AU2018310753A1

AU2018310753A1 - Formwork panel frame

Info

Publication number: AU2018310753A1
Application number: AU2018310753A
Authority: AU
Inventors: Jian Wen Wang
Original assignee: Wangwealth Pty Ltd
Current assignee: Wangwealth Pty Ltd
Priority date: 2017-08-01
Filing date: 2018-07-31
Publication date: 2020-02-20
Anticipated expiration: 2038-07-31
Also published as: EP3662118A4; AU2018310753B2; EP3662118A1; WO2019023745A1; CN212897537U; EP3662118B1

Abstract

A formwork panel frame (10) includes a pair of generally parallel side beams (30) and a pair of generally parallel end beams (40) arranged perpendicular to the side beams (30) to form a generally rectangular outer frame of the formwork panel frame (10). Each end beam (40) has a hollow core (45) open at each end of the end beam (40). Four first connectors (70) join the side beams (30) to the end beams (40), with each first connector (70) having a projection (73) shaped to fit, in complementary fashion, into the hollow cores (45) of the end beams (40).

Description

Formwork panel frame

Related Application [0001] This application is related to Australian Provisional Patent Application

No. 2017903042 titled Formwork panel frame and filed on 1 August 2017 in the name of Wangwealth Pty Ltd, the entire content of which is incorporated by reference as if fully set forth herein.

Technical Field [0002] The present disclosure relates to concrete formwork and, in particular, to modular formwork panels for constructing formwork and a method of constructing a panel frame for a form work panel.

Background of the Invention [0003] Formwork is commonly used in construction to support and contain wet concrete and to hold the wet concrete in place until it cures to form self-supporting concrete formations such as elevated concrete slabs.

[0004] Typically, elevated concrete slabs are poured on formwork that is supported on scaffolding or by a number of vertical shores. The scaffolding or shores support a number of timber stringer beams, which in turn support a number of transverse timber joists, which in turn support a plywood formwork surface. The construction of this common timber formwork is very labour intensive, is slow to assemble and also slow to disassemble. With the increasing cost of labour on construction sites, this leads to a very high labour cost for erecting elevated concrete slabs using traditional timber formwork.

[0005] One solution is to use modular formwork panels with an aluminium frame that can be supported on scaffolding posts during use and then dismantled and reused.

[0006] However, construction of aluminium frames can be time consuming and labour intensive when the frames are welded with full length welds connecting each of the frame members. The welding process can also result in dimensional variations from one panel frame to the next and can result in minor curves between welding points or panel frames with sides that are not parallel. This can be problematic when assembling adjacent formwork panel modules.

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Object of the Invention [0007] It is an object of the present invention to substantially overcome or at least ameliorate one or more of the above disadvantages, or to provide a useful alternative.

Summary of the Invention [0008] In a first aspect, the present invention provides a disassemblable formwork panel frame comprising:

a pair of longitudinal side beams; and a pair of longitudinal end beams, each end beam having an opening at each end, each opening providing access to a corresponding internal cavity that extends longitudinally from the opening into the end beam; and four first connectors either connectable to, or formed on, the side beams, each first connector having a projection shaped and sized to slide longitudinally via one of the openings into the corresponding internal cavity;

wherein the formwork panel frame has a disassembled configuration, in which the side beams and end beams are not joined, and an assembled configuration, in which the end beams are arranged parallel to each other and perpendicular to the side beams and are joined to one another by the projections of the first connectors, each first connector projection being longitudinally and slidably received in a respective one of the end beam cavities and secured in place by at least one releasable fastener securing each first connector projection against longitudinal sliding movement within the respective end beam cavity.

[0009] In one embodiment:

the first connectors are separate components that are each attachable to the side beams by way of a mounting flange that is perpendicular to the projection;

the side beams each have a first aperture formed transversely through the side beam at each end; and the first apertures are shaped to receive the projections of the first connectors, such that in the assembled configuration the first connector projections extend through the first apertures of the side beams and into the respective end beam cavity.

[0010] Alternatively, the first connectors are separate components that are each attachable to an internal wall of the side beams by way of a mounting flange that is perpendicular to the first connector projection.

