AU781538B2 - Method and apparatus for erecting formwork for the manufacture of a slab of settable material - Google Patents

Description

AUSTRALIA

Patents Act 1990 COMPLETE SPECIFICATION STANDARD PATENT Applicant(a): KATINA PTY LTD A.C.N. 009 007 701 Invention Title: METHOD AND APPARATUS FOR ERECTING FORMWORK FOR THE MANUFACTURE OF A SLAB OF SETTABLE MATERIAL The following statement is a full description of this invention, including the best method of performing it known to me/us: 2 Method and Apparatus for Erecting Formwork for the Manufacture of a Slab of Settable Material Field of the Invention The present invention relates to a method and apparatus for erecting formwork for the manufacture of a settable material such as, but not limited to, concrete and also to a method of manufacturing slabs of settable material using such apparatus.

Background of the Invention Slabs of settable material such as concrete are widely used in the construction industry for example as prefabricated walls or wall floor panels. These slabs are typically manufactured using wooden beams, window box or metal shutters locked together to form a box section to nominal heights 600, 700, 800 mm high depending on the nominal size of the wall panel required. The box sections are nailed, screwed, bolted, braced or locked together to define boundary area into which concrete is poured to form a slab.

Typically, the slabs are manufactured in a stacked fashion with one slab being formed on top of another. This is achieved by vertically dividing by way of metal, plastic or wood strips, skirting or batons nailed or screwed to the box once an underlying slab has sufficiently set.

The construction of the formwork is a slow and tedious process, which is further exacerbated if it is required to form the slab in a shape other than rectangular and/or having one or more diagonal edges.

Summary of the Invention It is an object of the present invention to provide an apparatus and method that attempts to reduce the time taken to erect formwork used in the manufacture of a slab of settable material.

H:\terryr\Keep\Speci\METHOD AND APPARATUS FOR ERECTING FORMNORK FOR THE MANUFACTURE OF A SLAB OF SETTABLE MATERIAL COCPLETE.doc 3 According to one aspect of the present invention there is provided an apparatus for use in the erecting of formwork for the manufacture of a slab of settable material, said apparatus including at least: a bracket adapted for attachment to a surface; and, a framework support means adjustably coupled to said bracket in a manner to allow adjustment of the position of said framework support means in at least a horizontal plane; whereby, in use, a formwork member can be coupled to said formwork support means and positioned in a horizontal plane in a desired location to define an edge of a slab of a settable material.

Preferably said formwork support means is adjustably coupled to said bracket in a manner to also allow adjustment of the position of said formwork support means in a vertical plane.

Preferably said bracket includes an upright to which said formwork support means is coupled.

Preferably said upright is provided with an elongated channel or slot to which said 20 formwork support means is coupled.

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Preferably said apparatus further includes clamping means for selectively clamping said formwork support means to said upright within said slot.

25 Preferably said clamping means includes a pair of co-acting elements each coupled to said formwork support means on opposite sides of said upright wherein said elements can be moved relatively toward each other along said formwork support means to clamp said formwork support means to said upright and, can be moved relatively away from each other along said formwork support means to release said formwork support means from said upright to whereby the position of said formwork member can be adjusted in said vertical and/or horizontal planes.

H:\terryr\Keep\Speci\METHOD AND APPARATUS FOR ERECTING FORMWORK FOR THE MANUFACTURE OF A SLAB OF SETTABLE MATERIAL COMHPLETE.doc 4 In one embodiment each of said elements is in the form of a nut or turnbuckle threadingly engaged on said formwork support means.

In an alternate embodiment one of said elements is a nut or turnbuckle threading engaged on said formwork support means and another of said elements is an abutment means coupled to said formwork support element.

Preferably said other of said elements includes one or more packer means adopted for disposition between said abutment means and said upright, whereby the position of said formwork member can be adjusted in said horizontal plane and said upright by adjustment of the position of said nut or turnbuckle along said formwork support means.

Preferably said formwork support means includes an elongated threaded rod and said 15 co-acting elements threadingly engage said rod.

Preferably said formwork support means further includes a plate attached to an end of said rod adjacent a slab being manufactured and to which said formwork member can be coupled.

Preferably said apparatus further includes a threaded collar fixed at one end to said plate and threadingly engaged with said one end of said rod, for attaching said plate to said rod.

