AU2020203328A1

AU2020203328A1 - Wall footing formwork structure

Info

Publication number: AU2020203328A1
Application number: AU2020203328A
Authority: AU
Inventors: Daniel PSZCZONKA
Original assignee: Rise Form Pty Ltd
Current assignee: Rise Form Pty Ltd
Priority date: 2019-05-20
Filing date: 2020-05-21
Publication date: 2020-12-10

Abstract

A footing formwork structure for constructing a footing with a flowable curable material like concrete, the footing formwork structure including: a base; a top portion; and at least one support extending between the base and top portion; wherein the base and top portion substantially define a footing volume therebetween, and wherein the top portion includes a wall mount region above which at least one wall formwork element is to be mounted, the wall mount region including at least one aperture therein such that, on depositing curable material into a mounted wall formwork element, the curable material is permitted to flow through the at least one aperture into the footer volume. 1/4 Figure 1 1 3 7 89 12 11 4 5 6 10 2 10 12 11

Description

1/4 Figure 1

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WALL FOOTING FORMWORK STRUCTURE

Field of the invention

[001] The present invention relates to a wall footing formwork structure, and method of implementing same.

Background of the invention

[002] Construction of a foundation wall often first requires the placement of a footing. Being of a larger footprint than the wall, the footing acts to spread the weight of the wall across a greater area. Footings are thus important where the wall is heavy and/or the soil has a low bearing capacity.

[003] In conventional methods, footings are generally constructed in an ad hoc manner. At first instance, a trench or hole roughly the size of the footing required is dug out at the building site. Thereafter, optionally, timber formwork is placed around the outer perimeter of the trench. Reinforcement elements, typically steel bars, are positioned within the trench before concrete is poured into trench to form the footing slab. Formwork for the foundation walls is subsequently placed on the footing slab and the foundation walls poured.

[004] These conventional methods have several disadvantages. In the first instance, it can be onerous to place the footer formwork around the perimeter of the trench as it often comprises multiple timber panels that need to be secured together. Furthermore, during placement, surrounding soil is often displaced into the footing trench. Conventional methods also require a two-step concrete pouring process where the footing is poured first and allowed to harden before the wall is poured.

[005] The present invention seeks to address at least some of the above mentioned disadvantages associated with conventional wall and footing construction methods.

[006] Any reference herein to known prior art does not, unless the contrary indication appears, constitute an admission that such prior art is commonly known by those skilled in the art to which the invention relates, at the priority date of this application.

Summary of the invention

[007] In one broad form, the present invention provides a footing formwork structure for constructing a footing with a flowable curable material like concrete, the footing formwork structure including: a base; a top portion; and at least one support extending between the base and top portion; wherein the base and top portion substantially define a footing volume therebetween, and wherein the top portion includes a wall mount region above which at least one wall formwork element is to be mounted, the wall mount region including at least one aperture therein such that, on depositing curable material into a mounted wall formwork element, the curable material is permitted to flow through the at least one aperture into the footer volume.

[008] In one form, the top portion further includes at least one indicator aperture located outside the wall mount region. In one form, the wall mount region includes at least one guide member to guide placement of the wall formwork element.

[009] In one form, the footing formwork structure further includes one or more side walls extending between the base and top portion. In one form, the footing volume is substantially encased by the base, the top portion, and a plurality of side walls. In one form, the base and top portion are substantially planar, parallel and co-extensive.

[010] In one form, the structure is formed of a polymer or polymer composite material.

[011] In one form, the structure is an assembly assembled at least partially of a plurality of connectable formwork modules. In one form, the connectable formwork modules are connectable to each other via tool-less engagement. In one form, the connectable formwork modules are connectable to each other via snap engagement.

[012] In one form, the connectable formwork modules are each single extruded pieces.

[013] In one form, the connectable formwork modules are formed of a polymer material.

