CA2243905C - Oil canning resistant element for modular concrete formwork systems - Google Patents

Oil canning resistant element for modular concrete formwork systems Download PDF

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Publication number
CA2243905C
CA2243905C CA 2243905 CA2243905A CA2243905C CA 2243905 C CA2243905 C CA 2243905C CA 2243905 CA2243905 CA 2243905 CA 2243905 A CA2243905 A CA 2243905A CA 2243905 C CA2243905 C CA 2243905C
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Canada
Prior art keywords
formwork
flat wall
wall segment
segment
flat
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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.)
Expired - Fee Related
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CA 2243905
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French (fr)
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CA2243905A1 (en
Inventor
David Richardson
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GLOBAL ENGINEERING TRUST
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THE GLOBAL ENGINEERING TRUST
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Priority to CA 2243905 priority Critical patent/CA2243905C/en
Publication of CA2243905A1 publication Critical patent/CA2243905A1/en
Application granted granted Critical
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Classifications

    • EFIXED CONSTRUCTIONS
    • E04BUILDING
    • E04BGENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
    • E04B2/00Walls, e.g. partitions, for buildings; Wall construction with regard to insulation; Connections specially adapted to walls
    • E04B2/84Walls made by casting, pouring, or tamping in situ
    • E04B2/86Walls made by casting, pouring, or tamping in situ made in permanent forms
    • E04B2/8635Walls made by casting, pouring, or tamping in situ made in permanent forms with ties attached to the inner faces of the forms
    • E04B2/8641Walls made by casting, pouring, or tamping in situ made in permanent forms with ties attached to the inner faces of the forms using dovetail-type connections

Abstract

A thin-walled, flexible element made of PVC (or other material subject to heat expansion) for use in stay-in-place modular concrete formwork is characterized by at least one longitudinally extending reinforcing projection or rib to prevent oil canning of the element. Preferably the projection or rib has a surface which is perpendicular to the wall formed by the formwork. The invention is particularly adapted for use where the concrete is not in direct contact with the portion of the element which is to be reinforced, such as when a layer of insulation is interposed between the element and the concrete.