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PCT/AU2018/050795 [0011] Preferably, the formwork panel frame further comprises:

at least one longitudinal crossbeam having at each end an opening and a corresponding internal cavity that extends longitudinally from the opening into the crossbeam; and at least two second connectors either connectable to, or formed on, the side beams, each second connector having a projection shaped and sized to slide longitudinally via one of the openings into the corresponding internal cavity of the crossbeam;

wherein, in the assembled configuration, the crossbeams are joined to the side beams, each second connector projection being longitudinally and slidably received in a respective one of the crossbeam cavities and secured in place by at least one releasable fastener securing each second connector projection against longitudinal sliding movement within the respective crossbeam cavity.

[0012] In one embodiment:

the second connectors are separate components that are each attachable to the side beams by way of a mounting flange that is perpendicular to the projection;

the side beams each have at least one second aperture formed transversely through the side beam longitudinally in between the first apertures; and the second apertures are shaped to receive the projections of the second connectors, such that in the assembled configuration the second connector projections extend through the second apertures of the side beams and into the respective crossbeam cavity.

[0013] Alternatively, the second connectors are separate components that are each attachable to an internal wall of the side beams by way of a mounting flange that is perpendicular to the second connector projection.

[0014] In a preferred embodiment, the formwork panel frame further comprises:

at least one brace member extending perpendicular to the at least one crossbeam and secured to the at least one crossbeam.

[0015] Preferably, the at least one brace member is secured to the at least one crossbeam by way of mechanical fasteners.

[0016] In a preferred embodiment, the hollow core of each end beam and the perpendicular projection of each first connector have a generally right trapezoidal crosssection.

[0017] Preferably, the hollow core of each crossbeam and the perpendicular projection of each second connector have a generally rectangular cross-section.

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PCT/AU2018/050795 [0018] In a preferred embodiment, the side beams and the end beams have an upper L-shaped flange, which when the side beams and end beams are assembled together form a rectangular frame for receiving a formwork panel.

[0019] Preferably, each of the side beams, end beams, crossbeams, and brace members is formed by aluminium extrusion.

[0020] Preferably, the first connectors are secured to the side beams and end beams by way of mechanical fasteners.

[0021] Further preferably, the second connectors are secured to the side beams and crossbeams by way of mechanical fasteners.

Brief Description of the Drawings [0022] A preferred embodiment of the invention will now be described by way of specific example with reference to the accompanying drawings, in which:

[0023] Fig. 1 depicts a formwork panel frame in perspective view;

[0024] Fig. 2 is a plan view of the formwork panel frame of Fig. 1;

[0025] Fig. 3A depicts a side beam of the formwork panel frame of Fig. 1 in isolation;

[0026] Fig. 3B is a cross-sectional view of the side beam of Fig. 3A;

[0027] Fig. 4A depicts an end beam of the formwork panel frame of Fig. 1 in isolation;

[0028] Fig. 4B is a cross-sectional view of the end beam of Fig. 4A;

[0029] Fig. 5A depicts a crossbeam of the formwork panel frame of Fig. 1 in isolation;

[0030] Fig. 5B is a cross-sectional view of the crossbeam of Fig. 5A;

[0031] Fig. 6A depicts a brace member of the formwork panel frame of Fig. 1 in isolation;

[0032] Fig. 6B is a cross-sectional view of the brace member of Fig. 6A;

[0033] Fig. 7 depicts a first connector of the formwork panel frame of Fig. 1 in isolation;

[0034] Fig. 8 depicts a second connector of the formwork panel frame of Fig. 1 in isolation;

[0035] Fig. 9 is a partially exploded view of the area labelled X in Fig. 1, showing the assembly of the connector of Fig. 7; and [0036] Fig. 10 is a partially exploded view of the area labelled Y in Fig. 1, showing the assembly of the connector of Fig. 8.

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Detailed Description of the Preferred Embodiments [0037] As depicted in Figs. 1 and 2, in the assembled configuration, the disassemblable formwork panel frame 10 is formed from a pair of parallel longitudinal side beams 30, a pair of parallel longitudinal end beams 40, a number of longitudinal crossbeams 50, and a pair of parallel longitudinal brace members 60. Each of the side beams 30, end beams 40, crossbeams 50, and brace members 60 are typically hollow aluminium extrusions.

[0038] As shown in isolation in Figs. 3A and 3B, the longitudinal side beams 30 have a generally flat wall 31 with an upper, L-shaped flange 32 and a lower shoulder 33. The wall 31 has a pair of rectangular first apertures 35 formed transversely through the wall 31 at either end of the side beam 30 and mounting holes 38 through the wall 31 are provided adjacent to, and on the inside of, the first apertures 35. A plurality of rectangular second apertures 36 (in this example five) are also formed transversely through the wall 31 at intervals in between the two first apertures 35 and mounting holes 39 through the wall 31 are provided on either side of each of the second apertures 36. Circular holes 37 are also formed in the wall 31 to help minimise heat or twist transition along the side beam 30 if welding is required.