[014] In a further broad form, the present invention provides a method for constructing a wall with a footing including the steps of: excavating a footing bed; placing a footing formwork structure as described in any one of the above forms into the footing bed; mounting one or more wall formwork elements to the mount region of the footing formwork structure; and pouring a flowable curable material, like concrete, into the wall formwork element.

[015] In a further broad from, the present invention provides a kit for constructing a footing formwork structure, the kit including: a plurality of connectable formwork modules, that, when assembled, form a footing structure as described in any one of the above forms. In one form, the kit further includes a wall formwork element configured to be mounted to the wall mount region of the footing formwork structure.

Brief description of the drawings

[016] A detailed description of a preferred embodiment will follow, by way of example only, with reference to the accompanying figures of the drawings, in which:

[017] Figure 1 shows a perspective view of one example of a wall footing formwork structure according to the invention;

[018] Figure 2 shows a perspective view of one example of a connectable formwork element (expanded form) that may be implemented in the assembly of a footing formwork structure as shown in figure 1;

[019] Figure 3 shows a perspective view of one example of a connectable formwork element (collapsed form) that may be implemented in the assembly of a footing formwork structure as shown in figure 1;

[020] Figure 4 shows a partial top view of one example of a connectable formwork element (expanded form) that may be implemented in the assembly of a footing formwork structure as shown in figure 1;

[021] Figure 5 shows a partial top view of one example of a connectable formwork element (collapsed form) that may be implemented in the assembly of a footing formwork structure as shown in figure 1;

[022] Figure 6 shows a side view of one example of a wall formwork element mounted to a wall mount region of a wall footing formwork structure according to one example of the invention; and

[023] Figure 7 shows an enlarged side view of one example of engagement between connectable formwork modules, including a water proofing material at the join.

Detailed description of the embodiment or embodiments

[024] Embodiments of the invention provide a footing formwork structure for constructing a footing for a wall from a flowable curable material like, for example, concrete. The footing formwork structure includes a base, a top portion, and at least one support extending between the base and top portion. The base and top portion substantially define a footing volume therebetween,

[025] The top portion includes a wall mount region above which at least one wall formwork element is to be mounted. The wall mount region includes at least one aperture therein such that, on depositing curable material into a mounted wall formwork element, the curable material is permitted to flow through the at least one aperture into the footer volume. This permits that a footing and supporting wall can be poured at the same time.

[026] It will be appreciated that the curable material may take a variety of forms, such as, for example, concrete. In the description of the embodiments that follow, concrete will be referred to as the curable material.

[027] The top portion may also include at least one indicator aperture located outside the wall mount region. This provides that, during pouring of the concrete, a builder can observe the level of concrete in the footing structure at various points across its area. Furthermore, when the concrete reaches the level of an indicator aperture or begins to emerge therefrom, it indicates/confirms to the worker that that area of the footing is sufficiently full with concrete. The indicator apertures also provide access points for workers to insert concrete vibrators at different areas of the footing so as to evenly disperse the concrete in the footing.

[028] To facilitate placement of the wall formwork element at the wall mount region of the footing formwork structure, the wall mount region may also include at least one guide element, to guide placement of the wall formwork element. In one embodiment, the mount region includes linear tracks or walls that guide placement.

[029] Optionally, the footing formwork structure includes one or more side walls extending between the base and top portion to at least partially enclose the footing volume.

[030] In example use of the footing formwork structure, typically a footing bed/trench is first excavated, and then a formwork structure as described herein placed in the bed/trench. If the footing formwork structure is of the form that has no side walls, the walls of the trench bed act as the boundary side walls of the footer volume. Alternatively, if the footing formwork structure is of the form that incudes side walls, these would act as the side wall boundary of the footer volume. The inclusion of one or more side walls has advantages in that soil from the bed/trench walls is prevented from collapsing into the footing volume, which can reduce the integrity of the footing.

[031] In one preferred form, the footing volume is substantially encased by the base, the top portion, and a plurality of side walls. Generally, the base and top potion are substantially planar, parallel and co-extensive. The at least one support member typically elevating the top portion above the base (which usually rests on the soil) providing the footer volume therebetween. It will be appreciated that, in some forms, the support member may comprise one or more side walls extending between the base and top portion, and there may not be any additional members extending between the non periphery body portions of the base and top portion.

