AU2020200564A1 - Integrated formwork method for concrete structures - Google Patents
Integrated formwork method for concrete structures Download PDFInfo
- Publication number
- AU2020200564A1 AU2020200564A1 AU2020200564A AU2020200564A AU2020200564A1 AU 2020200564 A1 AU2020200564 A1 AU 2020200564A1 AU 2020200564 A AU2020200564 A AU 2020200564A AU 2020200564 A AU2020200564 A AU 2020200564A AU 2020200564 A1 AU2020200564 A1 AU 2020200564A1
- Authority
- AU
- Australia
- Prior art keywords
- steel shell
- exterior steel
- reinforced concrete
- concrete structure
- formwork
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Pending
Links
Classifications
-
- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
- E04B2/00—Walls, e.g. partitions, for buildings; Wall construction with regard to insulation; Connections specially adapted to walls
- E04B2/84—Walls made by casting, pouring, or tamping in situ
- E04B2/86—Walls made by casting, pouring, or tamping in situ made in permanent forms
- E04B2/8635—Walls made by casting, pouring, or tamping in situ made in permanent forms with ties attached to the inner faces of the forms
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B28—WORKING CEMENT, CLAY, OR STONE
- B28B—SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
- B28B23/00—Arrangements specially adapted for the production of shaped articles with elements wholly or partly embedded in the moulding material; Production of reinforced objects
- B28B23/02—Arrangements specially adapted for the production of shaped articles with elements wholly or partly embedded in the moulding material; Production of reinforced objects wherein the elements are reinforcing members
- B28B23/18—Arrangements specially adapted for the production of shaped articles with elements wholly or partly embedded in the moulding material; Production of reinforced objects wherein the elements are reinforcing members for the production of elongated articles
-
- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
- E04B1/00—Constructions in general; Structures which are not restricted either to walls, e.g. partitions, or floors or ceilings or roofs
- E04B1/16—Structures made from masses, e.g. of concrete, cast or similarly formed in situ with or without making use of additional elements, such as permanent forms, substructures to be coated with load-bearing material
- E04B1/161—Structures made from masses, e.g. of concrete, cast or similarly formed in situ with or without making use of additional elements, such as permanent forms, substructures to be coated with load-bearing material with vertical and horizontal slabs, both being partially cast in situ
-
- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
- E04B2/00—Walls, e.g. partitions, for buildings; Wall construction with regard to insulation; Connections specially adapted to walls
- E04B2/84—Walls made by casting, pouring, or tamping in situ
- E04B2/86—Walls made by casting, pouring, or tamping in situ made in permanent forms
- E04B2/8658—Walls made by casting, pouring, or tamping in situ made in permanent forms using wire netting, a lattice or the like as form leaves
-
- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04G—SCAFFOLDING; FORMS; SHUTTERING; BUILDING IMPLEMENTS OR AIDS, OR THEIR USE; HANDLING BUILDING MATERIALS ON THE SITE; REPAIRING, BREAKING-UP OR OTHER WORK ON EXISTING BUILDINGS
- E04G11/00—Forms, shutterings, or falsework for making walls, floors, ceilings, or roofs
- E04G11/06—Forms, shutterings, or falsework for making walls, floors, ceilings, or roofs for walls, e.g. curved end panels for wall shutterings; filler elements for wall shutterings; shutterings for vertical ducts
- E04G11/08—Forms, which are completely dismantled after setting of the concrete and re-built for next pouring
- E04G11/12—Forms, which are completely dismantled after setting of the concrete and re-built for next pouring of elements and beams which are mounted during erection of the shuttering to brace or couple the elements
- E04G11/16—Forms, which are completely dismantled after setting of the concrete and re-built for next pouring of elements and beams which are mounted during erection of the shuttering to brace or couple the elements with beams placed within the wall
-
- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
- E04B2/00—Walls, e.g. partitions, for buildings; Wall construction with regard to insulation; Connections specially adapted to walls
