EP2155455A2 - Coffrage à forme amorphe - Google Patents

Coffrage à forme amorphe

Info

Publication number
EP2155455A2
EP2155455A2 EP08734537A EP08734537A EP2155455A2 EP 2155455 A2 EP2155455 A2 EP 2155455A2 EP 08734537 A EP08734537 A EP 08734537A EP 08734537 A EP08734537 A EP 08734537A EP 2155455 A2 EP2155455 A2 EP 2155455A2
Authority
EP
European Patent Office
Prior art keywords
formwork
concrete
elements
support structure
model
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.)
Withdrawn
Application number
EP08734537A
Other languages
German (de)
English (en)
Inventor
Karl Christiansen
Anders Gammelgaard Nielsen
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Newton Concrete ApS
Original Assignee
Newton Concrete ApS
Priority date (The priority date 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 date listed.)
Filing date
Publication date
Application filed by Newton Concrete ApS filed Critical Newton Concrete ApS
Publication of EP2155455A2 publication Critical patent/EP2155455A2/fr
Withdrawn legal-status Critical Current

Links

Classifications

    • 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
    • B28B7/00—Moulds; Cores; Mandrels
    • B28B7/34—Moulds, cores, or mandrels of special material, e.g. destructible materials
    • B28B7/348—Moulds, cores, or mandrels of special material, e.g. destructible materials of plastic material or rubber
    • 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
    • B28B7/00—Moulds; Cores; Mandrels
    • B28B7/34—Moulds, cores, or mandrels of special material, e.g. destructible materials
    • B28B7/346—Manufacture of moulds
    • 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
    • B28B7/00—Moulds; Cores; Mandrels
    • B28B7/36—Linings or coatings, e.g. removable, absorbent linings, permanent anti-stick coatings; Linings becoming a non-permanent layer of the moulded article
    • B28B7/364—Linings or coatings, e.g. removable, absorbent linings, permanent anti-stick coatings; Linings becoming a non-permanent layer of the moulded article of plastic material or rubber
    • 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
    • B28B7/00—Moulds; Cores; Mandrels
    • B28B7/38—Treating surfaces of moulds, cores, or mandrels to prevent sticking
    • 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
    • B28B7/00—Moulds; Cores; Mandrels
    • B28B7/38—Treating surfaces of moulds, cores, or mandrels to prevent sticking
    • B28B7/384—Treating agents
    • 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
    • E04G11/04—Forms, shutterings, or falsework for making walls, floors, ceilings, or roofs for structures of spherical, spheroid or similar shape, or for cupola structures of circular or polygonal horizontal or vertical section; Inflatable forms
    • 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
    • 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
    • E04G13/00—Falsework, forms, or shutterings for particular parts of buildings, e.g. stairs, steps, cornices, balconies foundations, sills
    • E04G13/02—Falsework, forms, or shutterings for particular parts of buildings, e.g. stairs, steps, cornices, balconies foundations, sills for columns or like pillars; Special tying or clamping means therefor
    • 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
    • E04G9/00—Forming or shuttering elements for general use
    • E04G9/02—Forming boards or similar elements