[032] It will be appreciated the footing formwork structure may be formed of a variety of materials, such as, for example, metal, wood, polymer or composite materials. Preferably, the structure is formed of a polymer or polymer composite material like, for example, Polyvinyl Chloride or Polypropylene. Polymer forms have weight as well as manufacturing advantages. When formed of a polymer material, the structure or component parts thereof may be extruded. It will also be appreciated that the footing formwork structure may be formed of a single piece or assembled from multiple components.

[033] In one example, the structure may be an assembly assembled at least partially of a plurality of connectable formwork modules. It will be appreciated that the modules may be like modules or modules that vary in shape and functionality. For example, the modules may be main body pieces, end pieces, corner pieces, wall mount region pieces/track modules etc. Typically, the connectable formwork modules are connectable to each other via tool-less engagement. For example, the connectable formwork modules may be connectable to each other via snap engagement. In some examples, the connectable formwork modules may include a water proofing material at the join between modules, such as, for example, a sealant, swelling material, and/or a hygroscopic or water absorbing material (e.g. a bentonite clay). In one example, the connectable formwork modules that make up the footing formwork structure are each single extruded pieces. Generally, the connectable formwork modules are formed of a polymer material or polymer composite material.

[034] It will be appreciated that the footing formwork structure allows for more expedient and less ad hoc formation of a footing and associated wall or the like. Therefore, embodiments of the invention also provide a method for constructing a wall with a footing. For example, in general, the method would typically include the steps of:

1. excavating a footing bed or trench; 2. placing the footing formwork structure as described herein into the footing bed or trench; 3. mounting one or more wall formwork elements to the mount region of the footing formwork structure; and 4. pouring a flowable curable material, like concrete, into the wall formwork element.

[035] It will also be appreciated that the footing formwork structure may be provided in kit form to be, for example, assembled at a building site. Thus embodiments of the invention also provide a kit for constructing a footing formwork structure, the kit including a plurality of connectable formwork modules, that, when assembled, form a footing structure as described herein. Optionally, for example, the kit may further including one or more wall formwork elements configured to be mounted to the mount region of the footing formwork structure.

[036] One preferred form of the footing formwork structure is shown in figure 1. In this example, the footing formwork structure (1) includes a base (2) and a top portion (3) and a plurality of supports (4) extending therebetween. The base (2) and top portion (3) substantially define a footing volume (5) therebetween. The top portion (3) includes a wall mount region (6), above which, at least one wall formwork element (e.g. 100) can be mounted. The wall mount region (6) includes a plurality of apertures (7) therein. This way, when concrete or the like is deposited into a mounted wall formwork element, it is permitted to flow though the apertures (7) into the footing volume (5).

[037] The top portion (3) further includes a plurality of indicator apertures (8) located outside the wall mount region (6). This allows that as concrete (or other curable material) is filled into the footing volume (5), a builder can assess the filling level through the indicator apertures (8). For example, as concrete reaches the aperture (8) level or emerges therefrom, a builder knows that that region of the footing volume (5) is filled sufficiently. The indicator apertures (8) also provide an access point for the footing volume (5) for a builder to insert a concrete vibrator into the footing volume (5) (i.e. with a view to evenly dispersing the mix).

[038] The base (2) and top portion (3) are substantially planar (it will be appreciated that the top portion includes apertures and mounting elements etc.), parallel and co-extensive, defining the footing volume (5) therebetween. The wall mount region (6) includes linear guide walls (9) to guide placement of a wall formwork element (e.g. 100). The wall formwork element (e.g.100) may be, for example, further secured to the guide walls (9) using fasteners like screws or the like. In some examples, the linear guide walls (9) may be provided as part of a separate track module to be secured to the wall mount region (6), For example, the track module may resemble the shape of typical C-beam, having a base that extends between two side walls (i.e. the linear guide walls (9). The base of the track module having apertures therein that would align to the apertures (7) of the wall mount region (6) when the track module is mounted thereto.

