling the reinforced panel mold 100 from the panel structures 102 using the splice plates 110 for use in constructing or prefabricating the plurality of concrete structural components. The process starts by providing the panel structures 102 having the parallel reinforcement beams 108 positioned spaced apart and molded within the sides 106 of the panel structures 102 as in block 200. The reinforcement beam 108 passed through at least one groove extending throughout a length of the plurality of sides 106 of the panel structure 102 increases the structural rigidity and loadbearing capacity of the reinforced panel mold 100. Now, for extending the size of the reinforced panel mold 100 in horizontal or vertical direction, a plurality of additional panel structures 14 102 are attached to the sides 106 of the existing panel structures 102 as in block 202. The additional panel structures 102 are spliced to the next panel structure 102 by adding the splice plate 110 into the preformed pockets on each panel structure 102 as in block 204. The splice plate 110 maintains the loadbearing capacity of the single panel structure 102 throughout the reinforced panel mold 100 assembled from the multiple panel configurations. The splice plates 110 are fixed at the top and bottom of the panel structures 102 using mechanical attachment means 114 such as pins or attachment plates, screws etc. as in block 206. The splice plate 110 enables the panel structures 102 to maintain the loadbearing capacity of the single panel structure 102 throughout. Then as in block 208, the assembled reinforced panel mold 100 can directly be used to support in the construction of concrete structures such as walls and floors without much additional supports to the base portion 104. The reinforced panel mold 100 has the advantages of lightweight and portability, rapid stripping and resetting, with high durability to provide many expected reuses. Further the reinforced panel mold 100 can be employed in either in-plant production or on-site pre-casting of concrete structural parts, which can be rapidly stripped and reset and reused numerous times. Another advantage of the reinforced panel mold 100 is that a mold frame designed for the new construction may be used for other lengths of concrete structures and other products by only making another type of partitioning and adding/removing the individual panel structure 102 spliced using the splice plates 110, or that the sides 106 of the individual panel structure 102 can be equipped with partitioning or intermediate walls of different sizes in order to produce differently sized concrete structures and other products in the same configuration. 2017100083 24 Jan 2017 15

The foregoing description of the specific embodiments will fully reveal the general nature of the embodiments herein that others can, by applying current knowledge, readily modify 5 and/or adapt for various applications such specific embodiments without departing from the generic concept, and, therefore, such adaptations and modifications should and are intended to be comprehended within the meaning and range of equivalents of the disclosed embodiments. It is to be understood that the 10 phraseology or terminology employed herein is for the purpose of description and not of limitation. Therefore, while the embodiments herein have been described in terms of preferred embodiments, those skilled in the art will recognize that the embodiments herein can be practiced with modification within 15 the spirit and scope of the appended claims. Although the embodiments herein are described with various specific embodiments, it will be obvious for a person skilled in the art to practice the invention with modifications. However, all such modifications are deemed to be within the scope of the claims.

Claims

CLAIM:

