AU2019100345A4

AU2019100345A4 - Formwork element and formwork system

Info

Publication number: AU2019100345A4
Application number: AU2019100345A
Authority: AU
Inventors: Clayton Price; Lee Price
Original assignee: Winterlong Project Services Pty Ltd
Current assignee: Winterlong Project Services Pty Ltd
Priority date: 2019-04-03
Filing date: 2019-04-03
Publication date: 2019-05-09
Anticipated expiration: 2027-04-03

Abstract

Abstract There is disclosed herein a formwork element for casting a concrete floor or foundation slab. The formwork element comprises a web portion having a planar concrete engaging surface, and upper and lower flange portions extending from the web portion to define a channel therebetween. The formwork element further comprises first and second cap portions disposed at respective ends of the channel. Each of the cap portions is configured to engage with an attachment mechanism to connect the formwork element with a further formwork element such that the planar concrete engaging surface is substantially contiguous and planar with the planar concrete engaging surface of said further formwork element.

Description

FORMWORK ELEMENT AND FORMWORK SYSTEM

Technical Field [0001] The present disclosure relates to a formwork element for casting a concrete floor or foundation slab. The present disclosure also relates to a formwork system.

Background [0002] Formwork is used in the construction of concrete floors or foundation slabs to provide a temporary or permanent mould into which concrete or similar materials may be poured.

[0003] In the construction industry, timber is a commonly used material for formwork. Typically, concreters cut timber pieces on-site and connect the timber pieces together by way of nails and/or screws to form the required formwork. However, the use of timber as formwork presents a number of problems.

[0004] One problem is that the timber pieces as well as the nails and/or screws are often discarded after a single use, which creates a vast amount of wastage. This leads to higher costs associated with disposable goods and rubbish bins on-site. Further, it is often difficult to ensure that the timber pieces are cut accurately at the first instance, which may require the same timber pieces to be cut further or additional timber pieces to be added to the formwork to make up for perceived measurement gaps. This not only can be time-consuming for the concreter, but may also lead to inaccurate results in the concrete floor or foundation slab. A further problem is that timber can be bulky and heavy, thus requiring larger vehicles and lifting machinery for transporting such timber pieces to, and around, the construction site as well as requiring a significant number of workers to install and remove the timber formwork.

Object [0005] It is an object of the present disclosure to substantially overcome or ameliorate one or more of the above problems.

2019100345 03 Apr 2019

Summary [0006] There is disclosed herein a formwork element for casting a concrete floor or foundation slab, the formwork element comprising:

a web portion having a planar concrete engaging surface;

upper and lower flange portions extending from the web portion to define a channel therebetween; and first and second cap portions disposed at respective ends of the channel, wherein each of the cap portions is configured to engage with an attachment mechanism to connect the formwork element with a further formwork element such that the planar concrete engaging surface is substantially contiguous and planar with the planar concrete engaging surface of said further formwork element.

[0007] Each of the cap portions may define at least one aperture.

[0008] The formwork element may be formed from aluminium.

[0009] There is also disclosed herein a formwork system, comprising:

first and second formwork elements, each of the formwork elements according to that described above; and an attachment mechanism configured to engage with the first cap portion of the first formwork element and the second cap portion of the second formwork element to connect the first formwork element to the second formwork element such that the planar concrete engaging surface of the first formwork element is substantially contiguous and planar with the planar concrete engaging surface of the second formwork element.

[0010] The attachment mechanism may comprise a connecting pin defining an elongate slot, and a locking mechanism for engagement with the elongate slot to connect the first formwork element to the second formwork element.

2019100345 03 Apr 2019

Brief Description of Drawings [0011] Embodiments of the present disclosure will now be described hereinafter, by way of examples only, with reference to the accompanying drawings, in which:

[0012] Fig. 1 is a perspective view of an embodiment of a formwork system;

[0013] Fig. 2 is a perspective view of an embodiment of a formwork element, in the form of a panel;

[0014] Fig. 3 is another perspective view of the formwork element of Fig. 2;

[0015] Fig. 4 is a perspective view of an embodiment of a formwork element, in the form of an in-comer piece;

[0016] [0017]

Fig. 5 is a top view of the formwork element of Fig. 4;

Fig. 6 is another perspective view of the formwork element of Fig. 4;

[0018] Fig. 7 is a perspective view of another embodiment of a formwork element, in the form of an out-comer piece;

[0019] Fig. 8 is a perspective view of an embodiment of an attachment mechanism, showing a connecting pin only;