[0039] The end beams 40 are depicted in isolation in Fig. 4A and in cross-section in

Fig. 4B. Referring to Fig. 4B, the end beams 40 have a generally flat outer wall 41, an inner wall 42, a slanted base wall 43, and an upper wall 44. The longitudinal ends of the end beams 40 have openings 49 that provide access to end cavities 45 that extend longitudinally into the end beam 40 from either end and, in the embodiment depicted, form a hollow core 45 that extends throughout the length of the end beams 40 from one opening 49 to the other opening 49 and has a generally right trapezoidal cross-section. In alternative embodiments, the end cavities 45 may not extend throughout the entire length of the end beam 40. In some embodiments, for further increased stiffness, the hollow core 45 may have one or more transverse webs extending between the outer wall 41 and inner wall 42. The openings 49 have the same cross-sectional shape as the end cavities 45 shown in Fig. 4B.

[0040] The end beams 40 also have an upper, L-shaped flange 46, a lower base flange 47, and a longitudinal ridge 48 for increased stiffness formed adjacent to the base flange 47. Mounting holes 59 adjacent each end of the end beams 40 are formed through both the outer wall 41 and inner wall 42. At the centre of the end beams 40, a rectangular hole 68 is also formed through both the outer wall 41 and inner wall 42 to receive tools, such as crow bars, for assisting the assembly and disassembly of the formwork panel frame 10.

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PCT/AU2018/050795 [0041] The crossbeams 50 are depicted in isolation in Fig. 5A and in cross-section in Fig. 5B. Referring to Fig. 5B, the crossbeams 50 have a pair of generally parallel side walls 51, a top wall 52 that projects laterally beyond the side walls 51, and a bottom wall 53. The longitudinal ends of the crossbeams 50 have openings 58 that provide access to end cavities 55 that extend longitudinally into the crossbeam 50 from either end and, in the embodiment depicted, form a hollow core 55 that extends throughout the length of the crossbeams 50 from one opening 58 to the other opening 58 and has a generally rectangular cross-section. The openings 58 have the same cross-sectional shape as the end cavities 55 shown in Fig. 5B. An internal stiffening web 54 extends between, and perpendicular to, the side walls 51 adjacent to the top wall 52 for increased stiffness. Mounting holes 57 adjacent each end of the crossbeams 50 are formed through both side walls 51.

[0042] The brace members 60 are depicted in isolation in Fig. 6A and in cross-section in Fig. 6B. Referring to Fig. 6B, the brace members 60 have a hollow cross-section formed by a pair of opposing parallel side walls 61 and a pair of opposing arcuate end walls 62. Each of the side walls 61 have a longitudinally extending, internal ridge 63 running centrally along the length of the side walls 61 to provide increased stiffness. Mounting holes 64 are provided at intervals along the side walls 61.

[0043] A first connector 70 adapted to join the side beams 30 and end beams 40 at each corner of the formwork panel frame 10 is depicted in isolation in Fig. 7. The first connector 70 has a generally flat mounting plate 71 with mounting holes 72 and a perpendicular projection 73 having a generally right trapezoidal cross-section that is complementary in shape to the internal shape of the end cavities 45 of the end beams 40. Mounting holes 74 are also provided through the perpendicular projection 73.

[0044] A second connector 80 adapted to join the crossbeams 50 to the side beams 30 is depicted in isolation in Fig. 8. The second connector 80 has a generally flat mounting plate 81 with mounting holes 82. A perpendicular projection 83 extends from the mounting plate 81, the perpendicular projection 83 having a generally rectangular cross-section that is complementary in shape to the internal shape of the end cavities 55 of the crossbeams 50. A mounting hole 84 is provided through the walls of the perpendicular projection 83.

[0045] In an alternative embodiment, the first and second connectors 70, 80 are formed on, or permanently secured to, or detachably mountable on, the inside of the wall 31 of each side beam 30. In such an embodiment, the first and second connectors 70, 80 may not be separate components but merely projections projecting perpendicularly from the walls 31 of the side beams 30. Any of these arrangements obviates the need for the first and second

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PCT/AU2018/050795 apertures 35, 36, which can be omitted, simplifying the design and assembly. In all other aspects, the assembly of the formwork panel frame is essentially the same.

