AU2019101285A4 - Moulding System for Surface Profiling of Poured Concrete Slabs - Google Patents

Moulding System for Surface Profiling of Poured Concrete Slabs Download PDF

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Publication number
AU2019101285A4
AU2019101285A4 AU2019101285A AU2019101285A AU2019101285A4 AU 2019101285 A4 AU2019101285 A4 AU 2019101285A4 AU 2019101285 A AU2019101285 A AU 2019101285A AU 2019101285 A AU2019101285 A AU 2019101285A AU 2019101285 A4 AU2019101285 A4 AU 2019101285A4
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AU
Australia
Prior art keywords
moulding system
hob
curved
component
sidewall
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AU2019101285A
Inventor
Filip Pantano
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Masterform Systems Pty Ltd
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Masterform Systems Pty Ltd
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Priority to AU2019101285A priority Critical patent/AU2019101285A4/en
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Assigned to MASTERFORM SYSTEMS PTY LTD reassignment MASTERFORM SYSTEMS PTY LTD Request for Assignment Assignors: MAX & WILS PTY. LTD.
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    • EFIXED CONSTRUCTIONS
    • E04BUILDING
    • E04BGENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
    • E04B5/00Floors; Floor construction with regard to insulation; Connections specially adapted therefor
    • E04B5/16Load-carrying floor structures wholly or partly cast or similarly formed in situ
    • E04B5/32Floor structures wholly cast in situ with or without form units or reinforcements
    • E04B5/36Floor structures wholly cast in situ with or without form units or reinforcements with form units as part of the floor
    • EFIXED CONSTRUCTIONS
    • E04BUILDING
    • E04GSCAFFOLDING; FORMS; SHUTTERING; BUILDING IMPLEMENTS OR AIDS, OR THEIR USE; HANDLING BUILDING MATERIALS ON THE SITE; REPAIRING, BREAKING-UP OR OTHER WORK ON EXISTING BUILDINGS
    • E04G13/00Falsework, forms, or shutterings for particular parts of buildings, e.g. stairs, steps, cornices, balconies foundations, sills
    • E04G13/06Falsework, forms, or shutterings for particular parts of buildings, e.g. stairs, steps, cornices, balconies foundations, sills for stairs, steps, cornices, balconies, or other parts corbelled out of the wall
    • E04G13/062Falsework, forms, or shutterings for particular parts of buildings, e.g. stairs, steps, cornices, balconies foundations, sills for stairs, steps, cornices, balconies, or other parts corbelled out of the wall for stairs or steps
    • EFIXED CONSTRUCTIONS
    • E04BUILDING
    • E04GSCAFFOLDING; FORMS; SHUTTERING; BUILDING IMPLEMENTS OR AIDS, OR THEIR USE; HANDLING BUILDING MATERIALS ON THE SITE; REPAIRING, BREAKING-UP OR OTHER WORK ON EXISTING BUILDINGS
    • E04G13/00Falsework, forms, or shutterings for particular parts of buildings, e.g. stairs, steps, cornices, balconies foundations, sills
    • E04G13/06Falsework, forms, or shutterings for particular parts of buildings, e.g. stairs, steps, cornices, balconies foundations, sills for stairs, steps, cornices, balconies, or other parts corbelled out of the wall
    • E04G13/068Falsework, forms, or shutterings for particular parts of buildings, e.g. stairs, steps, cornices, balconies foundations, sills for stairs, steps, cornices, balconies, or other parts corbelled out of the wall for window or door sills
    • EFIXED CONSTRUCTIONS
    • E04BUILDING
    • E04BGENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
    • E04B5/00Floors; Floor construction with regard to insulation; Connections specially adapted therefor
    • E04B5/16Load-carrying floor structures wholly or partly cast or similarly formed in situ
    • E04B5/32Floor structures wholly cast in situ with or without form units or reinforcements
    • E04B2005/322Floor structures wholly cast in situ with or without form units or reinforcements with permanent forms for the floor edges