[0020] Fig. 9 is a perspective view of the attachment mechanism of Fig. 7, showing a locking mechanism only;

[0021] Fig. 10 is a perspective view of the formwork element of Fig. 2, prior to being connected to a further formwork element;

[0022] Fig. 11 is a perspective view of the formwork element of Fig. 2 aligned with a further formwork element, prior to being connected;

2019100345 03 Apr 2019 [0023] Fig. 12 is a perspective view of the formwork element of Fig. 2 aligned with a further formwork element, and partially connected with the connecting pins of Fig. 7 inserted therebetween;

[0024] Fig. 13 is an enlarged partial perspective view of the formwork element of Fig. 2 connected with a further formwork element;

[0025] Fig. 14 is an enlarged rear view of the formwork element of Fig. 2 connected with a further formwork element;

[0026] Fig. 15 is a perspective view of an embodiment of a spacer;

[0027] Fig. 16 is a partial perspective view of the formwork element of Fig. 2 connected to a ground anchoring member; and [0028] Fig. 17 is a partial perspective view of the formwork element of Fig. 2 connected to a ground anchoring member as well as an upper formwork element via a supporting member.

Description of Embodiments [0029] The present disclosure provides a formwork system comprising a plurality of formwork elements 100, 200 that are connected together by a plurality of attachment mechanisms 300. The formwork elements 100, 200 and the attachment mechanisms 300 can be selectively combined to form a formwork 10 for casting a concrete floor or foundation slab 20, as shown in Fig. 1. It will be appreciated that the formwork elements 100, 200 of the present disclosure, as generally described herein and illustrated in the drawings can be arranged, substituted, combined, separated and designed in a wide variety of different configurations, all of which are contemplated in this disclosure.

[0030] Figs. 2 and 3 show an embodiment of a formwork element 100, in the form of a panel. The formwork element 100 comprises a web portion 102 having a planar concrete engaging surface 104. The formwork element 100 also comprises opposed upper and lower flange portions 106, 108 that extend substantially perpendicular from the web portion 102.

The web portion 102 and the upper and lower flange portions 106, 108 together define a channel 110 therebetween. The channel 110 has a first end 112 and a second end 114. Each of

2019100345 03 Apr 2019 the upper and lower flange portions 106, 108 defines at least one aperture 116 therein for engagement with the attachment mechanism 300. In this embodiment, each flange portion 106, 108 has 15 apertures 116 that are spaced equidistantly from one another. However, in other embodiments, the spacing between the apertures 116 may be uneven.

[0031] The formwork element 100 further comprises a strengthening member 118 in the form of a series of parallel ribs that extend between the upper and lower flange portions 106, 108. Moreover, the formwork element 100 comprises at least one supporting wall 120 that is spaced from the web portion 102 and that extends between the upper and lower flange portions 106, 108. In this embodiment, the formwork element 100 has four supporting walls 120, with each supporting wall 120 defining two apertures 122 therein for engagement with the attachment mechanism 300.

[0032] The formwork element 100 further comprises first and second cap portions 124, 126 disposed at respective first and second ends 112, 114 of the channel 110. Each of the cap portions 124, 126 defines at least one aperture 128 for engagement with the attachment mechanism 300 to connect the formwork element 100 with another formwork element. In this embodiment, each cap portion 124, 126 defines a first aperture 128a and a second aperture 128b disposed therebelow. The dimensions of the first and second apertures 128a, 128b are substantially the same. The formwork element 100 is formed from aluminium and has a length ranging from 50mm to 3,000mm and a height ranging from 100mm to 300mm. The formwork element 100 may be integrally formed or welded together.

[0033] Figs. 4 to 6 show an embodiment of a formwork element 200, in the form of an incomer piece. The in-corner piece is used for casting an inside corner of the concrete floor or foundation slab 20. The formwork element 200 comprises a web portion 202 having a first planar concrete engaging surface 204 and a second planar concrete engaging surface 206 extending therefrom. The first and second concrete engaging surfaces 204, 206 define an angle a therebetween. In the embodiment shown in Fig. 5, the angle a is substantially 90 degrees. However, in other embodiments, the angle a may be more or less depending on formwork requirements. The formwork element 200 also comprises opposed upper and lower flange portions 208, 210 that extend substantially perpendicular from the web portion 202. The web portion 202 and the upper and lower flange portions 208, 210 together define a channel 212 therebetween. The channel 212 has a first end 214 and a second end 216. Each

2019100345 03 Apr 2019 flange portion 208, 210 defines at least one aperture 218 therein for engagement with the attachment mechanism 300.