[039] As shown in figure 6, a water proofing material (16) may be located at the inner sides of the linear guide walls, so as to facilitate water proofing between a wall formwork element (e.g. 100) mounted within the linear guide walls (9). The water proofing material may, for example, be located at the join between the wall mount region (6) and a mounted wall formwork element or between, for example, the inner sides of the liner guide walls (9) and the outer surfaces of a mounted wall formwork element (e.g.100). The waterproofing material may, for example, be a sealant, a swelling material, and/or a hygroscopic/water absorbing material. In one preferred form, the waterproofing material is a bentonite clay. As shown in figure 6, the placement of the water proofing material at the inner side of linear guide walls (9) typically stop a water flow path as indicated by arrow (W).

[040] The footing formwork structure (1) also includes side walls (10) extending between the base (2) and top portion (3). The walls (10) help to prevent soil from the bed/trench from collapsing into the footing volume (5).

[041] In this example, the structure (1) is an assembly assembled from a plurality of connectable formwork modules (e.g. 100). The connectable formwork modules are connectable to each other via tool-less engagement. Cooperating male and female connection elements (11, 12) allow for snap engagement between modules. As shown in figure (7) the female connection elements (12) may also include a water proofing material (18) therein (e.g. a bentonite clay or the like), to facilitate water proofing of the join between modules.

[042] Figures 2 to 5 show more detail of one example of a connectable formwork module (100) that be combined with other modules to form the footing formwork structure. The module (100) includes a pair of opposing side wall panels (102, 103) and a plurality of connectors (104) extending between the panels (102, 103). When used to form the footing formwork structure (1), the connector members (104) ultimately become the supports (4).

[043] The formwork module (100) is collapsible. It is movable between an expanded configuration, wherein the opposing panels (102, 103) are spaced apart, and a collapsed configuration wherein the opposing panels (102, 103) are relatively closer together. Movement between the expanded and collapsed configurations is permitted by two hinge portions (105) in the connector members (104). Operation of the hinge portions (105) is most clearly shown in Figures 4 and 5, which show partial top views of the module (100). The hinge portions (105) are formed of a material that is more flexible in nature than the remainder of connector member (104). In other forms the hinge portions may be provided by a thinning in the connector members (104). It will be appreciated that, in alternate forms, other modules may be implemented to form the formwork structure (1) that are not collapsible.

[044] As also evident from figures 4 and 5, the connector members (4) are releasably engaged to the opposing side panels (102, 103) via a sliding engagement with slots (108) in the panels (102, 103). The slots (108) in the panels (102, 103) being configured to receive respective opposite hinged ends (10) of connector members (104). It will be appreciated that this releasable engagement permits components of the formwork module (e.g. connector members, side wall panels etc.) to be manufactured separately. Furthermore, it will be appreciated that as the components have a fixed cross sectional profile, they are particularly suited for manufacture by extrusion.

[045] The connector members (104) and side panels (102, 103) are typically formed of one or more suitable polymer materials, such as, for example, Polypropylene or Polyvinyl Chloride (PVC). In some instances, during assembly, the slots (108) of the panels are heated before or as the hinged ends (110) are slid in. This causes less stress to the components during assembly, and a more secure engagement on cooling (as the ends (10) can be sized slightly larger and slot walls are more able to flex).

[046] The connector members (104) take the form of apertured centre panels (or webs) having hinged ends (110) that are configured to be engaged with the side wall panels (102, 103). The panel apertures (107) have wave-like top and bottom edges (109) to provide options for placement of steel reinforcement rods/bars or the like. The rods/bars to can be placed at different troughs in the wave like edges (109). The panel apertures (107) are typically punched into the connector member panels (104) after extrusion.