[0046] In order to assemble the formwork panel frame 10, the first connectors 70 are used to assemble the side beams 30 to the end beams 40 at each corner of the formwork panel frame 10, as demonstrated in Fig. 9, which demonstrates one method of assembly. At each corner, the respective first aperture 35 is aligned with the respective opening 49 and end cavity 45 of the respective end beam 40. The perpendicular projection 73 of the respective first connector 70 is inserted through the respective first aperture 35 of the respective side beam 30 and is longitudinally and slidably received in the end cavity 45 of the respective end beam 40 until the mounting plate 71 of the first connector 70 abuts against the wall 31 of the side beam 30 on one side and the end beam 40 abuts against the wall 31 of the side beam 30 on the other side.

[0047] This arrangement aligns the mounting holes 72 of the mounting plate 71 of the first connector 70 with the mounting holes 38 adjacent to the first apertures 35 of the side beams 30 and aligns the mounting holes 74 of the perpendicular projection 73 of the first connector 70 with the mounting holes 59 at each end of the end beams 40. The first connectors 70 are then secured to the side beams 30 and the end beams 40 by fasteners 90 (shown in Fig. 1) such as bolts, rivets, studs, or screws inserted through the aligned mounting holes 72, 38, 74, 59 to join the side beams 30 to the adjoining end beams 40 to form the outer frame of the rectangular formwork panel frame 10 shown in Figs. 1 and 2. Preferably, the fasteners 90 are releasable fasteners, allowing them to be reusable when the formwork panel frame 10 is disassembled and reassembled.

[0048] In this way, the first connectors 70 are secured to the side beams 30 and the perpendicular projection 73 of each first connector 70 is secured against longitudinal sliding movement within the respective end cavity 45 of the end beam 40.

[0049] In the assembled configuration, the L-shaped flanges 32 of the side beams 30 and the L-shaped flanges 46 of the end beams 40 form a rectangular border with an L-shaped cross-section that is adapted to receive and support a rectangular formwork panel.

[0050] The second connectors are used to assemble the crossbeams 50 between the side beams 30, as demonstrated in Fig. 10, which demonstrates one method of assembly. At each interval on the side beams 30, the respective second aperture 36 of the side beam 30 is aligned with the hollow core 55 of the respective crossbeam 50 and the perpendicular projection 83 of the respective second connector 80 is inserted through the respective second aperture 36 of the respective side beam 30 until the mounting plate 81 of the second

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PCT/AU2018/050795 connector 80 abuts against the wall 31 of the side beam 30 on one side and the crossbeam 50 abuts against the wall 31 of the side beam 30 on the other side.

[0051] This arrangement aligns the mounting holes 82 of the mounting plate 81 of the second connector 80 with the mounting holes 39 on either side of each of the second apertures 36 of the side beams 30 and aligns the mounting hole 84 of the perpendicular projection 83 of the second connector 80 with the mounting holes 57 at each end of the crossbeams 50. The second connectors 80 are then secured to the side beams 30 and the crossbeams 50 by fasteners 92 such as bolts, rivets, studs, or screws inserted through the aligned mounting holes 82, 39, 84, 57 to mount the crossbeams 50 between the parallel side beams 30.

[0052] In this way, the second connectors 80 are secured to the side beams 30 and the perpendicular projection 83 of each second connector 80 is secured against longitudinal sliding movement within the respective end cavity 55 of the crossbeam 50.

[0053] In an alternative embodiment, the first connectors 70 and second connectors 80 are removably mounted on the inside of the wall 31 of each side beam 30. This obviates the need for the first and second apertures 35, 36, which can be omitted, simplifying the design and assembly. In all other aspects, the assembly of the formwork panel frame is essentially the same. In a particular embodiment, the first and second apertures 35, 36 are provided and the first and second connectors 70, 80 can be attached via the same mounting holes optionally either on the inside of the wall 31 of each side beam 30 without using the first and second apertures 35, 36 or on the outside of the wall 31 of each side beam 30 with the projections 73, 83 extending through the first and second apertures 35, 36.

[0054] Finally, the brace members 60 are aligned perpendicular to the crossbeams 50 with one of the side walls 61 abutting the crossbeams 50 and are secured to the crossbeams 50 by fasteners (not shown) such as bolts, rivets, studs, or screws inserted through the mounting holes 64 of the brace members 60.