[0034] The formwork element 200 further comprises first and second cap portions 220, 222 disposed at respective first and second ends 214, 216 of the channel 212. Each of the cap portions 220, 222 comprises at least one aperture 224 for engagement with the attachment mechanism 300 to connect the formwork element 200 with another formwork element. In this embodiment, each of the cap portions 220, 222 has a first aperture 224a and a second aperture 224b disposed therebelow. The dimensions of the first and second apertures 224a, 224b are substantially the same. Moreover, the dimensions of the first and second apertures 224a, 224b and the dimensions of the first and second apertures 128a, 128b are substantially the same.

The formwork element 200 is formed from aluminium and may be integrally formed or welded together.

[0035] In another embodiment, the formwork element 200 may be in the form of an outcomer piece, as shown in Fig. 7. The out-comer piece is used for casting an outside corner of the concrete floor or foundation slab 20. The out-corner piece is substantially similar to the incomer piece and like features have been indicated with like reference numerals. However, in this embodiment, the web portion 202 is disposed on the opposite side of the upper and lower flange portions 208, 210.

[0036] Figs. 8 and 9 show an embodiment of an attachment mechanism 300. The attachment mechanism 300 is used to connect components of the formwork system together. The attachment mechanism 300 comprises a connecting pin 302 (Fig. 8) and a locking mechanism 304 (Fig. 9). With reference to Fig. 8, the connecting pin 302 has a head portion 306 with a flange 308 and an elongate body 310 that extends from the flange 308 to a free end 312. The elongate body 310 is sized and shaped to be received by the apertures 116, 122, 128, 218, 224 of the formwork elements 100, 200. The elongate body 310 defines an elongate slot 314 spaced from the head portion 306 and comprises a first slot end 316 and a second slot end 318. The elongate slot 314 is sized and shaped to receive the locking mechanism 304 therein. The flange 308 defines a width that is greater than a width of the apertures 116, 122, 128, 218, 224 to limit insertion of the connecting pin 302 through the apertures 116, 122, 128, 218, 224.

2019100345 03 Apr 2019 [0037] Referring now to Fig. 9, the locking mechanism 304 is in the form of a wedge having a first end 320, a second end 322, and first and second edges 324, 326 that extend between the first and second ends 320, 322. The locking mechanism 304 is configured to be inserted into the slot 314 via the first end 320. The locking mechanism 304 has a width that tapers from the second end 322 to the first end 320. The width W2 at the second end 322 is greater than the length L of the slot 314 and the width Wi at the first end 320 is less than the length L of the slot 314. The locking mechanism 304 further defines an aperture 328 disposed adjacent the second end 322 to facilitate removal of the locking mechanism 304 from the connecting pin 302. The connecting pin 302 and the locking mechanism 304 are formed from steel or the like.

[0038] Construction of the formwork 10 using the above described formwork elements 100, 200 will now be described hereinafter. It will be appreciated that the formwork elements 100, 200 may be available in a wide range of different configurations, each of which may be selectively combined to form the required formwork 10. An initial assessment can be made to determine the exact number and type of formwork elements 100, 200 required for a particular concrete floor or foundation slab 20 so that only the required formwork elements 100, 200 are transported to the work site. The formwork elements 100, 200 are each connected together by way of the attachment mechanism 300.

[0039] An example of one such connection between the formwork element 100 and a further formwork element 100’ will now be described with reference to Figs. 10 to 14. The further formwork element 100’ is substantially similar to the formwork element 100 and like features have been indicated with like reference numerals and an apostrophe. With reference to Figs.

and 11, the formwork element 100 and the further formwork element 100’ are positioned such that the second cap portion 126’ of the further formwork element 100’ is adjacent to the first cap portion 124 of the formwork element 100, and the first and second apertures 128a’, 128b’ of the second cap portion 126’ are substantially aligned with respective first and second apertures 128a, 128b of the first cap portion 124. In this embodiment, two attachment mechanisms 300 are used to connect the formwork element 100 and the further formwork element 100’ together. The connecting pins 302 of the attachment mechanisms 300 are inserted through the respective first apertures 128a, 128a’ and respective second apertures 128b, 128b’, as shown in Fig. 12, such that the flanges 308 of the connecting pins 302 abut the first cap portion 124 (see Fig. 14). The elongate slots 314 of the connecting pins 302 are

2019100345 03 Apr 2019 substantially exposed in the channel 110’ of the further formwork element 100’ so as to allow the locking mechanisms 304 to be inserted therein.