- E04B2/84—Walls made by casting, pouring, or tamping in situ
- E04B2/86—Walls made by casting, pouring, or tamping in situ made in permanent forms
- E04B2/8647—Walls made by casting, pouring, or tamping in situ made in permanent forms with ties going through the forms
-
- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
- E04B2/00—Walls, e.g. partitions, for buildings; Wall construction with regard to insulation; Connections specially adapted to walls
- E04B2/84—Walls made by casting, pouring, or tamping in situ
- E04B2/86—Walls made by casting, pouring, or tamping in situ made in permanent forms
- E04B2002/8694—Walls made by casting, pouring, or tamping in situ made in permanent forms with hinged spacers allowing the formwork to be collapsed for transport
-
- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04G—SCAFFOLDING; FORMS; SHUTTERING; BUILDING IMPLEMENTS OR AIDS, OR THEIR USE; HANDLING BUILDING MATERIALS ON THE SITE; REPAIRING, BREAKING-UP OR OTHER WORK ON EXISTING BUILDINGS
- E04G11/00—Forms, shutterings, or falsework for making walls, floors, ceilings, or roofs
- E04G11/06—Forms, shutterings, or falsework for making walls, floors, ceilings, or roofs for walls, e.g. curved end panels for wall shutterings; filler elements for wall shutterings; shutterings for vertical ducts
- E04G2011/067—Integrated forms comprising shuttering skin, bracing or strutting arrangements, workplatforms and railings
Abstract
5
A method of constructing an integrated formwork and reinforced concrete
structure 18 is described. The method comprises providing an exterior steel
shell 12 adapted to provide reinforcement and also to function as a formwork
for concrete. The exterior steel shell 12 includes a plurality of ties and
10 reinforcing elements 16 which also serve to maintain dimensional stability
prior to concrete placement. The method also comprises pouring concrete 14
into the exterior steel shell 12 and allowing it to cure to form a reinforced
concrete structure 18. In use, the exterior steel shell 12 forms a permanent
and integral component of the reinforced concrete structure 18. An
15 integrated formwork and reinforcement arrangement 10 for a reinforced
concrete structure is also provided.
Figure to accompany abstract: Figure 2
2-12
10
122
2iur 22
Description
2-12
10
122
2iur 22
Patents Act 1990
Invention title:
Applicant:
Lycopodium Minerals Pty Ltd
Associated Provisional Application No.: 2019901106
The following statement is a full description of the invention, including the best method of performing it known to me:
Field of the Invention
The present invention relates to an integrated formwork method and arrangement for reinforced concrete structures and relates more particularly, though not exclusively, to a steel exoskeleton forming an integrated (and combined) reinforcing steel and formwork assembly.
Background to the Invention
Conventional reinforced concrete design consists of concrete and reinforcement steel embedded in the concrete. Since concrete is a largely compression-only medium, reinforcing steel is added to the concrete to provide additional tensile and shear capacity. The location of the reinforcing steel within the concrete is critical to its effectiveness in that the steel must be located as far as possible from the neutral axis, notwithstanding the requirements for concrete cover (for durability purposes) , i.e. the reinforcing steel must be sufficiently covered and surrounded with concrete to protect it from corrosion.
Conventional formwork for reinforced concrete employs temporary wood or steel formwork panels which are designed and erected to ensure that all final dimensions and levels of the concrete are as required, and any cast-in items are correctly positioned. This formwork is not permanent but is demolished after the concrete is cured. Figure 1 illustrates a conventionally formed concrete structure with typical reinforcing steel for a reclaim tunnel.
There are a number of disadvantages associated with conventional reinforced concrete design and formwork methods. A typical current concrete reinforcement and formwork arrangement is characterised by:
• Complexity - a large number of individual pieces of steel reinforcing. This requires a large amount of cutting and bending on site, requiring on-site supervision and participation, and therefore has negative scheduling and direct cost impacts.