25 Preferably said apparatus further includes one or more clips for releasably coupling a formwork member to said plate.

According to a further aspect of the present invention there is provided a method of erecting the formwork for the manufacture of a slab of settable material including the steps of: H:\terryr\Keep\Speci\METHOD AND APPARATUS FOR ERECTING FORMWORK FOR THE MANUFACTURE OF A SLAB OF SETTABLE MATERIAL COMPLETE.doc 5 providing a plurality of apparatus according to the first aspect of the present invention; attaching said brackets to a surface at spaced apart locations about a perimeter; attaching a formwork member to the formwork support means of at least a number of said brackets; adjusting the position of said formwork support means so that said formwork members attached thereto define a bound area in which settable material can be poured to form a slab.

Brief Description of the Drawings Embodiments of the present invention will now be described by way of example only in which: Figure 1 is an elevation view of an apparatus for erecting formwork in accordance 15 with first embodiment of the present invention; Figure 2 is a plane view of a bracket incorporated in the apparatus shown in Figure 1; Figure 3 is a side view of the bracket shown in Figure 2; Figure 4 is an enlarged end view of a formwork support incorporated in the 20 apparatus depicted in Figure 1; Figure 5 is a side view of a second embodiment of the apparatus for erecting formwork; and Figure 6 is a schematic representation in plan of a plurality of the apparatus as shown in Figure 1 arranged for the manufacture of a plurality of stacked 25 slabs of settable material.

Description of Preferred Embodiment Referring to the accompanying drawings, and in particular to Figures 1-4, an apparatus for erecting formwork for the manufacture of a slab of settable material such as concrete is shown as including a bracket 12 adaptable for attachment to a surface such as the ground 14 and a framework support 16 adjustably coupled to the bracket 12 in a H:\terryr\Keep\Speci\METHOD AND APPARATUS FOR ERECTING FORWORK FOR THE MANUFACTURE OF A SLAB OF SETTABLE MATERIAL COMPLETE.doc 6 manner that allows adjustment of the position of the support 12 in a horizontal plane. A formwork member in the form of a strip 18 can be coupled to the support 16 and positioned in a horizontal plane at a desired location to delimit an edge of a slab of concree.

The bracket 12 includes a leg or upright 20 having a foot 22 extending transversely from one end. The upright 20 is provided with an elongated axially extending slot 24. The slot 24 has opposite ends 26 and 28 that are disposed inboard of lower end 30 and upper end 32 respectively of the upright 20. As depicted in Figure 2, two transversely extending flanges 34 and 36 are attached to an underside of the foot 22. The flanges 34 and 36 are provided with respective holes 38 on opposite sides of the foot 20. When the apparatus is in use, bolts (not shown) are passed through the holes 38 to fix the apparatus 10 to the ground 14.

The support 16 includes an elongated threaded rod 40 that extends through the slot 24 is coupled to a plate 42 (shown most clearly in Figure An internally threaded collar 44 is attached at one end to one side of the plate 42. The thread in the collar 44 is of a complimentary configuration to the thread on the rod 40 to allow the collar 44 to be screwed onto the rod 40 thus coupling the plate 42 to the rod.

The apparatus 10 further includes a clamp 46 for selectively clamping and releasing the support 16/rod 40 to the upright 20. The clamp 46 includes co-acting turnbuckles 48 and 50 which threadingly engage the rod 16 on opposite sides of the upright 20/slot 24.

By screwing the turnbuckles 48 and 50 relatively towards each other along the rod 16, 25 the clamp 16 can effectively clamp the rod 40 in a desired position. By screwing the turnbuckles 48 and 50 relatively away from each other along the rod the clamp 46 is released to allow a repositioning of the rod 40. It will be appreciated that when the clamp 46 is released, the rod 40 can be moved vertically along this slot 24. Also, by appropriate screwing of the turnbuckles 48 and 50 the rod 16 can also be moved in a horizontal plane, ie in a direction transverse to the slot 24.

H:\terryr\Keep\Speci\METHOD AND APPARATUS FOR ERECTING FORMWORK FOR THE MANUFACTURE OF A SLAB OF SETTABLE MATERIAL COMPLETE.doc 7 Figure 4 depicts a spring clip 52 incorporated in the apparatus 10 for releasably attaching a formwork strip 18 to the plate 42. The clip 52 is in the form of a shaped length of spring steel having a pair of opposing free ends 54 that are biased toward each other in between which the formwork strip 18 and plate 42 can be gripped. Typically several clips 52 would be used to releasably attach a formwork strip 18 to a plate 42.

It is envisaged that the formwork strips 18 will be made from shaped steel and preferably with inwardly inclined longitudinal edges 56 to form corresponding bevels along opposite edges of the sides of a slab manufactured using the apparatus 10. The formwork strips 18 can also typically be made of a length longer than the plate 42 to which they are attached and can conveniently come in a range of widths.