[0040] Turning now to Figs. 13 and 14, the locking mechanisms 304 are inserted into respective elongate slots 314 to lock the formwork element 100 and the further formwork element 100’ together. The first edges 324 of the locking mechanisms 304 engage the second cap portion 126’ and the second edges 326 of the locking mechanisms 304 engage the second slot ends 318, thus preventing movement of the second cap portion 126’ away from the first cap portion 124. One or more washers (not shown) may also be used to adjust the positioning of the slots 314 in the channel 110’ to ensure that the locking mechanisms 304 engage both the second cap portion 126’ and the second slot ends 318. Further insertion of the locking mechanisms 304 through the slots 314 forces both the first cap portion 124 and the second cap portion 126’ closer together. When the formwork element 100 and the further formwork element 100’ are connected, the planar concrete engaging surface 104 of the formwork element 100 is substantially contiguous and planar with the planar concrete engaging surface 104’ of the further formwork element 100’.

[0041] It will be appreciated that the pins 302 may alternatively be inserted into the first and second apertures 128a, 128a’, 128b, 128b’ of the first cap portion 124 and the second cap portion 126’ such that the flanges 308 abut the second cap portion 126’ and the elongate slots are exposed in the channel 110 of the formwork element 100.

[0042] It will also be appreciated that the formwork element 100 and the formwork element 200 may be connected by the attachment mechanism 300 in the same or similar manner described above.

[0043] A spacer 400 (Fig. 15) may be disposed between the formwork element 100 and the further formwork element 100’ to extend the length of a section of the formwork 10. In this embodiment, the spacer 400 has first and second surfaces 402, 404 on opposed sides thereof, and a planar concrete engaging surface 406. The spacer 400 is formed from aluminium and has a thickness of 10mm that is defined between the first and second surfaces 402, 404. The spacer thickness provides a 10mm extension in the length of a section of the formwork 10.

The spacer 400 also defines at least one aperture 408 therein for engagement with the attachment mechanism 300. In this embodiment, the spacer 400 has two apertures 408

2019100345 03 Apr 2019 substantially corresponding to the apertures 128a, 128b of the formwork element 100 and the apertures 128a’, 128b’ of the further formwork element 100’. When the spacer 400 is connected, by the attachment mechanism 300, between the formwork element 100 and the further formwork element 100’, the planar concrete engaging surface 406 of the spacer 400 is substantially contiguous and planar with the planar concrete engaging surfaces 104, 104’ of the formwork elements 100 and the further formwork element 100’.

[0044] It will be appreciated that the spacer 400 may be disposed between the formwork element 100 and the formwork element 200. In some embodiments, the formwork system may comprise one or more spacers 400, with each spacer 400 disposed at different locations along a section of the formwork 10 so as to achieve a desired length of the formwork 10. For example, if a 30mm extension is required in a section of the formwork 10, then three 10mm spacers 400 may be disposed at three different locations along the section of the formwork 10.

[0045] One or more ground anchoring members 500 are connected to the formwork element 100 to fix the formwork 10 to the ground. With reference to Fig. 16, the ground anchoring member 500 is in the form of an angled aluminium bracket having a base 502 and a sidewall 504 extending upwardly from the base 502. In this embodiment, the sidewall 504 is substantially perpendicular to the base 502 such that the ground anchoring member 500 is generally L-shaped in profile. The base 502 defines a plurality of equidistantly spaced apertures 506 therein for receiving one or more stakes 30. The sidewall 504 defines a plurality of elongate apertures 508 therein for engagement with the attachment mechanism 300.

[0046] The supporting wall 120 of the formwork element 100 and the sidewall 504 of the ground anchoring member 500 are connected together by the attachment mechanism 300 in a similar manner described above, by first inserting the connecting pin 302 through one of the apertures 122 of the supporting wall 120 and one of the apertures 508 of the sidewall 504, and then inserting the locking mechanism 304 into the elongate slot 314 of the connecting pin 302 to lock the ground anchoring member 500 and the formwork element 100 together. The elongate apertures 508 of the sidewall 504 allow a user to make adjustments to the vertical positioning of the formwork element 100 relative to the ground, with such adjustments being limited to within the apertures 508. It will be appreciated that the formwork element 100 may be connected, by the attachment mechanism 300, to any of the plurality of elongate apertures 508 in a similar manner described above.