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  • Engineering & Computer Science (AREA)
  • Architecture (AREA)
  • Civil Engineering (AREA)
  • Structural Engineering (AREA)
  • Mechanical Engineering (AREA)
  • Physics & Mathematics (AREA)
  • Electromagnetism (AREA)
  • Forms Removed On Construction Sites Or Auxiliary Members Thereof (AREA)
  • Bridges Or Land Bridges (AREA)
  • Moulds, Cores, Or Mandrels (AREA)

Abstract

- 14 The manufacture of formwork for curved step changes in height, or curved hobs, in cast in-situ concrete floor slabs can be time consuming and costly. The present invention provides a moulding system for surface profiling of poured concrete slabs that includes 5 sheet metal horizontal components that have curved edges, and sheet metal sidewall components that are curved to match the curved edges of horizontal component. The sidewall components are welded to them to the horizontal components along their curved edges. These curved moulds can be supported on chairs to position them at a predetermined height, and both the chairs and the curved moulds become an integral part 10 of the concrete floor once it is poured. 33 Figure 1 331 Figure 2

Description

Moulding System for Surface Profiling of Poured Concrete Slabs
FIELD OF THE INVENTION
This invention relates to a moulding system for surface profiling of poured concrete slabs, and in particular, but not exclusively to a moulding system for producing surface profiling that contains curvature in a plan view.
BACKGROUND
A significant part of the construction of multi-story buildings is the assembly of formwork for each of the poured concrete floors. The formwork defines the lower surfaces and the outer edges of the slab floors, and the top surfaces are generally open and the concrete is smoothed off as it sets. Increasingly, however, there is a demand for profiling of the upper surfaces, that is, the provision of step changes in the height of the upper surface, or the provision of raised hobs to provide waterproof bases at the bottom of windows or wall structures.
And as the architectural requirements for buildings increase, there is often a need for curved structures. And this requirement for curved structures in turn produces a need for curved or radiused surface profiling of the upper surfaces of the floor slabs.
The construction of moulds or formwork to facilitate the creation of surface profiling is often complex, and can be very time consuming and expensive in both manpower and materials. For example, the formwork or moulds that are required to form a raised hob, or a rebated edge on a floor slab must be cantilevered from the formwork that has been set up to form the floor slab.
Curved or radiused profiling of a concrete slab is that much more complex. The task of producing three dimensional formwork in free space, above the reinforcing steelwork for the slab is particularly demanding. At the same time the curved or radiused shaping must be dimensionally accurate in plan view, to ensure that the profiling will accurately support the window or wall or other structure that will be installed above the curved profile.
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Considerable time is spent shaping and positioning plywood formers, and bending thin panels to produce the curvature, and then fixing the formwork together in a robust enough manner so that it will retain its shape and position when the concrete is poured.
Similarly when a curved raised hob is to be placed on an already cast floor slab, much 5 time and considerable cost in materials can be incurred in laying out the desired shape and location, and in forming a mould for the hob, and in providing structural attachment to the floor slab.
What is needed is a better system of producing curved profiles that will not only save on time and materials, but which will also provide the dimensional accuracy and structural integrity that is required.
OBJECT
It is therefore an object of the present invention to provide a moulding system for surface profiling of poured concrete slabs which will at least go some way towards overcoming one or more of the above mentioned problems, or at least provide the public with a useful choice.
STATEMENTS OF THE INVENTION
Accordingly, in a first aspect, the invention may broadly be said to consist in a moulding system for surface profiling of poured concrete slabs, the moulding system having;
• one or more horizontal components that have one or more curved edges, and · one or more sidewall components that are curved to match the or each curved edge of the or each horizontal component;
and the or each sidewall component is structurally attached to the or each horizontal component along at least one curved edge of the or each horizontal component.
Preferably the or each horizontal component and the or each sidewall component is made 25 of sheet steel.
Preferably the sheet steel is galvanised sheet steel.
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Preferably the structurally attachment is achieved by welding the components together.
Preferably the shape of the or each horizontal component is produced by profile cutting a shape of the or each horizontal component from sheet metal stock.
Preferably the or each sidewall component is an elongate component with a top edge that 5 is parallel to a bottom edge.
In a second aspect, the invention may broadly be said to consist in a set down moulding system for producing step changes in the height of a concrete floor slab, wherein the set down moulding system incorporates the features of the moulding system for surface profiling of poured concrete slabs substantially as specified herein