Description

TITLE OF THE INVENTION
OIL CANNING RESISTANT ELEMENT FOR MODULAR
CONCRETE FORMWORK SYSTEMS
FIELD OF THE INVENTION
This invention relates to the structure of an element for a stay-in-place modular concrete formwork system.
BACKGROUND OF THE INVENTION
Stay-in-place modular concrete formwork systems are relatively well known.
Such systems typically include a plurality of vertical modular elements which are designed to interconnect to create a wall of formwork into which concrete is poured and is allowed to cure and such systems are exemplified by Piccone, PCT/CA95/00281 (WO
96/35845), Nessa, United States Patent No. 5,216,863 and Rodighiero, Canadian Patent No.
957,816.
It is also well known to fabricate the modular elements out of polyvinylchloride (PVC).
PVC is well suited to modular formwork systems due to its light weight, which contributes to reducing transportation costs, its relative ease of manufacture into the particular shapes required for a given system, and its resiliency and flexibility to accommodate deformation when the concrete is being poured and contraction of the concrete as it cures.
However, PVC tends to expand as it warms up. If lengths of PVC material are fixed at their ends and sides and are subjected to heat or warming, they will tend to "oil can", i.e.
buckle or ripple along their length. This problem has been recognized in the context of building siding panels made of PVC in which case the problem has been addressed by ensuring relatively loose engagement between interconnected panels as well as providing slidable engagement of the siding panels with the underlying surface.
In modular concrete formwork systems, once the concrete is poured, the weight of the concrete exerts a very strong expanding force on the joints of the formwork resulting in very tight engagement between the various elements. Once the concrete cures, the joints become essentially fixed and allow no movement between adjoining elements.
Moreover, the formwork elements are also usually constrained at the top by a roof or other such structure and at the bottom by a footing on which the wall and formwork rests.
As a result each element of the formwork becomes effectively fixed both along its sides and at its ends. When such formwork made of relatively thin PVC is erected, a subsequent rise in temperature can cause the formwork elements to undergo unsightly oil canning along their length. This problem tends to occur only when the concrete is not in direct contact with the element, such as when a layer of insulation is interposed between the element and the concrete in an exterior wall, and the inventors believe that the reason the problem does not occur when the concrete is in direct contact with the element is due to the concrete presenting a rigid physical barrier against rippling of the element.
We are not aware of any prior art which offers a solution to the problem of oil canning in the context of relatively thin stay-in-place PVC modular formwork systems, and it is therefore an object of this invention to provide a modular formwork element which resists oil canning even when it is not in direct contact with concrete.
SUMMARY OF THE INVENTION
The invention comprises an element for use in a stay-in-place modular formwork system for pouring concrete which is thin walled, flexible, and made of a material which tends to expand when subjected to heat. In one aspect of the invention, the element has at least one flat wall segment for use in defining a substantially flat outside wall of the formwork, and comprises at least one lengthwise rib extending at an angle, preferably perpendicularly, from the flat wall segment.
In another aspect of the invention, the element has engagement means at its longitudinal edges and a substantially flat wall segment extending between said engagement means, comprising at least one lengthwise rib extending at an angle from the flat wall segment.
In another aspect of the invention, the element comprises a segment defining the visible portion of the erected formwork bounded by two longitudinal edges and said segment having at least one curved wall portion, and at least one lengthwise rib extends from the curved wall portion substantially perpendicularly to the plane defined between the two longitudinal edges.
In another aspect of the invention, the element comprises a portion defining a visible surface of said formwork. The portion comprises a plurality of longitudinally continuous flat sections each of which is angularly disposed in relation to the next adjacent section.
In another aspect of the invention, the element is made of PVC, is of a thickness of between about 1 and about 2 millimeters and the lengthwise ribs or element edges are spaced every 80 millimeters or less along the width of the flat wall segment of the element. In another aspect of the invention, the element further comprises at least one inwardly extending structure for abutting against a layer of insulation, and preferably said structure is such a rib.
The invention also comprises a method of use of the elements in an assembly of formwork in which the concrete is not in direct contact with the wall segment which includes the rib, and a method of use in which a layer of insulation is interposed between the concrete and the flat wall segment.
Other aspects of the invention are described in the detailed description of the best mode and preferred embodiment below and in the claims.
Brief Description of the Drawings Other aspects of the invention will be evident from the following disclosure and description of the preferred embodiment by reference to the drawings in which:
Figure 1 is a plan view of a prior art assembly of formwork illustrating wall elements, connecting members and cross connecting elements to produce a wall;
Figure 2 is an end view of an element according to the preferred embodiment of the invention;
Figure 3 is an end view of an alternative embodiment of an element according to the invention;
Figure 4 is an end view of another embodiment of an element according to the invention;
Figure 5 is an end view of a further embodiment of an element according to the invention.
DETAILED DESCRIPTION OF THE BEST MODE
AND PREFERRED EMBODIMENT
