EP2655762B1 - Coffrage - Google Patents

Coffrage Download PDF

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Publication number
EP2655762B1
EP2655762B1 EP11804769.5A EP11804769A EP2655762B1 EP 2655762 B1 EP2655762 B1 EP 2655762B1 EP 11804769 A EP11804769 A EP 11804769A EP 2655762 B1 EP2655762 B1 EP 2655762B1
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EP
European Patent Office
Prior art keywords
support structure
shuttering
walls
depth
mould
Prior art date
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Application number
EP11804769.5A
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German (de)
English (en)
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EP2655762A2 (fr
Inventor
Alastair SEATON
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Cordek Ltd
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Cordek Ltd
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    • 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
    • E04G9/08—Forming boards or similar elements, which are collapsible, foldable, or able to be rolled up
    • E—FIXED CONSTRUCTIONS
    • E02—HYDRAULIC ENGINEERING; FOUNDATIONS; SOIL SHIFTING
    • E02D—FOUNDATIONS; EXCAVATIONS; EMBANKMENTS; UNDERGROUND OR UNDERWATER STRUCTURES
    • E02D31/00—Protective arrangements for foundations or foundation structures; Ground foundation measures for protecting the soil or the subsoil water, e.g. preventing or counteracting oil pollution
    • E02D31/10—Protective arrangements for foundations or foundation structures; Ground foundation measures for protecting the soil or the subsoil water, e.g. preventing or counteracting oil pollution against soil pressure or hydraulic pressure
    • E—FIXED CONSTRUCTIONS
    • E02—HYDRAULIC ENGINEERING; FOUNDATIONS; SOIL SHIFTING
    • E02D—FOUNDATIONS; EXCAVATIONS; EMBANKMENTS; UNDERGROUND OR UNDERWATER STRUCTURES
    • E02D31/00—Protective arrangements for foundations or foundation structures; Ground foundation measures for protecting the soil or the subsoil water, e.g. preventing or counteracting oil pollution
    • E02D31/10—Protective arrangements for foundations or foundation structures; Ground foundation measures for protecting the soil or the subsoil water, e.g. preventing or counteracting oil pollution against soil pressure or hydraulic pressure
    • E02D31/14—Protective arrangements for foundations or foundation structures; Ground foundation measures for protecting the soil or the subsoil water, e.g. preventing or counteracting oil pollution against soil pressure or hydraulic pressure against frost heaves in soil
    • 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
    • E04G9/05—Forming boards or similar elements the form surface being of plastics
    • 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
    • E04G9/08—Forming boards or similar elements, which are collapsible, foldable, or able to be rolled up
    • E04G9/086—Forming boards or similar elements, which are collapsible, foldable, or able to be rolled up which are specially adapted to be degradable in time, e.g. by moisture or water
    • 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
    • E04G9/10—Forming or shuttering elements for general use with additional peculiarities such as surface shaping, insulating or heating, permeability to water or air

Definitions

  • This invention relates to shuttering for use, particularly in the construction industry, in casting slabs or beams over a substrate, and to a method of manufacturing such shuttering.
  • the invention relates, more especially, to shuttering for use in casting floor slabs or ground beams over a substrate in which upward movement is expected.
  • the upward movement may, for example, be caused by heaving movement in a clay substrate; this is a common cause of such movement, but other factors may also cause such movement.
  • a floor slab or ground beam cast directly on such a substrate would be at risk of cracking or breaking as a result of excessive upward movement in the substrate applying an upward force on the slab or beam, but the risk can be substantially reduced if the slab or beam can be spaced from the substrate to enable such upward movement to be accommodated.
  • shuttering which is intended to be destroyed by moisture emanating from the substrate or introduced deliberately after the slab has been cast.
  • This known form has the disadvantage that it can be destroyed prematurely by moisture from other sources, for example by rainwater.
  • a further disadvantage of this known form is the production of methane gas following its destruction by moisture.