Definitions

  • the present invention relates to formwork for casting concrete or concrete like elements where these elements may have an amorphous shape.
  • Fresh concrete has the ability to flow and thereby fill out spaces which would otherwise, with other materials be very difficult to fill out, which in turn makes it possible to create shapes and forms having an internal strength and integrity which could not be addressed by very many other materials. Until now the cost of formwork has made it prohibitive to contemplate such shapes for ordinary constructions.
  • the present invention therefore provides both a method for casting and a form work for casting concrete or concrete like elements where said elements may have an amor- phous shape.
  • amorphous shape covers a wide variety of shapes (symmetrical as well as asymmetrical) as will be evident from the description with reference to the detailed embodiments, see below.
  • the invention is directed at providing a method which is easy to carry out, at low cost, and where the finish on the manufactured elements is greatly improved compared to the state of the art.
  • the invention accordingly provides a method which is new and inventive in that the method for casting concrete or concrete like elements where said elements may have an amorphous shape, comprises the following steps:
  • a model of the element is cut out, thereby creating an inner formwork;
  • an outer load bearing support structure having an inner size corresponding to the outer dimensions of the block is created;
  • the parts of the block not representing the model are arranged in the interior of the load bearing support structure, thereby creating a cavity corresponding to the model;
  • a release agent either in liquid form or as a foil or membrane is arranged covering the cavity in the inner formwork;
  • the block hi order to be able to cut a model out of the formable block, the block must be of a size larger than the element to be cast.
  • the inner formwork is therefore made up of the cavity created in the block when the model of the element to be cast has been removed, hi some instances it may be necessary to partition the block of formable material in order to remove the model depending on the shape of the model.
  • the inner formwork will therefore consist of a number of parts which will thereafter be assembled inside an outer load bearing support structure, where the size of the support structure corresponds to the size of the block so that an efficient support for the block of formable material is created.
  • the removal of the inner formwork from the cured concrete element will usually be carried out by firstly removing the concrete and the inner formwork from the load bearing support structure and thereafter removing the inner formwork from the concrete element, hi some instances depending on the material from which the formable material is selected it may be difficult to remove the inner formwork from the cast element and in these instances a suitable release agent should be applied to the inner formwork prior to casting the concrete.
  • a traditional retarder was applied to the inner formwork before casting the concrete.
  • This substance for example a simple sugar solution, made it very easy to part the cast element from the formwork, and at the same time had no effect on the formwork, such that the formwork was suitable to be reused.
  • the micro-surface of the concrete element was relatively large/open, and it is contemplated that elements manu-
  • oils based on vegetables such as for example oils derived from sunflowers, sesame, grapes, flax and the like is also usable.
  • a suitable wax also showed remarkable results.
  • a wax from X-Coating, a Danish corporation, sold under the tradename X-1 1000 proved very usefull.
  • a mixture of oil and 25 wax was used where the oil was pure oil used for medical purposes containing 3 % to 15 % wax.
  • the surfaces of the cast elements showed no signs of the release agent.
  • the block is made from a polystyrene based product and a hot wire is used for cutting the model.
  • polystyrene material By selecting a polystyrene material it becomes very easy to shape the model simply by pulling a hot wire through the polystyrene material which will thereby melt and pro- vide for an easy and very smooth cut. Furthermore, polystyrene based products are usually very cheap and very light and as such easy to handle, and furthermore by selecting an appropriate, high quality polystyrene, a very smooth form surface may.be achieved by this method.
  • the invention is also directed at a formwork for use in the inventive method where said formwork comprises:
  • an outer load bearing support structure which support structure has means allowing the structure to be disassembled, thereby freeing - an inner formable structure, which inner structure defines the outer shape of the element to be cast.
  • Fig. 1 illustrates prior art formwork
  • Fig. 2 illustrates a wall created using the invention
  • Fig. 3 illustrates form elements used for the wall in fig. 2
  • Fig. 4 illustrates a block before being shaped
  • Fig. 5 illustrates a template
  • Fig. 6 illustrates a template arranged on a block
  • Fig. 7 illustrates the assembly of the formwork
  • Fig. 8 illustrates how the inner form is cut;
  • Fig. 9 illustrates how separate forms fit together for longer constructions
  • Fig. 10 and 11 illustrate a further embodiment where the formwork is used in a very complex shaped construction.
  • Fig. 11 a- 16 illustrate various methods of carrying out the invention.
  • FIG 1 is illustrated a traditional formwork used to cast the underside of a staircase. Due to the flowing shape of the staircase it is necessary to build a rather complicated formwork in order to achieve this shape for the actual staircase.
  • the traditional formwork as illustrated in figure 1 comprises a large number of latches 1 which are arranged side by side in order to create the form face. The bottom shape is created by the latches 1 being shaped by plate members 2 arranged along the sides of the formwork.
  • the plates 2 are bolted 3 to an under structure 4 in order to create a construction stiff enough to maintain the shape of the formwork during the casting process of the concrete. It is evident that this type of construction requires a substantial amount of labour and thereby becomes very costly.
  • the invention provides a relatively cheap alternative to this, which furthermore may be able to provide much smoother transitions between curved sections and therefore also achieve a far more pleasing result with less effort and less cost.
  • the wall element has a substantial homogenous thickness which is created by having substantially parallel lines from the bottom of the wall to the top of the wall, but apart from that the wall may be given any suitable shape. From figure 2 it is evident that both curves in the vertical as well as the horizontal plane are possible, and also double curvature may be achieved.
  • the wall may furthermore be equipped with support sections 6 which will be described below.
  • RMRRTlTl JTE SHEET help this particular shape to keep its balance on its own, but for practical purposes the wall element 5 will be placed on a foundation and fastened in a traditional way, e.g. with bolts, to the underlying foundation structure.
  • the wall as depicted in figure 2 may be achieved with a formwork as illustrated in figure 3.
  • FIG 4 a block of a formable material 10, in this example polystyrene is depicted.
  • the block has a size, i.e. a width, height and length larger than the object which is to be cast.
  • a heated wire 11 in this instance connected by handle 12 to a source of electrical energy the heated wire may easily cut through the block of polystyrene.
  • the "cutting" is achieved by melting the polystyrene as the wire is pulled
  • a template as illustrated in figure 5 and 6 may be used.
  • the template 13 is fastened in either end of the block 10.
  • the template 13 is decisive for the shape of the end of the element to be cast.
  • the template 14 will provide for a different shape of the element to be cast.
  • the pieces 18, 19, 20 will be the inner formwork against which the fresh concrete will be cast.
  • the part of the block material 10 between the template 14 in either end of the block is a model of the concrete structure to be cast, but will not be used for the casting process.
  • the inner mould sections are hereafter arranged in an outer load bearing support structure, where this load bearing support structure has an inner size corresponding to the outer size of the block material 10.
  • the inner formwork for the wall as illustrated in figure 2 is illustrated.
  • the inner formwork consists of a front and back part 30, 31 and for illustrative purposes the templates 32, 33, 34, 35 are also illustrated.
  • the inner moulds have been shaped by pulling the hot wire along the template 32 as illustrated in figure 8.
  • the corresponding inner moulds 30, 31, do not have end sections which correspond to the next consecutive element.
  • the first set of inner moulds 41, 42 is created as explained above by using templates and cutting with a hot wire through the block material.
  • the template used on the face 43 of the inner mould 41 is also used for the next set of inner moulds 44, 45 so that the inner mould 45 on one end surface is cut along the same template 43 as the first set of inner moulds '4I, 42. In this manner it is ensured that the inner mould elements 41, 45 will create a smooth transition such that a continuous element e.g. as illustrated in figure 2 may be created.
  • FIG 10 is illustrated an inner mould created according to the principles described above which inner mould 50 may be fitted inside an outer load bearing support structure 51.
  • the elements cast in the inner mould 50 are depicted in figure 11 and are mentioned here in order to illustrate the versatility and the wide variety of possibilities which are possible with the inventive formwork according to the invention.
  • With traditional formwork the structures as illustrated with reference to figures 2, 6 and 11 would have been so expensive that in fact it is very likely that they would have been taken out of the projects had it not been possible to manufacture them by using the versatile and relatively cheap formwork system according to the present invention.
  • a membrane 47 made from latex or synthetic rubber, typically having a thickness of from a few tenths of a millimetre to a few millimetres is fastened to a frame 48.
  • the membrane 47 is not pre-shaped, but is a straight flat membrane section.
  • the size of the frame 48 is such that it may be supported on the upper ledge 49 of the load bearing outer formwork 50.
  • the block of formable material 51, made from polystyrene, is provided with a cavity 52 corresponding to the desired shape of the finished cast element.
  • the formwork is ready to receive the concrete.
  • the concrete is poured on the membrane 47, which thereby deforms to the shape of the cavity 52.
  • the surface finish of the concrete element is very smooth, due to the surface characteristics of the membrane, in particular when made from Latex.
  • the embodiment illustrated in fig. 12 corresponds to the embodiment described with reference to fig. 11a. Only in this embodiment the membrane 53 is pre-shaped. When pouring the concrete the membrane does not need to stretch as much, and with this
  • Rl IRCTITI ITC QMPPT embodiment it is therefore possible to make larger constructions compared to the previous embodiment.
  • This embodiment also corresponds to the embodiment illustrated in fig. 15, where an element having a limited cross section, but a relatively long shape is illustrated.
  • the release agent is in the shape of a liquid 54.
  • a mixture of oil and wax is used as a coating on the inside of the cavity 52.
  • fig. 14 is illustrated an embodiment of the invention suitable to manufacture surface elements.
  • the formable material is sand 55, which is placed inside the outer formwork 50.
  • the upper surface of the sand 55 will determine the surface shape of the element to. 1 .. be cast.
  • The. membrane 47 will due to its stretchability and flexibility conform to the shape of the sand 55, when the concrete is poured on top of the membrane 47.
  • the inner formwork may also be preformed.
  • a computer based design aid may be contemplated, where the software automatically reserves a central zone for reinforcement, tension cables etc, and sufficient concrete cover over the reinforcement, such that the designer is free to use the rest of a given cross section in order to create the desired shape.

