AU2021107220A4 - A pod for forming waffle slabs - Google Patents

Abstract

The present invention is a pod used in the construction of concrete foundations of buildings. The pod comprises a plurality of intersecting planes of material used to form a grid structure and a tray of material formed with folded intersecting edges. The grid structure is inserted within the tray to form a tray to support the concrete in the foundation. 3/4 Figure 4 F r30 Figure 5

Description

3/4

Figure 4

F r30 Figure 5

A POD FOR FORMING WAFFLE SLABS TECHNICAL FIELD

[0001] The present invention relates to the building industry and, more particularly a pod support structure for concrete formwork in waffle slab building foundations.

BACKGROUND

[0002] Polystyrene pods are commonly used as formwork for concrete foundations of buildings. An example of a such prior polystyrene pod 10 is shown in figure 1 on the back of a truck 12. Most polystyrene pods are 1.09 m2 in area, with a height of around 22.5 cm and width of around 1.09 m. The pods are bulky. They take up a large amount of volume in the delivery vehicle and on the building site.

[0003] As shown in figure 2, the pods are arranged around the defined area for the foundation of the building. The area is surrounded by wooden formwork 14 and steel mesh 16 is placed over the polystyrene pods 10. Workers 18 then pour concrete 20 over the mesh 16 and polystyrene pods 10 to form a "waffle" foundation for the building.

[0004] There are many problems with polystyrene. Styrene is one of the main ingredients used to make polystyrene pods and it is carcinogenic. Many of the chemicals used in the manufacturing process of polystyrene are toxic. Emissions from polystyrene factories pollute the air, and the liquid and solid waste produced need disposal. Polystyrene requires about 500 years to decompose as it is resistant to photolysis (the breaking down of materials by photons originating from light). The amount of polystyrene waste that accumulates is colossal. Another reason that polystyrene is harmful for the environment is that it is made with petroleum, which is a non-sustainable resource. Furthermore, the bright white polystyrene reflect a lot of sunlight which can cause glare and bum the skin of workers on site.

[0005] The object of the present invention is to provide a means of supporting steel mesh during the construction of building foundations which does not require the use of polystyrene.

SUMMARY OF THE INVENTION

[0006] According to a first aspect of the present invention, there is provided a pod used in the construction of concrete foundations of buildings, the pod comprising:

(a) a plurality of intersecting planes of material used to form a grid structure; and (b) a tray of material formed with folded intersecting edges, wherein the grid structure is inserted within the tray to support the concrete in the foundation.

[0007] Preferably, the material is cardboard, but may also be plastic, fibreglass, a composite fibre material, hard rubber, or any other suitable material.

[0008] The tray is preferably formed from a single sheet of material and the sides of the sheet are cut and joined with hook and eye connections.

[0009] The planes preferably intersect along regularly spaced incisions along the edge of each plane.

[0010] According to a second aspect of the present invention, there is provided a method of forming a building foundation, the method comprising:

(a) forming a grid structure of intersecting planes of material; (b) inserting the grid structure within trays to form pods; (c) inverting the pods on the ground; and (d) pouring concrete into channels between the pods and over the pods so as to envelope the pods and thereby form the foundation.

[0011] Any of the features described herein can be combined in any combination with any one or more of the other features described herein within the scope of the invention.

BRIEF DESCRIPTION OF DRAWINGS

[0012] Embodiments of the invention will be described with reference to the following drawings, in which:

[0013] Figure 1 is an illustration of a truck carrying prior art polystyrene pods used to form conventional concrete slabs for building foundations.

[0014] Figure 2 is an illustration of the prior art polystyrene pods of figure 1 during formation of a conventional concrete slab.

[0015] Figure 3 is a perspective view of an assembled pod according to an embodiment of the present invention for the construction of concrete foundations of buildings.

[0016] Figure 4 is a perspective view of a grid structure of intersecting planes inside the pod of figure 3.

[0017] Figure 5 is a perspective view of a tray holding the grid structure of figure 4.

[0018] Figure 6 is a side view of an individual plane shown intersecting in the grid figure 4.

[0019] Figure 7 is a top view of a tray offigure 5 in collapsed form.

DETAILED DESCRIPTION

[0020] A pod 22 according to an embodiment of the present invention is shown in figure 1. The pod 22 has a plurality of intersecting planes 24 of cardboard (see figure 6), which intersect along regularly spaced lines 26 to form a grid 28 (as shown in figure 4). The grid 28 is inserted within a tray 30 (see figure 5), which is formed from a sheet 32 of cardboard (see figure 7). The sheet 32 has a base 34 with folded side walls 36 and end walls 38. The side walls 36 have folded edges 40 with eye slits 42 and the end walls 38 have hook slits 44, which are connected to form the tray 30 as shown in figure 5.

[0021] On site, the sheets 32 are formed into trays 30 and the planes 24 are formed into the grid 28. The grid 28 is placed into the tray 30 to form the pods 22. The pods 22 are inverted on the ground and positioned in rows. The pods 22 are separating the pods by spacers (not shown). Reinforcing mesh 16 is positioned on chairs 46 over the pods 22. Concrete is poured into channels between the pods 22 and over the pods 22 to envelope the pods 22 and mesh 16 and thereby form the foundation for the building.

[0022] The pods 22 thereby provide a means of supporting steel mesh during the construction of building foundations which does not require the use of polystyrene.

Concluding Remarks

[0023] In the present specification and claims (if any), the word 'comprising' and its derivatives including 'comprises' and 'comprise' include each of the stated integers but does not exclude the inclusion of one or more further integers.

[0024] Reference throughout this specification to 'one embodiment' or 'an embodiment' means that a particular feature, structure, or characteristic described in connection with the embodiment is included in at least one embodiment of the present invention. Thus, the appearance of the phrases 'in one embodiment' or 'in an embodiment' in various places throughout this specification are not necessarily all referring to the same embodiment. Furthermore, the particular features, structures, or characteristics may be combined in any suitable manner in one or more combinations.

[0025] In compliance with the statute, the invention has been described in language more or less specific to structural or methodical features. It is to be understood that the invention is not limited to specific features shown or described since the means herein described comprises preferred forms of putting the invention into effect. The invention is, therefore, claimed in any of its forms or modifications within the proper scope of the appended claims (if any) appropriately interpreted by those skilled in the art.

Claims (5)

1. A pod used in the construction of concrete foundations of buildings, the pod comprising:

(a) a plurality of intersecting planes of material used to form a grid structure; and (b) a tray of material formed with folded intersecting edges, wherein the grid structure is inserted within the tray to support the concrete in the foundation.

2. The pod of claim 1, wherein the material is cardboard.

3. The pod of claim 1, wherein the tray is formed from a single sheet of material and the sides of the sheet are cut and joined with hook and eye connections.

4. The pod of claim 1, wherein the planes intersect along regularly spaced incisions along the edge of each plane.

5. A method of forming a building foundation, the method comprising:

(a) forming a grid structure of intersecting planes of material; (b) inserting the grid structure within trays to form pods; (c) inverting the pods on the ground; and (d) pouring concrete into channels between the pods and over the pods so as to envelope the pods and thereby form the foundation.