Our commonly owned Canadian Patent Application No. 2,218,600 filed 17 October entitled "Modular Formwork Elements and Assembly" discloses a modular formwork system designed to overcome the problem of bulging of wall elements resulting from the outward pressure of the concrete. This outward bulging of individual wall elements, when compounded across several such elements forming a wall of formwork, produces an "accordion" effect tending to shorten the lateral width of the formwork after it has been erected and to thereby dislocate it from the surfaces to which the sides of the formwork were secured.
The system, illustrated generally in Figure l, relies on the use of connecting members 10 which serve to simultaneously connect adjacent and facing wall elements 12, 14, 16, 18.
Two T-shaped connectors 20, 22 are provided along the longitudinal (vertical) extent of each wall element in spaced relationship to the longitudinal edges of the wall elements.
Each of the two T-shaped connectors are located about 40 millimeters from each longitudinal edge of a wall element. A relatively larger central space 24 extended between the two T-shaped connectors 20, 22. Similar T-shaped connectors 26 are provided on the connecting member 10 and a cross connecting element 28 extends diagonally between a portion of the wall element 14 and a connecting member.
The foregoing structure substantially avoids the problem of bulging and accordion effect at wall 11.
Where the elements of Figure 1 are used for an exterior wall, a layer of insulation 36 is interposed between the flat wall elements 16, 18 and the concrete. In such case, no cross connecting elements 28 are used and the wall elements typically do not include T-connectors. We have observed that in some such cases, notably in warmer climates, oil canning occurs across the flat wall elements 16, 18.
We have conducted testing to determine whether oil canning would occur in an insulated wall if a wall element having T-connectors (such as elements 12, 14) was used rather than a flat wall element such as elements 16, 18. We have observed that oil canning occurs in the central space 24 between the two T-shaped connectors. On the other hand, there is substantially no oil canning effect in the spaces 30, 32 between each connector and their adjacent longitudinal edges.
The inventors have found that the remaining oil canning along the length of the central space 24 can also be avoided by including a longitudinal projection or rib 34 along the center of the central space 24, as illustrated in Figure 2. While no other element need necessarily be connected to such projection 34, it has been found that the presence of the projection effectively solves the oil canning problem, particularly if the rib includes a surface (such as at 35) which is perpendicular to the wall element.
In the embodiment illustrated in Figure 2, the projection 34 is in the same T-shaped configuration as the connectors 20, 22. However, while the T-shape is used in the preferred embodiment, it is understood that any inward or outward longitudinal projection would achieve the same effect of preventing oil canning.
We have found that when wall elements having a thickness of about 1 to 2 millimeters are used, a sufficient number of projections or ribs should be provided along the width of the element such that there is either an edge of the element or a rib spaced at 80 millimeters or less.
The longitudinal projection preferably extends perpendicularly to the plane of the major surface of the wall element, but the lack of perpendicularity may be compensated by the thickness of the extension or by providing a plurality of such non-perpendicular extensions, as illustrated in the embodiment of Fig. 3. Fig. 3 illustrates a wall element 38 for use in conjunction with substantially the same connecting members 10 as in the embodiment of Fig. 1 to create a wall of formwork. However, according to this embodiment, rather than providing a continuous flat portion between the edges of the element as in the wall element of Fig. 2, a series of sharp changes in direction of the wall surface are provided resulting in diagonal wall sections 40, 42, 44 and 46, each being angularly disposed in relation to the next adjacent section.
While none of these wall sections are perpendicular, the cumulative effect of the diagonal sections and the sharp corners defining them is to provide significant resistance to oil canning.
In a variation on the embodiment of Fig. 3, such variation being illustrated in Fig. 4, additional perpendicular projections 48, 50 and 52 are provided centrally of the flat wall segments 54, 56 and 58 to thereby provide even further reinforcement. It will be appreciated that this arrangement allows the insulation to abut against the wall element without substantial interference from the projections.
A further alternative shape of a wall element embodying the invention is illustrated in Fig. 5. Wall element 60 comprises two flat portions 62, 64 adjacent the edges of the element, and a central curved portion 66. The curved portion provides depth to the element so as to accommodate three perpendicular projections 68, 70 and 72 according to the invention.
The embodiments of Figs. 3, 4 and 5 also provide useful noise attenuation properties due to the angled or curved portions of the walls as well as a pleasing external appearance to the completed formwork and the resulting wall.
While the embodiments described herein have all been for separate elements which define only the wall portion of the formwork, it will be appreciated that the invention is applicable to any wall forming portion of a modular formwork element, even if the element also includes non-wall forming components. Such would be the case for example with an element comprising a combined connecting member and wall defining surface, it being understood that the projections or ribs according to the invention would be located on the wall defining portion of the element.
Moreover, when the projections or ribs according to the invention abut against a layer of insulation, the resistance of the wall element to oil canning is further enhanced.. In addition insulation and the central connector appear to cooperate in providing increased resistance to bulging.
It will be appreciated by those skilled in the art that other variations of the preferred embodiment may also be practised without departing from the scope of the invention.