• Time consuming - the process of erecting the temporary formwork, and arranging, checking and verifying that all the pieces of steel reinforcing are in their correct position is extremely time-consuming and error-prone, with potential contractual and scheduling impacts.
• Scheduling restrictions - In general, work is restricted around the worksite because the formwork must remain in place while the concrete cures and gains strength, restricting the timing and scope of subsequent work which can be performed around the worksite.
The present invention was developed with a view to providing an integrated formwork and reinforcement method for concrete structures that is less susceptible to the above-noted disadvantages of conventional reinforced concrete design and construction methods.
References to prior art in this specification are provided for illustrative purposes only and are not to be taken as an admission that such prior art is part of the common general knowledge in Australia or elsewhere.
Summary of the Invention
According to one aspect of the present invention there is provided a method of constructing an integrated formwork and reinforced concrete structure, the method comprising:
providing an exterior steel shell adapted to provide reinforcement and also to function as a formwork for concrete, the exterior steel shell including a plurality of ties and reinforcing elements which also serve to maintain dimensional stability prior to concrete placement; and,
pouring concrete into the exterior steel shell and allowing it to cure to form a reinforced concrete structure wherein, in use, the exterior steel shell forms a permanent and integral component of the reinforced concrete structure.
Advantageously the method also comprises fabricating the exterior steel shell offsite and transporting it to a construction site.
Preferably the exterior steel shell is fabricated and transported in modules, and the step of providing the exterior steel shell comprises assembling the modules on site.
According to another aspect of the present invention there is provided an integrated formwork and reinforcement arrangement for a reinforced concrete structure, the arrangement comprising:
an exterior steel shell adapted to provide reinforcement and also to function as a formwork for concrete; and,
a plurality of ties and reinforcing elements fixed to the exterior steel shell which also serve to maintain dimensional stability prior to concrete placement,
wherein, in use, the exterior steel shell forms a permanent and integral component of the reinforced concrete structure.
Typically the exterior steel shell comprises first and second steel panels arranged a predetermined distance apart, forming a space within which the concrete will be placed to form the reinforced concrete structure, the steel panels being held in position by the plurality of ties and reinforcing members arranged in the space between the panels.
Advantageously the ties and reinforcing elements comprise shear studs which are adapted to resist shear forces in the reinforced concrete structure and at an interface between the concrete and exterior steel shell.
Preferably the durability of the exterior steel shell is improved either by increasing the thickness of the exterior steel shell via a corrosion allowance, or coating the external surface with a suitable surface finish, or some form of cathodic protection. The exterior steel shell grade is selected to best suit the application, i.e. grade 250, grade 350 or high strength steel.
Throughout the specification, unless the context requires otherwise, the word "comprise" or variations such as "comprises" or "comprising", will be understood to imply the inclusion of a stated integer or group of integers but not the exclusion of any other integer or group of integers. Similarly the word "preferably" or variations such as "preferred", will be understood to imply that a stated integer or group of integers is desirable but not essential to the working of the invention.
Brief Description of the Drawings
The nature of the invention will be better understood from the following detailed description of a specific embodiment of the integrated formwork and reinforcement method for concrete structures, given by way of example only, with reference to the accompanying drawings, in which: Figure 1 illustrates in cross-section view a conventional formwork structure shown with typical reinforcement for a reclaim tunnel; and,
Figure 2 is a cross-section view of a preferred embodiment of an integrated formwork and reinforcement concrete structure according to the present invention, in the form of a reclaim tunnel.
Detailed Description of Preferred Embodiments
A preferred embodiment of an integrated formwork and reinforcement arrangement 10 in accordance with the invention, for a reinforced concrete structure in the form of a reclaim tunnel as illustrated in Figure 2, comprises an exterior steel shell 12 which also functions as a formwork for concrete 14. The integrated formwork and reinforcement arrangement 10 further comprises a plurality of ties and reinforcing elements 16 which also serve to maintain dimensional stability prior to concrete placement. In use, after pouring and curing of the concrete 14, the exterior steel shell 12 forms a permanent and integral component of the reinforced concrete structure, in this case a reclaim tunnel 18.