  • shuttering which comprises a support surface on which material is cast, and a support structure of cellular construction located between the support surface and a substrate in which movement is expected.
  • the support structure which is made of expanded polystyrene supports the weight of the cast material but under a predetermined, higher, compressive force will fail.
  • Shuttering of this nature is disclosed in both GB 2206637 and GB 2241976 and has proved successful commercially.
  • Large blocks of expanded plastics material are formed and then cut into sections of the required size. As a result of this process the sections of expanded plastics material used to construct the support structure may not be of uniform density.
  • a support structure assembled from such sections may then have characteristics (for example, maximum load prior to failure) that are not uniform across the assembled structure.
  • first support structure panel can differ from that of a second panel which is nominally identical to the first.
  • Such variations can be disadvantageous, especially if it is desired to have only a small gap between the load that the shuttering can safely bear without collapse and the load at which the shuttering is required to have failed.
  • shuttering of the kind just described is modified by moulding it from expanded polystyrene. Shuttering formed in this way can be made with more uniform characteristics resulting in a more consistent and predictable performance of a given product of given dimensions.
  • Such moulded products are currently manufactured and sold by the Applicants under the trade marks CELLCORE and CELLFORM. Moulding products of this kind is challenging and GB 2390390 and GB 2417283 GB describe moulding procedures that make it feasible to mould such products cost effectively.
  • a particular issue that has to be addressed is the feeding of polystyrene beads into the mould and to all parts of the support structure.
  • the support structure comprises a multiplicity of four-sided cells bounded by a first set of walls extending across the structure in a first direction and a second set of walls extending across the structure in a second direction perpendicular to the first. It is challenging to feed material into the walls during the moulding process.
  • a support structure of the kind described above has a first supporting condition, in which it is manufactured, in which it can accommodate a given loading with very little compression of the material.
  • the depth of the support structure of the product in this condition is referred to herein as the depth (D) of the support structure in the first supporting condition.
  • the maximum loading at which the support structure is assured of remaining in the first supporting condition is referred to in commercial products as the "Safe Load” and during casting of a slab or beam this Safe Load should not of course be exceeded.
  • the support structure also has a second failed or failure condition, in which the walls have failed.
  • the minimum loading at which this is assured of having occurred is referred to in commercial products as the "Fail Load”.
  • the resistance of the product to compression stops increasing and even reduces until the product is much reduced in depth.
  • the product will again increase its resistance to compression and there is a reduced depth at which the load that has to be applied to cause yet further reduction in depth exceeds the Fail Load. That reduced depth is therefore the depth that the support structure has at the Fail Load and is referred to herein as the depth (d) of the support structure in the second failure condition.
  • the depth (d) of the support structure in the second failure condition As will be understood it is a simple matter to apply a test load to a product to establish the Safe Load and the Fail Load and also to establish the depth of the support structure in both the first supporting condition and the second failure condition.
  • Products of the kind referred to are used in a variety of applications and those different applications require different specifications of product.
  • variable to be specified one is the amount of upward movement that the product is required to accommodate; the other is the value of the Safe Load that the product is required to accommodate, with the Fail Load preferably being only slightly higher than the Safe Load.
  • the amounts of upward movement accommodated are 50mm, 100mm and 150mm.
  • the more movement that is required to be accommodated the greater the depth of product required in order that the difference in depth between the depth (D) of the support structure in the first supporting condition and the depth (d) of the support structure in the second failure condition is equal to the amount of upward movement to be accommodated.
  • the support structure for accommodating an upward movement of 50mm has a depth of about 95mm
  • a support structure for accommodating an upward movement of 100mm has a depth of about 170mm
  • a support structure for accommodating an upward movement of 150mm has a depth of about 245mm.
  • typical Safe Loads and Fail Loads are: a Safe Load of 20kN/m 2 and a Fail Load of 30kN/m 2 ; a Safe Load of 15kN/m 2 and a Fail Load of 22kN/m 2 ; a Safe Load of 10kN/m 2 and a Fail load of 15kN/m 2 ; a Safe Load of 8kN/m 2 and a Fail Load of 12kN/m 2 .