Preferably the set down moulding system includes at least one horizontal component which forms a base member of the set down moulding system.
Preferably the set down moulding system includes at least one sidewall component which defines the magnitude of the step change in height that is produced by the set down moulding system.
Preferably the set down moulding system includes a plurality of gusset members that are configured to strengthen the attachment between the sidewall component and the base member.
Preferably the gusset members are welded to the sidewall component and to the base member.
Preferably the set down moulding system is configured such that the base member and the gussets become embedded within the concrete when the floor slab is poured.
Preferably the set down moulding system further includes a plurality of supports configured to support the assembled sidewall component and base member at a predetermined height above a floor of a formwork structure for producing a concrete floor slab.
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Preferably the supports each include a base member, a column member and a top member, the column member having a structural connection to both the base member and the top member, the base member being configured for attachment to the floor of the formwork structure, and the top member being configured to engage with and support the assembled sidewall component and base member.
Preferably the supports each include a diagonal brace member configured to assist the column member in resisting side loads when concrete is poured on one side of the sidewall component.
In a third aspect, the invention may broadly be said to consist in a hob moulding system 10 for producing a raised hob formation on a concrete floor slab, wherein the hob moulding system incorporates the features of the moulding system for surface profiling of poured concrete slabs substantially as specified herein.
Preferably the hob moulding system includes at least two horizontal components which form a base member of the hob moulding system and an upper member of the hob moulding system.
Preferably the hob moulding system includes at least two sidewall components that are arranged in a side by side relationship and which form the sides of the raised hob.
Preferably the base member is welded to a lower edge of the two sidewall components along each long edge of the base member, and the upper member is welded to an upper edge of the two sidewall components along each long edge of the upper member.
Preferably the base member includes a plurality of openings, with each opening being situated between, and not extending to, the edges of the base member.
Preferably the upper member includes a plurality of openings, with each opening being situated between, and not extending to, the edges of the upper member.
Preferably the hob moulding system includes one or more spacer members which span between the sidewall components.
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Preferably the or each spacer member includes a vertical web portion which spans between the sidewall components and a horizontal base tab that includes at least one fastener hole.
Preferably the hob moulding system further includes a plurality of supports configured to 5 support the assembled base member, sidewall components and upper member at a predetermined height above a floor of a formwork structure for producing a concrete floor slab.
Preferably the supports each include a base member, a column member and a top member, the column member having a structural connection to both the base member and the top member, the base member being configured for attachment to the floor of the formwork structure, and the top member being configured to engage with and support the assembled base member, sidewall components and upper member.
In a fourth aspect, the invention may broadly be said to consist in a building incorporating at least one moulding system for surface profiling of poured concrete slabs substantially as specified herein.
The invention may also broadly be said to consist in the parts, elements and features referred to or indicated in the specification of the application, individually or collectively, and any or all combinations of any two or more of the parts, elements or features, and where specific integers are mentioned herein which have known equivalents, such equivalents are incorporated herein as if they were individually set forth.
DESCRIPTION
Further aspects of the present invention will become apparent from the following description which is given by way of example only and with reference to the accompanying drawings in which:
FIGURE 1 is a perspective view of a first example of a moulding system for surface profiling of poured concrete slabs according to the present invention,
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FIGURE 2 is a cross sectional view XX (as defined in Figure 1) showing the first example of a moulding system in use and embedded within a concrete slab,
FIGURE 3 is a perspective view of a second example of a moulding system for 5 surface profiling of poured concrete slabs according to the present invention,
FIGURE 4 is a cross sectional view YY (as defined in Figure 3) of the second example of a moulding system, and
FIGURE 5 is a perspective view of an alternative spacer for use in the second 10 example of a moulding system.
First Example
With reference to Figures 1 and 2, a first example of a moulding system for surface profiling of poured concrete slabs in the form of a set down moulding system (11) will now be described. The set down moulding system (11) has been designed for use in the construction of poured concrete floor slabs (13) of single and multi-story buildings. The set down moulding system (11) is used to create step changes in the height of the top surface of the floor slab (13) as shown in figure 2. The set down moulding system (11) becomes embedded within the poured concrete and becomes an integral part of the floor slab (13).