Typically the exterior steel shell 12 comprises first and second steel panels 20a and 20b arranged a predetermined distance apart. The steel panels are typically manufactured from steel plate of a strength grade selected to best suit the application, i.e. grade 250, grade 350 or high strength steel. High tensile steel may also be used for the exterior steel shell 12 where required as indicated by analysis. The steel panels 20a and 20b form a space within which the concrete 14 will be placed to form the reinforced concrete structure 18. The steel panels 20 are held in position by the plurality of ties and reinforcing members 16 arranged in the space between the panels 20. In the illustrated embodiment, a plurality of first and second steel panels 20 are provided in both vertical and horizontal orientations to form the side walls and roof of the integrated formwork arrangement 10 for the reclaim tunnel 18.
Advantageously the ties and reinforcing elements comprise shear studs 16 which are adapted to resist shear forces in the reinforced concrete structure 18 and at an interface between the concrete 14 and the exterior steel shell 12. The shear studs 16 are typically also manufactured from high grade steel, and are fixed to inside surfaces of the respective first and second steel panels 20a and 20b, e.g. by welding or bolting.
In the illustrated embodiment the integrated formwork and reinforcement arrangement 10 also comprises a base plate 22, fixed to a bottom of each vertical wall. In this embodiment, the base plates 22 are cast into a concrete base 24 for the reclaim tunnel 18.
Preferably the durability of the exterior steel shell 12 is improved either by increasing the thickness of the exterior steel shell via a corrosion allowance, or coating the external surface with a suitable surface finish, or some form of cathodic protection. A suitable paint can be applied for corrosion protection immediately prior to placement of concrete if required.
A preferred method of constructing an integrated formwork and reinforced concrete structure will now be described with reference to Figure 2. The method comprises providing an exterior steel shell 12 adapted to provide reinforcement and also to function as a formwork for concrete. The integrated formwork and reinforcement arrangement 10 includes a plurality of ties and reinforcing elements 16 fixed to the exterior steel shell 12 which also serve to maintain dimensional stability prior to concrete placement. Advantageously the method also comprises fabricating the integrated formwork and reinforcement arrangement 10 offsite and transporting it to a construction site. This reduces the time to erect the formwork on-site and minimises scheduling impacts.
The integrated formwork and reinforcement arrangement 10 is preferably fabricated and transported in modules, and the step of providing the exterior steel shell 12 comprises assembling the modules on-site. Dimensional stability is guaranteed prior to arrival on-site, therefore no on-site checking is required, only assembly.
The method further comprise pouring concrete into the exterior steel shell 12 on-site and allowing it to cure to form a reinforced concrete structure 18. In use, the exterior steel shell 12 forms an integral component of the reinforced concrete structure 18, effectively forming an exoskeleton for the concrete structure 18. This means that the external dimensions of the concrete structure, in this example reclaim tunnel 18, set the external dimensions of the exterior steel shell 12, and the total volume of concrete required to be poured is proportionally reduced. Less concrete results in direct cost savings, whilst the reduction in volume also has a positive schedule impact as the time required to pour the concrete is reduced.
No stripping of the formwork after the concrete has cured is required, because the exterior steel shell is permanent. This saves time, and also access to the immediate part of the site is available earlier allowing further savings to the schedule for ongoing work.
Now that preferred embodiment of the integral formwork method and structure have been described in detail, it will be apparent that the described embodiment provides a number of advantages over the prior art, including the following:
(i) The conventional formwork requirement is eliminated since the reinforcement is the formwork. This positively affects direct costs and schedule. (ii) Reduced complexity in placement of steel reinforcement positively impacts schedule and minimises expensive labour for construction and supervision in complex areas. Significant schedule benefits can be achieved by obviating site cutting and bending of steel reinforcement. (iii) No stripping of temporary formwork positively impacts schedule and allows immediate access for other trades on-site. (iv) Offsite fabrication of the exterior steel shell, incorporating a plurality of ties and reinforcing members, also positively impacts schedule and minimises disruption to on-site construction. (v) The method can be applied to a concrete structure of any desired shape.