Figure 5 depicts a further embodiment of the apparatus 10, for erecting formwork. In this embodiment, features which have the same or similar construction or function as those described in relation to the embodiment depicted in Figures 1-4 are denoted by the same reference numbers. The apparatus 10, differs from the apparatus 10 depicted in Figures 1-4 by replacement of the turnbuckle 48 where the abutment in the form of C sectioned member 50'. The member 50, abuts against the upright 20 and can be held in 20 place by turning of the nut or turnbuckle 48 along the threaded rod 40. The horizontal position of the strip 18 can be varied by either replacing the member 50, with another member 50, of different dimension. Alternately, and arguably more practical, the apparatus 10, can further include one or more packers (not shown) which can be placed between the member 50, and the upright 20 in order to vary the position, in a horizontal *e 25 plane, of the strip 18. The packers can, for example, take the form of strips of wood which are placed in a vertical orientation on opposite sides of the rod 40 between the upright 20 and the member 50, and then locked into place by appropriate screwing of the turnbuckle 48. By using strips of wood of different thickness, it would be appreciated that the position, in the horizontal plane, of the strip 18 can be varied. The variation of the position of the strip 18 in the vertical plane was achieved in the same H:\terryr\Keep\Speci\METHOD AND APPARATUS FOR ERECTING FORMWORK FOR THE MANUFACTURE OF A SLAB OF SETTABLE MATERIAL COMPLETE.doc 8 manner as described in relation to the apparatus 10 shown in Figures 1-4. In a further minor variation, in this embodiment, the plate 18 is attached to the plate 42 by tek screws rather than by a clip 52 as depicted in Figure 4.

In all other respects, the operation and function of the apparatus 1Oa is the same as that described therein before in relation to the apparatus Figure 6 depicts eighteen apparatuses 1 Oa-1 Or arranged about a rectangular perimeter with a pair of opposing sides having five apparatuses 10 each and another pair of opposing sides having four apparatuses 10 each. The brackets 12 are bolted to the ground by use of bolts passing through the holes 38 in flanges 34 and 36. In the illustrated embodiment, the apparatuses 10 are used for the manufacture of a slab of concrete of a generally rectangular shape but having two diagonal edges. To this end, a formwork strip 18 is attached to the plate 42 of each apparatus 10 except apparatus I Oa 15 and 1 On. The formwork strips 18 are positioned to form an enclosed boundary for the pouring of the concrete. In the drawing, a small gap is shown between adjacent sheets 18. This is for illustrative purposes only. The plates 42 of the apparatuses 1Oo and lOr are configured so as to extend at an included angle of around 45° to the respective rods This can be easily achieved by attaching the collar 44 to the plate 42 at a 450 angle.

A slab of concrete can be manufactured by simply pouring concrete into the area bound by the abutting formwork strips 18 and allowing the concrete to set. After the concrete has sufficiently set, the clamps 46 can be released to allow retraction of the rods leaving the concrete slab. As with conventional concrete slab manufacture, one or more 25 hooks or couplings can be embedded in the concrete during manufacture to assist in lifting when in use.

In order to manufacture a second slab on top of the first, the rods 40 are slid upwardly along respective slots 24 and then moved in the horizontal direction as required in order to define the shape of the next slab to be manufactured. Of course if the slab is to be the same shape as the one previously made, there is no need to vary the horizontal position H:\terryr\Keep\Speci\METHOD AND APPARATUS FOR ERECTING FORMWORK FOR THE MANUFACTURE OF A SLAB OF SETTABLE MATERIAL COMPLETE. doc 9 of the rods 40, all that is required is to slide the rods 40 upwardly in the vertical direction so as to create a boundary for the next slab to be made. The next slab is then poured directly onto the previous set slab. This process can be continued for the height of the uprights If it is desired to form a slab of a particular shape above a lower slab which extends beyond the perimeter of the lower slab, blanks of appropriate shape, typically made from wood, can be used to provide an underlying support surface for the overhanging portion of the upper slab.

It will be appreciated from the above description that embodiments of the present invention enjoy numerous advantages over the prior art. Most significantly, the present invention allows the very quick erection of formwork for the manufacture of concrete slabs and other slabs of settable material. It is very quick and easy to change the 15 configuration of a slab to be made by simply adjusting the position of the rods 40 in the direction of their length, ie in the horizontal plane. Also, plates 42 can be provided in a number of different configurations to provide various angles for the creation of diagonal or sloping edges of a slab. Slabs can be easily manufactured one on top of the other by simply vertically adjusting the position of the rods It will also be apparent to those skilled in the relevant arts that numerous variations and modifications may be made without departing from the basic inventive concepts. For example, the clamp 46 is depicted as comprising a pair of co-acting turnbuckles 48 and However other types of clamping mechanisms such as cam-like clamps can be used.