In this first example of a moulding system for surface profiling of poured concrete slabs the set down moulding system (11) has a horizontal component (15) and a sidewall component (17). An important feature of the system is that the horizontal component (15) is profile cut to produce a required shape or curve as specified by the architect.
Both the horizontal component (15) and the sidewall component (17) are made of galvanised sheet steel, and the sidewall component (17) is curved by light bending of the sheet metal material to match the shape of the curved edge (19) of the horizontal component (15). And then the sidewall component (17) is structurally attached to the
207076AUA_Innov_Spec_as_filed_240ct2019.doc/PA
-72019101285 24 Oct 2019 horizontal component (15) along the curved edge (19), by producing a welding joint along the curved edge (19).
As noted above, the shape of the curved edge (19) of the horizontal component (15) is produced by profile cutting, for example by plasma or laser cutting the sheet metal stock material. In this example, an outer or free edge (21) of the horizontal component (15) is similarly profiled or curved, and in this way the horizontal component (15) is essentially an elongate and slender curved section of sheet material where the long edges, (19) and (21), have a similar curved shape or profile and are generally parallel to one another.
The sidewall component (17) is also an elongate component with a top edge (23) that is 10 parallel to a bottom edge (25). The sidewall component (17) can simply be cut as a long strip using a guillotine, with the width of the cut strip determining the height or magnitude of the step change, or set down, produced by the set down moulding system (11).
The horizontal component (15) can be said to be a base member (27) of the set down moulding system (11). In cases where a long section of mould is required, two or more horizontal components (15) could be joined together, end to end, to produce a longer base member. Similarly, multiple lengths of the sidewall components (17) could be joined together, end to end, to match the length of the base member (27).
A number of gusset members (29) used are used to strengthen the attachment between the sidewall component (17) and the base member (27). The gusset members (29) are configured to hold the sidewall component (17) generally at right angles to the base member (27), and in the example shown the gusset members (29) are welded to both the sidewall component (17) and the base member (27). In figure 1 it can be seen that the gussets (29) are similarly cut from sheet metal material, and they are generally slender in shape and they include holes (31) that allow the concrete to flow, so that the gussets provide only a small discontinuity in the structure of the concrete adjacent to the set down.
It can be seen that the set down moulding system (11) further includes a number of supports or chairs (33). The supports (33) are configured to support the assembled
207076AUA_Innov_Spec_as_filed_240ct2019.doc/PA
-82019101285 24 Oct 2019 sidewall component (17) and base member (27) at a predetermined height above a floor of a formwork structure for producing a concrete floor slab.
The supports (33) each include a support base member (35), a column member (37) and a top member (39). The column member (37) has a structural connection to both the base member (35) and to the top member (39). The base member 35) is configured with fastener holes for attachment to the floor of the formwork structure. And the top member (39) is flat and is configured to engage with the mould base member (27) using suitable fasteners or welding, and in this way is able to support the assembled sidewall component (17) and base member (27).
Although not shown, the supports (33) can include a diagonal brace member that is configured to assist the column member (37) in resisting side loads when concrete is poured on one side of the sidewall component (17).
Second Example
With reference to Figures 3 and 4, a second example of a moulding system for surface profiling of poured concrete slabs, this time in the form of a hob moulding system (61), will now be described. The hob moulding system (61) has also been designed for use in the construction of poured concrete floor slabs of single and multi-story buildings. The hob moulding system (61) is used to create raised hobs in the top surface of the floor slab. As with the set down moulding system (11), the hob moulding system (61) also becomes embedded within the poured concrete and becomes an integral part of the floor slab.
The hob moulding system (61) has two horizontal components (63) and two sidewall components (65) that form a box section mould. The bottom of the box section mould is generally aligned with an upper level of the proposed floor slab, and the top of the box section defines an upper surface of a raised hob to be formed integrally with the floor slab.
Alternatively, the hob moulding system (61) can be used to produce a raised hob on an existing floor slab. In such a case the hob moulding system (61) can be structurally fastened to the floor slab, and/or reinforcing connections can be provided between the
207076AUA_Innov_Spec_as_filed_240ct2019.doc/PA
-92019101285 24 Oct 2019 existing concrete slab and the concrete that will be poured into the moulding system (61) to produce the raised hob.