[047] In the expanded configuration, the panels (104) extend substantially perpendicular to the side wall panels (102, 103) so as to provide substantially rectangular channels (118) in the concrete-receiving volume (106) of the formwork module (or volume (5) when part of the larger footing structure (1)). During filling, the apertures (107) in the connector member panels (104) provide a path for concrete to flow between the rectangular channels (118) of the element (100). As shown, the connector member panels (104) also extend substantially entirely between ends (100a, 100b) of the module (100).

[048] Furthermore, when the module (100) is moved into the expanded configuration, it snap locks/engages into position such that it cannot easily be returned to the collapsed configuration without human intervention. Seen most clearly in figures 3 and 4, snap lock engagement is provided by hook (or barbed) tabs (120) that extend from the connector member panels (104). The hook tabs (120) are configured to engage with corresponding catch projections (121) at the side wall panels, as the connector member (104) moves into the expanded configuration. The hook tabs (120) being flexible yet resilient, slide over the lip of the catch projections (121) during movement into the expanded configuration, before snapping into place, and hooking on to the catch projection (121). Movement into the collapsed configuration is thus substantially prevented by engagement between hook tabs (120) and catch projections (121). It will be appreciated the embodiment as described allows expansion in a single movement (i.e. the module is 'popped' open in a single movement and then maintains the expanded form due to the snap locking/engagement).

[049] In this example, the opposing side wall panels (102, 103) include a main outer wall (114) and a plurality of braced inner walls (115) that extend between the slots (108) for receiving the connector members (104). The internal walls (115) provide separation between the main concrete filling cavity (106 or 5 when part of the footing structure) and the outer walls (114) of the panels (102, 103).

[050] The internal walls (115) are connected to the outer walls (114) of the panels (102, 103) adjacent the walls of the slots (108) and via their bracing legs (116). The brace legs (116) extend substantially orthogonal from the outer wall (114) of side panels (102, 103), and divide the area between the internal wall (115) and outer wall

(114) to provide multiple channels/voids (117). It will be appreciated the channel/voids (117) travel between the ends of the element (100) in the same direction as the slots (108). The braced internal wall (115) helps to redirect and/or distribute pressure from received concrete along the outer wall (114) so as to minimise bulging.

[051] In some forms, the channels/voids (117) may be filled with an insulating material, such as insulating foam. The insulating material may be deposited into the channels/voids (117) in a variety of ways. As noted above, the wall panels (102, 103) are typically produced by an extrusion process whereby the main panel material is extruded through a mould. Any insulating material may be deposited into the channel/voids (117) during the extrusion process. To allow this, an outlet/pipe is built into the mould head through which the insulating material is ejected at the same extrusion rate as the main panel material. After extrusion, there is a cooling process whereby the main panel material stiffens, and the insulating material expands to fill the channels/voids (117). Typically, the cooling process is provided by cooling water tanks. When PVC is the panel material, it typically takes about 3 minutes to stiffen during cooling, and typically, any expansion of the insulation material occurs more slowly and does not act to distort the shape of the side panels (102, 103).

[052] It will be appreciated that the module (100) as described in figures 2 to 5, is only one example of a connectable formwork module that may be used to form the footing formwork structure (1). As shown in figure 1, modules that include the mount region (6) may be modified versions of the module (100) shown in figures 2 to 5 and, the side walls (10) are simply end or cap pieces with suitable male and female connection elements (11, 12).

[053] It will also be appreciated that the module (100), as described in figures 2 to 5, may be implemented as a wall formwork element that could be mounted to the wall mount region (6) of the footing formwork structure (1). It will also be appreciated that typically, when implemented as part of the footing formwork (1), the module (100) would be oriented substantially horizontally (i.e. substantially parallel to trench/bed surface) such that the panels (102,103) form part of the base (2), and top portion (3) of the footing structure (1). In such cases, modifications may be made to the module (100), such as, for example, to adjust the apertures (107) so that the wave-like edges are those edges closer to the panels (102, 103). This would allow apertures (107) to more suitably hold/place reinforcement bars/rods placed in the apertures (107) in the footing volume.