1. A reinforced panel mold (100) comprising: a panel structure (102) having a base portion (104) and a plurality of sides (106) forming a frame of the panel structure (102) ; at least one reinforcement beam (108) passing through at least one of the plurality of sides (106) forming the frame of the panel structure (102) for improving a loadbearing capacity of the panel structure (102); and at least one splice plate (110) connecting at a top and bottom of the panel structures (102) for maintaining the loadbearing capacity of the reinforced panel mold (100) formed by assembling the plurality of panel structures (102).
2. The reinforced panel mold (100) of claim 1 wherein the panel structure (102) is capable of being assembled to form the reinforced panel mold (100) for use in constructing a plurality of concrete structural components, wherein the at least one reinforcement beam (108) is passed through at least one of the plurality of sides (106) of the panel structure (102) to form the reinforced panel mold (100) .
3. The reinforced panel mold (100) of claim 1 wherein the splice plate (110) is attached to the at least one reinforcement beam (108) at the top and bottom of the panel structure (102) for maintaining the loadbearing capacity of the reinforced panel mold (100) formed by assembling the plurality of panel structures (102) .
4. The reinforced panel mold (100) of claim 1 wherein the at least one reinforcement beam (108) is passed through the at least one of the plurality of sides (106) of the panel structure (102) to form the reinforced panel mold (100) of the desired shape and size and having improved loadbearing capacity.
5. The reinforced panel mold (100) of claim 1 wherein the panel structure (102) is made from lightweight materials including plastic and the at least one reinforcement beam (108) is arranged in parallel, spaced apart and is molded to at least one side (106) of the panel structure (102) to provide a lightweight reinforced panel mold (100) having improved loadbearing capacity for use in form of the mold in construction purposes.
6. The reinforced panel mold (100) of claim 1 wherein at least one splice plate (110) connects at the top and bottom of the panel structures (102) to maintain the loadbearing capacity of the reinforced panel mold (100) formed by assembling the plurality of panel structures (102), wherein at least one splice plate (110) is attached to the at least one reinforcement beam (108) by passing through a predesigned pocket at the top and bottom of the panel structures (102), wherein at least one splice plate (110) is attached at the top and bottom of the panel structure (102) using at least one mechanical attachment means (114) to maintain the rigidity, structural strength and loadbearing capacity to the reinforced panel mold (100).
7. A reinforced panel mold (100) for use in constructing a plurality of concrete structural components, the reinforced panel mold (100) comprising: a panel structure (102) having a base portion (104) and a plurality of sides (106) forming a frame of the panel structure (102), the panel structure (102) is capable of being assembled to form the reinforced panel mold (100) for use in form of the mold for constructing the plurality of concrete structural components / at least one reinforcement beam (108) passing through at least one of the plurality of sides (106) forming the frame of the panel structure (102) for providing strength to the panel structure (102); and at least one splice plate (110) connecting at a top and bottom of the panel structures (102) for forming the reinforced panel mold (100), wherein the splice plate (108) is placed in a predesigned pocket at the top and bottom of the panel structure (102) and can be attached to the at least one reinforcement beam (108) encapsulated within at least one side (106) of the panel structure (102) for maintaining the loadbearing capacity of the reinforced panel mold (100) formed by assembling the plurality of panel structures (102).
8. The reinforced panel mold (100) of claim 7 wherein the at least one reinforcement beam (108) is passed through at least one groove extending throughout a length of the plurality of sides (106) of the panel structure (102) to increase a structural rigidity and loadbearing capacity of the reinforced panel mold (100) formed by assembling the plurality of panel structures (102) .
9. The reinforced panel mold (100) of claim 7 wherein at least one reinforcement beam (108) inserted through the plurality of sides of the plurality of panel structures (102) are molded to encapsulate at least one reinforcement beam (108) within the plurality of sides (106) of the plurality of panel structures (102), wherein at least one reinforcement beam (108) encapsulated within the plurality of sides (106) of the plurality of panel structures (102) forms an integral part of the reinforced panel mold (100).
10. The reinforced panel mold (100) of claim 7 wherein the plurality of panel structures (102) reinforced using at least one reinforcement beam (108) encapsulated within the plurality of sides (106) of the plurality of panel structures (102) are spliced to the adjacent panel structure (102) using at least one splice plate (110), wherein at least one splice plate (110) is placed in a predesigned pocket to align for attaching with the at least one reinforcement beam (108) using the mechanical attachment means (114) , wherein at least one splice plate (110) connecting at the top and bottom of the pair of panel structures (102) maintains the loadbearing capacity of the panel structure (102) throughout the reinforced panel mold (100) formed by assembling the plurality of panel structures (102).
11. The reinforced panel mold (100) of claim 7 wherein the at least one reinforcement beam (108) encapsulated within the plurality of sides (106) of the plurality of panel structures (102) is having a plurality of holes (112) for allowing a user to attach the at least one splice plate (110) at the top and bottom of the plurality of panel structures (102) for maintaining the loadbearing capacity of the reinforced panel mold (100), wherein at least one splice plate (110) placed in the predesigned pocket is attached to the at least one reinforcement beam (108) using a plurality of mechanical attachment means (114) including nuts and bolts, rivets, attaching plates, locking pins and screws.
12. A process of assembling a reinforced panel mold (100) for use in constructing a plurality of concrete structural components, the process comprising the steps of: providing a plurality of panel structures (102) having at least one reinforcement beam (108) molded within at least one side (106) of the panel structures (102); extending the size of the reinforced panel mold (100) in horizontal and/or vertical direction by assembling the plurality of panel structures (102); splicing a plurality of additional panel structures (102) to the plurality of existing panel structure (102) by adding at least one splice plate (110) into at least one pockets at an end on each of the panel structure (102); attaching a pair of ends of the panel structures (102) using mechanical attachment means (114) including pins, attachment plates, screws and/or nuts and bolts; and employing the reinforced panel mold (100) formed by assembling the plurality of panel structures (102) in the form of a support in construction of a plurality of concrete structures .
13. The process of claim 12 wherein at least one reinforcement beam (108) is an elongated metallic plate inserted through a cavity on at least one of the plurality of sides (106) of the plurality of panel structures (102) for improving a loadbearing capacity of the reinforced panel mold (100), wherein panel structures (102) are assembled in a horizontal and/or vertical direction with each of the plurality of elongated metallic plates running in parallel, spaced apart through the plurality of sides (106) of the panel structures (102) , wherein each of the plurality of elongated metallic plates is passed through the plurality of sides (106) of the panel structures (102) and are attached to the plurality of sides (106) of the panel structures (102) using a plurality of methods including injection molding to improve the loadbearing capacity of the reinforced panel mold (100) .
14. The process of claim 12 wherein the splice plate (110) includes a plurality of holes (116) to attach the splice plate (110) with the at least one reinforcement beam (108) using the mechanical attachment means (114) to maintain the loadbearing capacity of the panel structure (102) throughout the reinforced panel mold (100) formed by assembling the plurality of panel structures (102), wherein the plurality of hoes (116) on the splice plate (110) is made to align with the plurality of holes (112) on at least one reinforcement beam (108) passing through the plurality of sides (106) of the panel structures (102) and connected using the mechanical attachment means (114) including nuts and bolts, rivets, attaching plates, locking pins and screws .
15. The process of claim 12 wherein the plurality of panel structures (102) are assembled to form any desired shape for the mold for forming the plurality of concrete structural components, wherein the plurality of panel structures (102) are made from plastic and being lightweight, allows easier handling of the plurality of panel structures (102), wherein the reinforced panel mold (100) having at least one reinforcement beam (108) is formed by splicing the plurality of panel structures (102) using the splicing plates (110) .