As with the set down moulding system (11) described herein, the hob moulding system (61) is designed to produce non-straight, or curved profile changes in a floor slab. And for this reason, the two horizontal components (63) both have curved or shaped long edges. The sidewall components (65) are curved to match the curved edges of the horizontal components (63).
Both the horizontal components (63) and the sidewall components (65) are made of galvanised sheet steel. One of the horizontal components (63) forms a base member (67) of the hob moulding system (61), the other horizontal component (63) forms an upper member (69) of the hob moulding system (61).
As noted above, the hob moulding system (61) includes two sidewall components (65) and these are arranged in a side by side relationship and they form the sides of the box section and of the raised hob produced using the hob moulding system (61).
The shape of the two horizontal components (63) is produced by profile cutting sheet metal stock to meet the architects shape requirements. The upper member (69) is identical in overall shape to the base member (67). In figure 3 the upper member (69) is shown having a short straight section at each end, and a radiused curve in the centre section. However, it is envisaged that the upper member (69) and the base member (67) could have any shape, for example a “U” shape or a wavy shape.
Each sidewall component (65) is an elongate component in the form of a wide strip of sheet metal having a top edge (71) that is parallel to a bottom edge (73). Each sidewall component (65) is gently curved to match the shape of the curved edges of the upper member (69) and the base member (67). Both the top edge (71) and the bottom edge (73) of each sidewall component (65) are structurally attached by welding to the curved edges of the two horizontal components (63) to form the curved box section form shown in figures 3 and 4. The width of the strip that forms the upper member (69) and the base member (67) determines the height of the raised hob formed by the hob moulding system (61).
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The upper member (69) and the base member (67) each have large openings in the form of rectangular holes (75) cut in them, and in fact more than half of the area defined by each horizontal component (63) is cutaway. The cut-outs do not extend to the edges of the horizontal components (63) however, and bridging sections (77) remain between adjacent rectangular holes (75), the bridging sections (77) spanning between opposite edges.
The rectangular holes (75) allow concrete to be poured into the hob moulding system (61), and they allow the concrete within the hob moulding system (61) to be mix with, and cure with, the concrete of the rest of the floor slab.
In the figures it can be seen that the hob moulding system (61) includes a number of spacer members (79) which span between the sidewall components. The spacer members (79) include a vertical web portion which spans between the sidewall components (65), this vertical web portion containing a hole (80) to allow the concrete on either side of each spacer member (79) to join up to give the raised hob greater uniformity and strength. The spacer members (79) can be secured in place by welding them to the horizontal components (63) and the sidewall components (65).
Figure 5 shows an alternative spacer member design (81) which includes a horizontal base tab (83) that can include at least one fastener hole. Such a design is useful when creating a raised hob on an existing floor slab. The spacer member (81) can be structurally secured to the existing floor slab using suitable masonry fastening systems, and this way the raised hob becomes structurally secured to the existing floor slab when it is later poured and cured.
As an alternative to the use of the spacer members (79 or 81), or in addition, gussets of the type described in the first example could also be used within the hob moulding system (61) to help keep the sidewall components (65) at a specified angle (usually right angles) to the base member (67). As with the spacer members (79 or 81), the gussets could be welded in place.
The hob moulding system (61) can also include a plurality of supports of the type shown and described with reference to the set down moulding system (11) and figures 1 and 2.
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The supports perform the same function as the supports (33) of the first example in that they support the hob moulding system (61) at a predetermined height above a floor of a formwork structure for producing a concrete floor slab.
VARIATIONS
To those skilled in the art to which the invention relates, many changes in construction and widely differing embodiments and applications of the invention will suggest themselves without departing from the scope of the invention as defined in the appended claims. The disclosures and the description herein are purely illustrative and are not intended to be in any sense limiting.
DEFINITIONS
Throughout this specification the word comprise and variations of that word, such as comprises and comprising, are not intended to exclude other additives, components, integers or steps.
ADVANTAGES
Thus it can be seen that at least the preferred form of the invention provides a moulding system for surface profiling of poured concrete slabs which can be produced relatively simply in a factory using profile cutting equipment. The cutting equipment can be programmed using data from the engineering drawings to produce highly accurate curved moulds.
These pre-formed moulds can then be used on construction sites to quickly assemble the required formwork to produce a suitably profiled concrete slab to accurately meet the designer’s specifications.