It will be readily apparent to persons skilled in the relevant arts that various modifications and improvements may be made to the foregoing embodiments, in addition to those already described, without departing from the basic inventive concepts of the present invention. For example, the number, type and size of the plurality of ties and reinforcing elements included in connection with the exterior steel shell may vary significantly from that shown in the illustrated embodiment. Therefore, it will be appreciated that the scope of the invention is not limited to the specific embodiment described.
Claims (8)
1. A method of constructing an integrated formwork and reinforced concrete structure, the method comprising:
providing an exterior steel shell adapted to provide reinforcement and also to function as a formwork for concrete, the exterior steel shell including a plurality of ties and reinforcing elements which also serve to maintain dimensional stability prior to concrete placement; and,
pouring concrete into the exterior steel shell and allowing it to cure to form a reinforced concrete structure wherein, in use, the exterior steel shell forms a permanent and integral component of the reinforced concrete structure.
2. A method of constructing an integrated formwork and reinforced concrete structure as defined in claim 1, wherein the method also comprises fabricating the exterior steel shell offsite and transporting it to a construction site.
3. A method of constructing an integrated formwork and reinforced concrete structure as defined in claim 2, wherein the exterior steel shell is fabricated and transported in modules, and the step of providing the exterior steel shell comprises assembling the modules on site.
4. An integrated formwork and reinforcement arrangement for a reinforced concrete structure, the arrangement comprising:
an exterior steel shell adapted to provide reinforcement and also to function as a formwork for concrete; and,
a plurality of ties and reinforcing elements fixed to the exterior steel shell which also serve to maintain dimensional stability prior to concrete placement,
wherein, in use, the exterior steel shell forms a permanent and integral component of the reinforced concrete structure.
5. An integrated formwork and reinforcement arrangement as defined in claim 4, wherein the exterior steel shell comprises first and second steel panels arranged a predetermined distance apart, forming a space within which the concrete will be placed to form the reinforced concrete structure, the steel panels being held in position by the plurality of ties and reinforcing members arranged in the space between the panels.
6. An integrated formwork and reinforcement arrangement as defined in claim 4 or claim 5, wherein the ties and reinforcing elements comprise shear studs which are adapted to resist shear forces in the reinforced concrete structure and at an interface between the concrete and exterior steel shell.
7. An integrated formwork and reinforcement arrangement as defined in any one of claims 4 to 6, wherein the durability of the exterior steel shell is improved either by increasing the thickness of the exterior steel shell via a corrosion allowance, or coating the external surface with a suitable surface finish, or some form of cathodic protection.
8. An integrated formwork and reinforcement arrangement as defined in claim 7, wherein the exterior steel shell grade is selected to best suit the application from grade 250, grade 350 or high strength steel.
Dated this 24th day of January 2020
Lycopodium Minerals Pty Ltd by its Patent Attorneys WRAYS
Applications Claiming Priority (2)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| AU2019901106A AU2019901106A0 (en) | 2019-04-01 | Integrated formwork method for concrete structures | |
| AU2019901106 | 2019-04-01 |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| AU2020200564A1 true AU2020200564A1 (en) | 2020-10-15 |
Family
ID=72750339
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| AU2020200564A Pending AU2020200564A1 (en) | 2019-04-01 | 2020-01-24 | Integrated formwork method for concrete structures |
Country Status (1)
| Country | Link |
|---|---|
| AU (1) | AU2020200564A1 (en) |
-
2020
- 2020-01-24 AU AU2020200564A patent/AU2020200564A1/en active Pending
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