Landscapes

  • Engineering & Computer Science (AREA)
  • Architecture (AREA)
  • Mechanical Engineering (AREA)
  • Manufacturing & Machinery (AREA)
  • Chemical & Material Sciences (AREA)
  • Ceramic Engineering (AREA)
  • Civil Engineering (AREA)
  • Structural Engineering (AREA)
  • Moulds, Cores, Or Mandrels (AREA)
  • Devices For Post-Treatments, Processing, Supply, Discharge, And Other Processes (AREA)

Abstract

L'invention concerne un procédé et un coffrage permettant de couler du béton ou des éléments semblables au béton, lesdits éléments pouvant avoir une forme amorphe. Le procédé comprend les étapes suivantes consistant à : découper, dans un bloc de matériau configurable ayant une taille plus importante que l'élément à couler, un modèle de l'élément, ce qui crée un coffrage interne; créer une structure de support porte-charge externe dont la taille interne correspond aux dimensions externes du bloc; disposer les parties du bloc qui ne représentent pas le modèle à l'intérieur de la structure de support porte-charge, ce qui forme une cavité correspondant au modèle; disposer éventuellement un élément de renforcement dans la cavité; verser du béton frais ou un autre matériau semblable au béton dans la cavité et le laisser durcir; et retirer la structure de support porte-charge et le coffrage interne.
EP08734537A 2007-05-18 2008-05-16 Coffrage à forme amorphe Withdrawn EP2155455A2 (fr)