  • the Safe and Fail Loads are controlled primarily by adjusting the density of the supporting structure.
  • shuttering for use in casting a slab/beam over a substrate, comprising a hollow support structure including a plurality of spaced apart support walls defining cells therebetween, the support structure being able to be placed on the substrate to support the slab/beam during casting, wherein the support structure is formed with its spaced apart walls by a moulding process and from expanded plastics material, characterized in that the cells are of a substantially hexagonal shape.
  • a feature of a hexagonal structure is that each intersection of walls involves only three walls, rather than four in a rectangular structure.
  • the positions at which walls intersect tend to be more resistant to failing than positions midway between intersections; this impedes the provision of a supporting structure of uniform characteristics across its area.
  • Each substantially hexagonal cell may have the shape of a regular hexagon but in a preferred embodiment of the invention each cell has the shape of an irregular hexagon.
  • the cell has some symmetry: more particularly, it is preferred that at least one pair of opposite walls of each substantially hexagonal cell are substantially parallel to one another.
  • the shuttering is preferably a panel of rectangular shape and, in that case, one pair of substantially parallel walls preferably extend substantially parallel to shorter end edges of the panel. Said one pair of substantially parallel walls may be spaced apart by a distance less than the spacing of the other opposite walls of the substantially hexagonal cell. The difference in spacing is preferably small, and preferably less than 10%.
  • all three pairs of opposite walls are substantially parallel to one another; it should be understood, however, that even in this case the hexagonal shape need not be that of a regular hexagon.
  • each interior angle is 120 degrees.
  • the interior angles of the hexagonal cells are preferably not all the same but preferably lie in the range of 110 to 130 degrees.
  • the support structure preferably has a first supporting condition in which the depth of the support structure is D and a second failure condition in which the depth of the support structure is d, wherein d is less than 0.38D.
  • This reduction of depth represented by d being equal to about 0.30D may be contrasted to current commercially available shuttering of the same kind where to accommodate the same 150mm of movement the supporting structure has a depth D in a first supporting condition of 245mm and a depth d in the failure condition of 95mm.
  • d is less than 0.36D and more preferably d is less than 0.33D. It should be noted, however, that it is also within the scope of the broadest aspect of the invention for d to be greater than 0.38D. In such a case it is preferable, but not essential, that d is less than 0.45D and, more preferably, less than 0.4D.
  • shuttering embodying the invention has relatively thin walls.
  • the walls are preferably less than 15mm thick and more preferably less than 13.5mm thick.
  • all the walls are of the same thickness but it is within the scope of the invention for the walls to be of varying thickness and in that case a minority of the walls may have a thickness greater than the preferred upper ranges given above.
  • the raw material employed is non-expanded beads of polystyrene.
  • Such non-expanded beads typically have a diameter of the order of 1mm.
  • the beads are then steamed to cause them to expand and the degree of expansion at this stage can be controlled according to the density of the expanded polystyrene material required for the final product.
  • the size of the bead after this first stage of expansion for products that might be suitable for the present invention is likely to be in the range of 2mm to 10mm and the expanded beads have to be introduced into the mould cavity.
  • the bead size Whilst if the expanded bead size is only 2mm, the size is fairly immaterial, when a product of relatively low density, providing relatively low Safe and Fail Loads is required, the bead size has to be relatively big. For a larger expanded bead size, it can immediately be seen that there is a significant difference between moulding a wall having a thickness of 16.5mm and a wall having any less thickness. In general the wall thickness is preferably at least twice the expanded bead size. In embodiments of the invention described below, the walls have a thickness of only 13mm. As already indicated, in the preferred embodiments of the invention, the teaching towards the use of walls much thicker than 10mm to facilitate moulding is ignored and thinner walls are employed. Various techniques may then be used to make it feasible to mould even relatively low density products and these are referred to elsewhere in this specification.