25 Also, if desired, the plates 42 can be permanently fixed to the rods 40. However this will require a complete replacement of both the rod 40 and plate 42 if it is required to support a strip 18 at an angle different to the rod 40/plate 42 at hand. Further, the bracket 12 can be attached or fastened to the ground or other support surface by any conventional means.

H:\terryr\Keep\Speci\METHOD AND APPARATUS FOR ERECTING FORNWORK FOR THE MANUFACTURE OF A SLAB OF SETTABLE MA:ERIAL COMPLETE. doc 10 All such modifications and variations together with others that would be obvious to a person of ordinary skill in the art are deemed to be within the scope of the present invention the nature of which is to be determined from the above description.

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Claims (16)

1. An apparatus for use in the erecting of formwork for the manufacture of a slab of settable material, said apparatus including at least: a bracket adapted for attachment to a surface; and, a framework support means adjustably coupled to said bracket in a manner to allow adjustment of the position of said framework support means in at least a horizontal plane; whereby, in use, a formwork member can be coupled to said formwork support means and positioned in a horizontal plane in a desired location to define an edge of a slab of a settable material.

2. The apparatus according to Claim I wherein said formwork support means is 15 adjustably coupled to said bracket in a manner to also allow adjustment of the position of said formwork support means in a vertical plane.

3. The apparatus according to Claim 2 wherein said bracket includes an upright to which said formwork support means is coupled.

4. The apparatus according to Claim 3 wherein said upright is provided with an elongated channel or slot to which said formwork support means is coupled.

5. The apparatus according to Claim 3 or 4 further including clamping means for 25 selectively clamping said formwork support means to said upright within said slot.

6. The apparatus according to Claim 5 wherein said clamping means includes a pair of co-acting elements each coupled to said formwork support means on opposite sides of said upright wherein said elements can be moved relatively toward each H:\terryr\Keep\Speci\METHOD AND APPARATUS FOR ERECTING FORMNORK FOR THE MANUFACTURE OF A SLAB OF SETTABLE MATERIAL COMPLETE.doc 12 other along said formwork support means to clamp said formwork support means to said upright and, can be moved relatively away from each other along said formwork support means to release said formwork support means from said upright whereby the position of said formwork member can be adjusted in said vertical and/or horizontal planes.

7. The apparatus according to Claim 6 wherein each of said elements is in the form of a nut or turnbuckle threadingly engaged on said formwork support means.

8. The apparatus according to Claim 6 wherein one of said elements is a nut or turnbuckle threading engaged on said formwork support means and another of said elements is an abutment means coupled to said formwork support element.

9. The apparatus according to Claim 8 wherein said other of said elements includes 15 one or more packer means adopted for disposition between said abutment means and said upright, whereby the position of said formwork member can be adjusted in said horizontal plane by clamping of packers of different dimension between said abutment means and said upright by adjustment of the position of said nut or turnbuckle along said formwork support means.

The apparatus according to any one of Claims 1-9 wherein said formwork support means includes an elongated threaded rod and said co-acting elements threadingly engage said rod. 25

11. The apparatus according to Claim 10 further including a plate attached to an end of said rod adjacent a slab being manufactured and to which said formwork member can be coupled.

12. The apparatus according to Claim 11 further including a threaded collar fixed at 3 0 one end to said plate and threadingly engaged with said one end of said rod, for attaching said plate to said rod. H:\terryr\Keep\Speci\METHOD AND APPARATUS FOR ERECTING FRMWORK FOR THE MANUFACTURE OF A SLAB OF SETTABLE MATERIAL COMPLETE.doc -13-

13. The apparatus according to Claim 12 further including one or more clips for releasably coupling a formwork member to said plate.

14. A method of erecting the formwork for the manufacture of a slab of settable material including the steps of: providing a plurality of apparatus according to any one of the Claims 1 to 13; attaching the brackets of each apparatus to a surface at spaced apart locations about a perimeter; attached respective formwork member to the formwork support means of at least some of said brackets to define a bound area within said perimeter and in which said settable material can be poured to forma slab.

An apparatus for use in the erecting of formwork substantially herein described with reference to and as illustrated by the accompanying drawings.

16. A method of erecting formwork substantially herein described with reference •to and as illustrated by the accompanying drawings. DATED THIS 8TH DAY OF MARCH 2005. "Katina Pty Ltd By its Patent Attorneys LORD AND COMPANY PERTH, WESTERN AUSTRALIA. a