Claims (21)

1. An elongated element for use in a stay-in-place modular formwork system for pouring concrete, said element being thin walled, flexible, made of a material which tends to expand when subjected to heat and having at least one flat wall segment for use in defining a substantially flat outside wall of the formwork, comprising at least one lengthwise rib extending at an angle from said flat wall segment, wherein said material is PVC, said element is of a thickness of between 1 and 2 millimeters and has a sufficient number of said ribs along the width of said flat wall segment such that there is either a longitudinal edge of said flat wall segment or one of said ribs spaced at every 50 millimeters or less.
2. An element as in claim 1 wherein said rib includes a surface which is perpendicular in relation to said flat wall segment.
3. An element as in claim 2 wherein said element comprises accommodating means for accommodating a layer of insulation in contact with said flat wall segment.
4. An element as in claim 3 wherein said accommodating means comprises at least one inwardly extending structure for abutting against said insulation.
5. An element as in claim 4 wherein said structure is one of said ribs.
6. The use of an element, said element being thin walled, flexible, made of a material which tends to expand when subjected to heat and having engagement means at its longitudinal edges and a substantially flat wall segment extending between said engagement means, comprising at least one lengthwise rib extending at an angle from said segment, wherein said element is used in an assembly of formwork in which the concrete is not in direct contact with said flat wall segment.
7. The use of an element, said element being thin walled, flexible, made of a material which tends to expand when subjected to heat and having at least one flat wall segment for use in defining a substantially flat outside wall of the formwork, comprising at least one lengthwise rib extending at an angle from said flat wall segment, wherein said rib includes a surface which is perpendicular in relation to said flat wall segment, wherein said element is used in an assembly of formwork in which the concrete is not in direct contact with the flat wall segment.
8. The use of an element, said element being thin walled, flexible, made of a material which tends to expand when subjected to heat and having at least one flat wall segment for use in defining a substantially flat outside wall of the formwork, comprising at least one lengthwise rib extending at an angle from said flat wall, wherein said material is PVC, said element is of a thickness of between 1 and 2 mm and has a sufficient number of ribs along the width of said flat wall segment such that there is either a longitudinal edge of said flat wall segment or one of said ribs spaced at every 50 mm or less, and wherein said rib includes a surface which is perpendicular in relation to said flat wall segment, wherein said element is used in an assembly of formwork in which the concrete is not in direct contact with said flat wall segment.
9. The use of an element as claimed in claims 6, 7 or 8, in an assembly of formwork in which a layer of insulation is interposed between the concrete and the flat wall segment.
10. An elongated element for use in a stay-in-place modular form system for pouring concrete, said element being thin walled, flexible, made of a material which tends to expand when subjected to heat and having engagement means at its longitudinal edges and a substantially flat wall segment extending between said engagement means, comprising at least one lengthwise rib extending at an angle from said segment wherein said rib includes a surface which is perpendicular in relation to said segment and wherein said material is PVC, said element is of a thickness of between 1 and 2 mm and has a sufficient number of said ribs along the width of said element such that is either an engagement means or one of said ribs spaced at every 50 mm or less.
11. An elongated element for use in a stay-in-place modular formwork system for pouring concrete, said element being thin walled, flexible, made of a material which tends to expand when subjected to heat, said element comprising a segment defining the visible portion of the erected formwork bounded by two longitudinal edges, said segment having at least one curved wall portion and said curved wall portion including at least one lengthwise rib extending from said curved wall portion substantially perpendicularly to the plane defined between said two longitudinal edges.
12. The use of the element according to claim 11 in an assembly of formwork in which a layer of insulation is interposed between the concrete and said segment.
13. The use of an element, said element being thin walled, flexible, made of a material which tends to expand when subjected to heat, said element having a portion defining an outside surface of said formwork, wherein said portion comprises a plurality of longitudinally continuous flat sections each of which is angularly disposed from the next adjacent section, in an assembly of formwork in which a layer of insulation is interposed between the concrete and said portion.
14. An elongated element for use in a stay-in-place modular formwork system for pouring concrete, said element being thin walled, flexible, made of a material which tends to expand when subjected to heat and having at least one flat wall segment for use in defining a substantially flat outside wall of the formwork, said flat wall segment having an inside face and an outside face, said inside face having at least three lengthwise ribs extending at an angle from said inside face.
15. An element as in claim 14 wherein each of said ribs includes a surface which is perpendicular in relation to said flat wall segment.
16. An elongated element for use in a stay-in-place modular formwork system for pouring concrete, said element being thin walled, flexible, made of a material which tends to expand when subjected to heat and having engagement means at its longitudinal edges and a substantially flat wall segment extending between said engagement means, said flat wall segment having an inside face and an outside face, said inside face having at least three lengthwise ribs extending at an angle from said inside face.
17. An element as in claim 16 wherein said rib includes a surface which is perpendicular in relation to said segment.
18. An assembly of formwork as claimed in claims 14, 15, 16 or 17, wherein at least one of said ribs is a reinforcing rib that is not engaged to any other element of said assembly.
19. An assembly of stay-in-place formwork for pouring concrete comprising a plurality of elongated elements, said elements being thin walled, flexible, made of a material which tends to expand when subjected to heat and having at least one flat wall segment for use in defining a portion of a substantially flat outside wall of the formwork, said flat wall segment having an inside face and an outside face, said inside face having at least one lengthwise reinforcing rib extending from said inside face, said reinforcing rib not being connected to any other element of said assembly.
20. The use of an element, said element being thin walled, flexible, made of a material which tends to expand when subjected to heat, said element having a portion defining an outside surface of said formwork, wherein said portion comprises a plurality of longitudinally continuous flat sections, each of which is angularly disposed from the next adjacent section, and at least one longitudinal rib extending inwardly from one of said flat sections, in an assembly of formwork in which a layer of insulation is interposed between the concrete and said portion.
21. The use of an element, said element being thin walled, flexible, made of a material which tends to expand when subjected to heat, said element having a portion defining an outside surface of said formwork, wherein said portion comprises a plurality of longitudinally continuous flat sections each of which is angularly disposed from the next adjacent section, and wherein said plurality of flat sections define alternately inwardly and outwardly facing bay sections, in an assembly of formwork in which a layer of insulation is interposed between the concrete and said portion.
CA 2243905 1998-07-24 1998-07-24 Oil canning resistant element for modular concrete formwork systems Expired - Fee Related CA2243905C (en)