  • the actual depth D selected for the support structure in the first supporting condition depends upon the amount of upward movement of the substrate that is required to be accommodated. In one example where about 150mm of upward movement is to be accommodated by the shuttering, the depth D of the support structure in the first supporting condition is in the range of 200mm to 220mm and the depth d of the support structure in the second failure condition is more than 140mm less than the depth D in the first supporting condition. In another example where about 100mm of upward movement is to be accommodated by the shuttering, the depth D of the support structure in the first supporting condition is in the range of 140mm to 160mm and the depth d of the support structure in the second failure condition is more than 95mm less than the depth D in the first supporting condition.
  • the depth D of the support structure in the first supporting condition is in the range of 70mm to 80mm and the depth d of the support structure in the second failure condition is more than 45mm less than the depth D in the first supporting condition.
  • the Safe and Fail Loads of the shuttering for given dimensions of the support structure can be adapted by selecting an appropriate density of the expanded plastics material.
  • the Safe Load varies between about 7kN/m 2 and about 24kN/m 2 while the Fail Load varies between about 10kN/m 2 and about 30kN/m 2 .
  • Some examples of pairs of Safe/Fail loads, all in kN/m 2 are 7/10, 9/13, 13/18, 17/23 and 24/30.
  • the Safe Load is typically about three quarters of the Fail Load.
  • the Safe Load is at least 70% of the Fail Load.
  • the size and shape of the cells is preferably uniform across the support structure.
  • the shuttering may be a panel of rectangular shape and in that case the longest dimension of the hexagonal cells in a direction parallel to the short sides of the panel and measured between midpoints of the walls defining the cells is preferably in the range of 195mm to 205mm. Preferably this is the separation of opposite corners of each hexagonal cell.
  • the spacing of the centres of cells, measured in a direction parallel to the short sides of the panel, is preferably in the range of 140mm to 160mm and more preferably about 150mm.
  • a panel may have an overall length of 2400mm and an overall width of 1200mm; with the dimensions just mentioned the structure can be cut lengthwise at intervals of about 150mm to provide the same repeating cellular structure, for example to provide pieces of shuttering, each of appropriate cross-section, and of 450mm width, or of 600mm width.
  • hexagonal cells are of the width indicated above, if they were a regular hexagonal shape, the loads that the structure could accommodate would be reduced because of the size of the cells. It is therefore preferred that the spacing of the centres of the cells measured in a direction parallel to the long sides of the panel is in the range of 150mm to 160mm and more preferably about 155mm.
  • a centre-to-centre spacing widthwise of about 150mm and lengthwise of 155mm is achieved by having hexagons with three pairs of parallel sides, one pair being aligned with the widthwise direction and having interior angles for the hexagon of about 114 degrees for one pair of smaller angles and of about 123 degrees for two pairs of larger angles.
  • each support wall is preferably approximately vertical. Although the provision of vertical walls could be seen as making moulding difficult, as explained elsewhere, we have found a satisfactory method of moulding such a structure.
  • the walls are recessed in the regions of at least some of their intersections.
  • the recesses are formed during the moulding process but it is also possible to form them by removing material after moulding.
  • the recesses may be provided at the top and/or bottom of the support structure.
  • the recesses preferably define passageways between adjacent cells in the support structure.
  • a recess may define a passageway between only two adjacent cells, or, as in a preferred embodiment, between three adjacent cells. It is already known to provide such passageways away from the intersections of the walls to allow drainage, for example of water, from one cell to another.
  • passageways at the intersections of the walls also serves that purpose but is able additionally to serve two other purposes: firstly, it facilitates moulding of thin walls and, secondly, it facilitates an even collapse of the supporting structure when it fails.
  • a difficulty when moulding thin walls is the small physical size of the openings in the mould between opposite portions of the mould defining the space into which material has to be introduced to form the mould.
  • the size is greatest at the intersection of walls and it is therefore preferred to introduce material into the mould cavity at that position.