Applications Claiming Priority (3)

Application Number Priority Date Filing Date Title
DKPA200700741 2007-05-18
DKPA200701770 2007-12-12
PCT/DK2008/000180 WO2008141644A2 (fr) 2007-05-18 2008-05-16 Coffrage à forme amorphe

Publications (1)

Publication Number Publication Date
EP2155455A2 true EP2155455A2 (fr) 2010-02-24

Family

ID=39951567

Family Applications (1)

Application Number Title Priority Date Filing Date
EP08734537A Withdrawn EP2155455A2 (fr) 2007-05-18 2008-05-16 Coffrage à forme amorphe

Country Status (4)

Country Link
US (1) US20100117248A1 (fr)
EP (1) EP2155455A2 (fr)
AU (1) AU2008253382A1 (fr)
WO (1) WO2008141644A2 (fr)

Families Citing this family (8)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP2532808A1 (fr) 2011-06-10 2012-12-12 ETH Zurich Procédé de moulage sur place de structures en béton en forme libre
CA2909909C (fr) * 2013-02-21 2020-10-27 Laing O'rourke Australia Pty Limited Procede pour mouler un element de construction
WO2016023060A1 (fr) * 2014-08-15 2016-02-18 Laing O'rourke Australia Pty Limited Procédé permettant la fabrication d'un élément de construction composite
CN105201208B (zh) * 2015-08-12 2017-09-15 郑州市第一建筑工程集团有限公司 Y型墩柱斜支杆钢模拆除体系
ITUA20161637A1 (it) * 2016-03-14 2017-09-14 Milano Politecnico Metodo per la fabbricazione rapida di stampi
FR3065390B1 (fr) * 2017-04-25 2020-10-23 Spurgin Leonhart Procede de fabrication d'au moins une paroi d'un element de construction prefabrique a parement matrice et installation associee
AT521840B1 (de) 2018-11-06 2021-04-15 Franz Filzmoser Mag Verfahren zur Herstellung von Betonfertigteilen mit Hilfe einer Gussform
US11426897B2 (en) * 2018-12-19 2022-08-30 Powers Brown Architecture Holdings Kits suitable for casting concrete elements, and methods for casting concrete elements using such kits

Citations (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4887789A (en) 1988-04-26 1989-12-19 Harris Frank R Form for molding columns
US20050066602A1 (en) 2003-08-06 2005-03-31 Fulbright Joe Richard Expanded polystyrene formwork for cast in place concrete structures

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US3968711A (en) * 1975-11-24 1976-07-13 Huestic Machine Corporation Pattern cutting apparatus
DE2554834A1 (de) * 1975-12-05 1977-06-08 Rolf Dipl Ing Pfeifer Neue schalungsformen zur herstellung von probekoerpern aus beton oder moertel
US5139722A (en) * 1987-12-24 1992-08-18 P. G. Lawton (Industrial Svcs.) Limited Method of forming concrete structures
US5172532A (en) * 1988-04-01 1992-12-22 Gibbar Jr James H Prefabricated polymer building wall panels
CH681099A5 (fr) * 1990-01-30 1993-01-15 Construmat Ag
US5232646B1 (en) * 1990-11-07 1999-02-16 Concrete Design Specialties In Methods of forming contoured walls
US6260816B1 (en) * 1998-02-26 2001-07-17 Jose Manuel Valero Salinas Discardable formwork for columns
AU2003303669A1 (en) * 2003-01-11 2004-08-10 Numold (Uk) Limited Mould having flexible sidewalls with support members for moulding building products
US6817150B1 (en) * 2003-03-20 2004-11-16 Patrick E. Boeshart Form system for poured concrete

Patent Citations (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4887789A (en) 1988-04-26 1989-12-19 Harris Frank R Form for molding columns
US20050066602A1 (en) 2003-08-06 2005-03-31 Fulbright Joe Richard Expanded polystyrene formwork for cast in place concrete structures

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Title
HERHOLDT A.D. ET AL: "Beton-Bogen", 1985, pages: 430, XP003028169
TAGE HERTZELL: "The exterior of concrete - a handbook for architects and others", 1984, pages: 117, XP003028168

Also Published As

Publication number Publication date
WO2008141644A2 (fr) 2008-11-27
AU2008253382A1 (en) 2008-11-27
WO2008141644A3 (fr) 2009-01-15
US20100117248A1 (en) 2010-05-13

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