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CA2243905C true CA2243905C (en) 2002-05-21

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US8458969B2 (en) 2008-01-21 2013-06-11 Cfs Concrete Forming Systems Inc. Stay-in-place form systems for form-work edges, windows and other building openings
US8458985B2 (en) 2007-04-02 2013-06-11 Cfs Concrete Forming Systems Inc. Fastener-receiving components for use in concrete structures
US8555590B2 (en) 2007-11-09 2013-10-15 Cfs Concrete Forming Systems Inc. Pivotally activated connector components for form-work systems and methods for use of same
US8793953B2 (en) 2009-02-18 2014-08-05 Cfs Concrete Forming Systems Inc. Clip-on connection system for stay-in-place form-work
US8943774B2 (en) 2009-04-27 2015-02-03 Cfs Concrete Forming Systems Inc. Methods and apparatus for restoring, repairing, reinforcing and/or protecting structures using concrete
US9206614B2 (en) 2011-11-24 2015-12-08 Cfs Concrete Forming Systems Inc. Stay-in-place formwork with engaging and abutting connections
US9273479B2 (en) 2009-01-07 2016-03-01 Cfs Concrete Forming Systems Inc. Methods and apparatus for restoring, repairing, reinforcing and/or protecting structures using concrete
US9315987B2 (en) 2012-01-05 2016-04-19 Cfs Concrete Forming Systems Inc. Systems for restoring, repairing, reinforcing, protecting, insulating and/or cladding structures with locatable stand-off components
US9441365B2 (en) 2011-11-24 2016-09-13 Cfs Concrete Forming Systems Inc. Stay-in-place formwork with anti-deformation panels
US9453345B2 (en) 2012-01-05 2016-09-27 Cfs Concrete Forming Systems Inc. Panel-to-panel connections for stay-in-place liners used to repair structures
US10407895B2 (en) * 2016-12-23 2019-09-10 Dieter Krohmer Portable modular system for structural assemblies
US11674322B2 (en) 2019-02-08 2023-06-13 Cfs Concrete Forming Systems Inc. Retainers for restoring, repairing, reinforcing, protecting, insulating and/or cladding structures
US11821204B2 (en) 2017-04-03 2023-11-21 Cfs Concrete Forming Systems Inc. Longspan stay-in-place liners