  • By providing a recess at the intersection a bigger space is created in which to provide a point for introducing material into the mould cavity.
  • an advantage of making the support structure by moulding is that a more consistent product can be obtained and of course this is advantageous in facilitating prediction of the load at which the structure fails.
  • those intersections represent regions of increased resistance to failure and consequently there is a tendency for the structure to behave non-uniformly as the load on it is increased beyond the Safe Load.
  • the shuttering further comprises a top sheet of material on the top of the support structure.
  • the sheet may be placed loosely on top of the support structure but preferably is attached to the support structure, for example by adhesive.
  • the top sheet may be of the same width as the support structure.
  • the top sheet may be wider than the support structure; in that case, portions of the top sheet projecting beyond the sides of the support structure may be able to be folded upwardly, for example to provide shuttering sides for a beam cast between the upwardly extending portions.
  • the shuttering may further comprise a bottom sheet of material on the bottom of the support structure. That sheet is preferably also attached to the support structure, for example by adhesive.
  • the sheet or sheets of material may be of any suitable form but may comprise a polypropylene sheet which may be fluted or may comprise a sheet of expanded polystyrene with a thin sheet of polypropylene on the outside.
  • the sheet may be 5mm to 10mm thick.
  • the present invention further provides a method of manufacturing shuttering for use in casting a slab/beam over a substrate, the method including the step of moulding a support structure from expanded polystyrene material to provide shuttering of the first aspect of the invention.
  • the method may further include the step of introducing material into the mould at locations corresponding to intersections of the support walls.
  • the method of the invention may include the step of cutting the moulded product into two halves along a plane partway between the top and bottom of the support structure. If the moulded product is cut midway between the top and bottom of the support structure, then both halves may be employed for shuttering of relatively small depth.
  • a substantially hexagonal cell in the support structure is preferably created by the combination of a first mould portion inserted into the cell from one side of the support structure and a second mould portion inserted into the cell from the opposite side of the support structure.
  • the first and second mould portions preferably have complementarily inclined confronting faces that come together in the middle of a hexagonal cell when the expanded plastics material is introduced into the mould.
  • the inclination is preferably only a few degrees. In that case the mould portions are naturally slightly tapered and it becomes much easier to produce a hexagonal cell with vertical sides of constant thickness.
  • the method preferably further includes the step of securing a top sheet over the support structure.
  • non-expanded beads of a smaller size than are conventionally used for building products made of expanded polystyrene, in order that the size of the expanded beads introduced into the mould are not too large.
  • the shuttering panel 1 shown in Figures 1 and 2 comprises a hollow support structure 2 and a top sheet 3.
  • the top sheet 3 has a pair of long sides 4 and a pair of short sides 5.
  • the top sheet 3 is formed from any suitable material. It may, for example, be heavy duty polypropylene sheet or a sheet of expanded polystyrene topped with a thin sheet of polypropylene.
  • the support structure may be bonded to the top sheet in any suitable manner, for example by an impact adhesive.
  • the hollow support structure 2 comprises a plurality of support walls which together define a multiplicity of hexagonal cells 6.
  • Each hexagonal cell is bounded by a pair of opposite walls 7 which extend parallel to one another and parallel to the short sides 5 of the panel, a pair of opposite walls 8 which define an angle, in this particular example an angle of about 123 degrees, to the walls 7, and a pair of opposite walls 9 which define an angle, in this particular example again an angle of about 123 degrees, to the walls 7.
  • the plane of each of the walls 7, 8 and 9 is perpendicular to the plane of the top sheet 3.
  • the support walls 7, 8 and 9 are of a uniform thickness in order to obtain more uniform performance characteristics across the hollow support structure.
  • each of the walls 7, 8 and 9 is of 13mm thickness.
  • the hollow support structure 2 is formed in its hollow form by a moulding process, from expanded plastics material.
  • the support structure is moulded from expanded polystyrene.
  • Figure 3 shows the support structure in greater detail and shows a repeating portion of the structure.