Claims (5)

1. A moulding system for surface profding of poured concrete slabs, the moulding system having;
• one or more horizontal components made of sheet steel that have one or
5 more curved edges, and • one or more sidewall components made of sheet steel that are curved to match the or each curved edge of the or each horizontal component;
and the or each sidewall component is structurally attached to the or each horizontal component along at least one curved edge of the or each horizontal
10 component.
2. A moulding system as claimed in claim 1, wherein the shape of the or each horizontal component is produced by profile cutting a shape of the or each horizontal component from sheet metal stock, and the or each sidewall component is an elongate component with a top edge that is parallel to a bottom edge.
15
3. A moulding system as claimed in claim 1 or claim 2, wherein the moulding system further includes a plurality of supports configured to support the or each horizontal component at a predetermined height above a floor of a formwork structure for producing a concrete floor slab.
4. A set down moulding system for producing step changes in the height of a
20 concrete floor slab, wherein the set down moulding system incorporates the features of the moulding system for surface profiling of poured concrete slabs as claimed in any one of claims 1 to 3, and the set down moulding system includes at least one horizontal component which forms a base member of the set down moulding system, and includes at least one sidewall component which defines the
25 magnitude of the step change in height that is produced by the set down moulding system.
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5. A hob moulding system for producing a raised hob formation on a concrete floor slab, wherein the hob moulding system incorporates the features of the moulding system for surface profiling of poured concrete slabs as claimed in any one of claims 1 to 3, and the hob moulding system includes at least two horizontal
5 components which form a base member of the hob moulding system and an upper member of the hob moulding system, and includes at least two sidewall components that are arranged in a side by side relationship and which form the sides of the raised hob.
AU2019101285A 2019-09-16 2019-10-24 Moulding System for Surface Profiling of Poured Concrete Slabs Active AU2019101285A4 (en)

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AU2019229459A AU2019229459B2 (en) 2019-09-16 2019-09-16 Moulding System for Surface Profiling of Poured Concrete Slabs
AU2019101285A AU2019101285A4 (en) 2019-09-16 2019-10-24 Moulding System for Surface Profiling of Poured Concrete Slabs

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AU2014277653B1 (en) * 2014-12-10 2016-03-24 Pantano Investments Pty Ltd Creation of Curved or Circular Hobs in Cast-in-Situ Concrete Slabs

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