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US10151119B2 (en) 2012-01-05 2018-12-11 Cfs Concrete Forming Systems Inc. Tool for making panel-to-panel connections for stay-in-place liners used to repair structures and methods for using same
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US8844241B2 (en) 2007-04-02 2014-09-30 Cfs Concrete Forming Systems Inc. Methods and apparatus for providing linings on concrete structures
US8555590B2 (en) 2007-11-09 2013-10-15 Cfs Concrete Forming Systems Inc. Pivotally activated connector components for form-work systems and methods for use of same
US9080337B2 (en) 2007-11-09 2015-07-14 Cfs Concrete Forming Systems Inc. Connector components for form-work systems and methods for use of same
US8458969B2 (en) 2008-01-21 2013-06-11 Cfs Concrete Forming Systems Inc. Stay-in-place form systems for form-work edges, windows and other building openings
US9359780B2 (en) 2009-01-07 2016-06-07 Cfs Concrete Forming Systems Inc. Methods and apparatus for restoring, repairing, reinforcing and/or protecting structures using concrete
US9273479B2 (en) 2009-01-07 2016-03-01 Cfs Concrete Forming Systems Inc. Methods and apparatus for restoring, repairing, reinforcing and/or protecting structures using concrete
US9273477B2 (en) 2009-02-18 2016-03-01 Cfs Concrete Forming Systems Inc. Clip-on connection system for stay-in-place form-work
US8793953B2 (en) 2009-02-18 2014-08-05 Cfs Concrete Forming Systems Inc. Clip-on connection system for stay-in-place form-work
US8943774B2 (en) 2009-04-27 2015-02-03 Cfs Concrete Forming Systems Inc. Methods and apparatus for restoring, repairing, reinforcing and/or protecting structures using concrete
US9206614B2 (en) 2011-11-24 2015-12-08 Cfs Concrete Forming Systems Inc. Stay-in-place formwork with engaging and abutting connections
US9441365B2 (en) 2011-11-24 2016-09-13 Cfs Concrete Forming Systems Inc. Stay-in-place formwork with anti-deformation panels
US9315987B2 (en) 2012-01-05 2016-04-19 Cfs Concrete Forming Systems Inc. Systems for restoring, repairing, reinforcing, protecting, insulating and/or cladding structures with locatable stand-off components
US9453345B2 (en) 2012-01-05 2016-09-27 Cfs Concrete Forming Systems Inc. Panel-to-panel connections for stay-in-place liners used to repair structures
US10407895B2 (en) * 2016-12-23 2019-09-10 Dieter Krohmer Portable modular system for structural assemblies
US11821204B2 (en) 2017-04-03 2023-11-21 Cfs Concrete Forming Systems Inc. Longspan stay-in-place liners
US11674322B2 (en) 2019-02-08 2023-06-13 Cfs Concrete Forming Systems Inc. Retainers for restoring, repairing, reinforcing, protecting, insulating and/or cladding structures

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