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2019100345 03 Apr 2019 [0047] In the embodiment shown in Fig. 16, the ground anchoring members 500 are each fixed to the ground by two stakes 30, which are driven through the apertures 506 of the base 502 and into the ground. Additionally or optionally, a plastic cap (not shown) may be placed on top of each of the stakes 30 to enhance visibility thereof.

[0048] It will be appreciated that one or more ground anchoring members 500 may be used to fix other sections of the formwork 10 to the ground.

[0049] The formwork system can be used for casting a concrete floor or foundation slab 20 with a recessed section. The recessed section may be required for allowing brickwork or a building wall to be disposed therein. Fig. 17 shows an example of a tiered section of the formwork 10 for casting a concrete floor or foundation slab 20 with a recessed section. The tiered section includes the formwork element 100 and an upper formwork element 100” that is offset from the formwork element 100. The upper formwork element 100” is substantially similar to the formwork element 100 and like features have been indicated with like reference numerals and a double apostrophe. The upper formwork element 100” is connected to the formwork element 100 by a supporting member 600. The supporting member 600 is in the form of an angled aluminium bracket having a base 602 and a sidewall 604 that extends upwardly from the base 602. In this embodiment, the sidewall 604 is substantially perpendicular to the base 602 such that the supporting member 600 is generally L-shaped in profile. The base 602 defines a plurality of elongate apertures 606 therein for engagement with the attachment mechanism 300. The sidewall 604 also defines a plurality of elongate apertures 608 therein for engagement with the attachment mechanism 300.

[0050] The base 602 and the upper flange 106 of the formwork element 100 are connected together by the attachment mechanism 300 in a similar manner described above. Further, the sidewall 604 and the supporting wall 120” of the upper formwork element 100” are connected together by the attachment mechanism 300 in a similar manner described above. The elongate apertures 606, 608 allow a user to make adjustments to the horizontal and vertical positioning of the upper formwork element 100” relative to the formwork element 100, with such adjustments being limited to within the apertures 606, 608.

2019100345 03 Apr 2019 [0051] It will be appreciated that one or more supporting members 600 may be used to form other tiered sections of the formwork 10. In some embodiments, the tiered sections of the formwork 10 may comprise two or more levels.

[0052] Once the formwork 10 is constructed, concrete may then be poured into the formwork 10 through known methods to cast the concrete floor or foundation slab 20. To disassemble the formwork 10, the plurality of attachment mechanisms 300 that connect the components of the formwork system together may be removed by simply removing the locking mechanism 304 from the connecting pins 302.

[0053] The above described formwork system has numerous advantages. The formwork system is flexible to use and the formwork elements 100, 200 may be connected together in different configurations to achieve the desired formwork 10 without the need for cutting. This allows the formwork 10 to be constructed quickly and accurately. Further, the aluminium formwork elements 100, 200 are lighter compared to traditional timber pieces and are reusable, thus reducing waste and costs associated with labour, lifting machinery, transportation, and having rubbish bins on-site. Moreover, the attachment mechanism 300 provides a simple means of connecting components of the formwork system together, thus reducing the time required to assemble and disassemble the formwork 10. The attachment mechanism 300 is also reusable, thus reducing waste. The elongate apertures 508, 606, 608 also allow for minor adjustments to be made to the vertical and/or horizontal positioning of the formwork elements 100, 200.

[0054] It will be appreciated by persons skilled in the art that numerous variations and/or modifications may be made to the above-described embodiments, without departing from the broad general scope of the present disclosure. The present embodiments are, therefore, to be considered in all respects as illustrative and not restrictive.

Claims

1. A formwork element for casting a concrete floor or foundation slab, the formwork element comprising:

a web portion having a planar concrete engaging surface;

2. The formwork element according to claim 1, wherein each of the cap portions defines at least one aperture.

3. The formwork element according to claim 1 or 2, wherein the formwork element is formed from aluminium.

4. A formwork system, comprising:

first and second formwork elements, each of the formwork elements according to any one of the preceding claims; and an attachment mechanism configured to engage with the first cap portion of the first formwork element and the second cap portion of the second formwork element to connect the first formwork element to the second formwork element such that the planar concrete engaging surface of the first formwork element is substantially contiguous and planar with the planar concrete engaging surface of the second formwork element.

5. The formwork system according to claim 4, wherein the attachment mechanism comprises a connecting pin defining an elongate slot, and a locking mechanism for engagement with the elongate slot to connect the first formwork element to the second formwork element.