[054] It is clear how the presently described footing formwork structure and method of implementing same addresses disadvantages related to conventional methods of footing construction. In particular, the footing and associated wall can be poured at the same time, trench/bed wall collapse can be prevented, and assembly from modular snap fitting elements reduces time and tools required when compared to ad-hoc formwork assembly from timber.

[055] It will also be appreciated that the footing formwork structure as described herein may also be more generally implemented as a general building element, and may or may not be filled with material, to form part of a temporary or permanent structure. Furthermore, the filling material, if used, may vary, and may not be curable, For example, other filling materials may include sand, soil, a stiffening material, or a liquid (e.g. water).

[056] Where ever it is used, the word "comprising" is to be understood in its "open" sense, that is, in the sense of "including", and thus not limited to its "closed" sense, that is the sense of "consisting only of". A corresponding meaning is to be attributed to the corresponding words "comprise", "comprised" and "comprises" where they appear.

[057] It will be understood that the invention disclosed and defined herein extends to all alternative combinations of two or more of the individual features mentioned or evident from the text. All of these different combinations constitute various alternative aspects of the invention.

[058] While particular embodiments of this invention have been described, it will be evident to those skilled in the art that the present invention may be embodied in other specific forms without departing from the essential characteristics thereof. The present embodiments and examples are therefore to be considered in all respects as illustrative and not restrictive, and all modifications which would be obvious to those skilled in the art are therefore intended to be embraced therein.

Claims

1. A footing formwork structure for constructing a footing with a flowable curable material like concrete, the footing formwork structure including: a base; a top portion; and at least one support extending between the base and top portion; wherein the base and top portion substantially define a footing volume therebetween, and wherein the top portion includes a wall mount region above which at least one wall formwork element is to be mounted, the wall mount region including at least one aperture therein such that, on depositing curable material into a mounted wall formwork element, the curable material is permitted to flow through the at least one aperture into the footer volume.

2. A footing formwork structure as claimed in claim 1, wherein the top portion further includes at least one indicator aperture located outside the wall mount region.

3. A footing formwork structure as claimed in claim 1 or 2, wherein the wall mount region includes at least one guide member to guide placement of the wall formwork element.

4. A footing formwork structure as claimed in any one of claims 1 to 3, further including one or more side walls extending between the base and top portion.

5. A footing formwork structure as claimed in claim 4, wherein the footing volume is substantially encased by the base, the top portion, and a plurality of side walls.

6. A footing formwork structure as claimed in any one of the preceding claims, wherein the base and top portion are substantially planar, parallel and co extensive.

7. A footing formwork structure as claimed in any one of the preceding claims, the structure being formed of a polymer or polymer composite material.

8. A footing formwork structure as claimed in any one of the preceding claims, where in the structure is an assembly assembled at least partially of a plurality of connectable formwork modules.

9. A footing formwork structure as claimed in claim 8, wherein the connectable formwork modules are connectable to each other via tool-less engagement.

10. A footing formwork structure as claimed in claim 8 or 9, wherein the connectable formwork modules are connectable to each other via snap engagement.

11. A footing formwork structure as claimed in any one of claims 8 to 10, wherein the connectable formwork modules are each single extruded pieces.

12. A footing formwork structure as claimed in any one of claim 8 to 11, wherein the connectable formwork modules are formed of a polymer material.

13. A method for constructing a wall with a footing including the steps of: excavating a footing bed; placing a footing formwork structure as claimed in any one of claims 1 to 12 into the footing bed; mounting one or more wall formwork elements to the mount region of the footing formwork structure; and pouring a flowable curable material, like concrete, into the wall formwork element.

14. A kit for constructing a footing formwork structure, the kit including: a plurality of connectable formwork modules, that, when assembled, form a footing structure as claimed in any one of claims 1 to 12.

15. A kit as claimed in claim 14, further including a wall formwork element configured to be mounted to the wall mount region of the footing formwork structure.