[0055] This assembly method provides a quick and simple method for constructing the formwork panel frames 10. The formwork panel frames 10 produced in this way result in a modular product that is dimensionally consistent, with parallel and straight edges. The more consistently dimensioned formwork panel frame means that adjacent panels in a modular construction fit together more accurately, are easier to use, and provide a higher quality formwork surface.

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PCT/AU2018/050795 [0056] The construction method also produces formwork panel frames 10 that are structurally stronger and more durable, although simpler and quicker to produce. The formwork panel frames are also able to be easily dismantled, maintained for future use, and reassembled when necessary.

[0057] Although the invention has been described with reference to specific examples, it will be appreciated by those skilled in the art that the invention may be embodied in many other forms.

Claims

CLAIMS:

1. A disassemblable formwork panel frame, comprising:

a pair of longitudinal side beams; and a pair of longitudinal end beams, each end beam having an opening at each end, each opening providing access to a corresponding internal cavity that extends longitudinally from the opening into the end beam; and four first connectors either connectable to, or formed on, the side beams, each first connector having a projection shaped and sized to slide longitudinally via one of the openings into the corresponding internal cavity;

wherein the formwork panel frame has a disassembled configuration, in which the side beams and end beams are not joined, and an assembled configuration, in which the end beams are arranged parallel to each other and perpendicular to the side beams and are joined to one another by the projections of the first connectors, each first connector projection being longitudinally and slidably received in a respective one of the end beam cavities and secured in place by at least one releasable fastener securing each first connector projection against longitudinal sliding movement within the respective end beam cavity.
2. The form work panel frame of claim 1, wherein:

the first connectors are separate components that are each attachable to the side beams by way of a mounting flange that is perpendicular to the projection;

the side beams each have a first aperture formed transversely through the side beam at each end; and the first apertures are shaped to receive the projections of the first connectors, such that in the assembled configuration the first connector projections extend through the first apertures of the side beams and into the respective end beam cavity.
3. The formwork panel frame of claim 1 or 2, further comprising:

at least one longitudinal crossbeam having at each end an opening and a corresponding internal cavity that extends longitudinally from the opening into the crossbeam; and at least two second connectors either connectable to, or formed on, the side beams, each second connector having a projection shaped and sized to slide longitudinally via one of

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PCT/AU2018/050795 the openings into the corresponding internal cavity of the crossbeam;

wherein, in the assembled configuration, the crossbeams are joined to the side beams, each second connector projection being longitudinally and slidably received in a respective one of the crossbeam cavities and secured in place by at least one releasable fastener securing each second connector projection against longitudinal sliding movement within the respective crossbeam cavity.
4. The formwork panel frame of claim 3, wherein:

the second connectors are separate components that are each attachable to the side beams by way of a mounting flange that is perpendicular to the projection;

the side beams each have at least one second aperture formed transversely through the side beam longitudinally in between the first apertures; and the second apertures are shaped to receive the projections of the second connectors, such that in the assembled configuration the second connector projections extend through the second apertures of the side beams and into the respective crossbeam cavity.
5. The formwork panel frame of claim 1, wherein the first connectors are separate components that are each attachable to an internal wall of the side beams by way of a mounting flange that is perpendicular to the first connector projection.
6. The formwork panel frame of claim 3, wherein the second connectors are separate components that are each attachable to an internal wall of the side beams by way of a mounting flange that is perpendicular to the second connector projection.
7. The formwork panel frame of claim 3 or 4, further comprising:

at least one brace member extending perpendicular to the at least one crossbeam and secured to the at least one crossbeam.
8. The formwork panel frame of claim 7, wherein the at least one brace member is secured to the at least one crossbeam by way of mechanical fasteners.

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9. The formwork panel frame of claim 3 or 4, wherein the internal cavities of each crossbeam and the perpendicular projection of each second connector have a generally rectangular cross-section.
10. The formwork panel of any one of claims 1 to 9, wherein the internal cavities of each end beam and the perpendicular projection of each first connector have a generally right trapezoidal cross-section.
11. The formwork panel frame of any one of claims 1 to 10, wherein the side beams and the end beams have an upper L-shaped flange, which in the assembled configuration forms a rectangular frame for receiving a formwork panel.
12. The formwork panel of any one of claims 1 to 11, wherein each of the side beams, end beams, crossbeams, and brace members is formed by aluminium extrusion.