  • Some typical dimensions of the cellular structure are marked in Figure 3 .
  • a spacing S1 between intersections of the walls 8 and 9 on opposite sides of a cell is marked.
  • the spacing S1 is about 200mm and the spacing S2 is about 155mm, measured in each case between the middles of the walls 7, 8 and 9.
  • a spacing S3 which is the centre-to-centre spacing of the cells in a widthwise direction and a spacing S4 which is the centre-to-centre spacing of the cells in a lengthwise direction.
  • the spacing S3 is about 150mm and the spacing S4 is the same as S3 and therefore about 155mm.
  • FIG. 4 and 5 The manner in which the shuttering panel 1 is used in laying a floor slab of a building is illustrated in Figures 4 and 5 .
  • the normal surface level of the substrate 10 is shown, as is one of the piles 11 that are sunk into the substrate to support the building.
  • a conventional ground beam 12 of reinforced concrete extends along the top of a line of piles 11, to support one of the walls of the building between which a suspended floor slab is to be constructed.
  • the substrate over which the floor slab is to be constructed is excavated to the required depth and the surface of the substrate is made level.
  • Shuttering panels 13, each as shown in Figures 1 to 3 are then laid edge to edge to cover the prepared surface completely.
  • the joins between adjacent panels are covered over, for example with a formwork tape.
  • Full size panels may be cut to ensure the prepared surface is completely covered.
  • Conventional steel reinforcement (not shown) for the suspended floor panel is then secured over the panels 13, and is spaced slightly above the tops of the panels by conventional spacers (not shown). Concrete is then laid over the support panels 13 and vibrated in the normal way. When the top surface of the concrete has been finished, for example by tamping, the concrete is left to cure. During the laying and initial curing process, the concrete is supported by the panels 13 but, as the concrete cures, the floor slab 14 becomes self-supporting between the walls.
  • Figure 5 shows the situation where there has been some heaving movement but not as much as the shuttering is designed to accommodate.
  • Figure 5 shows the support structure as it is collapsing and occupying a depth d'. If no heaving movement of the substrate occurs to bring about the failure of the support walls 7, 8 and 9, the shuttering panel 1 and in particular, the hollow support structure 2, will remain intact.
  • shuttering of the type above it is also possible to use shuttering of the type above to provide support on which a ground beam 12 is cast. In this case, panels of a different size are likely to be required. Typically, shuttering panels for use in casting ground beams have a width in the range 300mm to 1200mm and, most commonly 450mm and 600mm.
  • Shuttering of the type above can be used in many situations in which concrete slabs or beams are cast over a substrate, for example, under reinforced suspended ground and basement floors, piled beams and piled rafts.
  • the support structure of the shuttering can compress and collapse under the load from the substrate, caused for example by swelling clay or ground heave, and allows movement and pressure release to occur.
  • the hollow support structure 2 of the shuttering panel also serves to insulate the concrete and thus accelerates the curing of the concrete, especially in cold weather.
  • the dimensions of the hollow support structure are determined by the mould.
  • the hollow support structure is produced in sections which are typically 2.4m long and 1.2m wide.
  • the top sheet 3 comprises simply a single polypropylene sheet, it will typically have a thickness of the order of 5mm to 10mm.
  • the top sheet 3 comprises a layer of expanded polystyrene on top of which there is a polypropylene sheet it may have a thickness of the order of 50mm.
  • the dimensions referred to above for the cells of the support structure and the overall dimensions of the panel described above are particularly advantageous as the most commonly used widths, 450mm and 600mm, can be easily cut from the moulded panel. Sections of support structures of these widths are generally used to support ground beams rather than cast floor slabs.
  • the full size moulded support structure panel may be cut using a saw or a hot wire. In the case of a beam of 600mm in width, the full size panel is cut, using hot wires, into two sections. The panel is cut parallel to the long sides 4.
  • the thickness, spacing and/or height of the support walls 7, 8 and 9 can be varied, having regard to the conditions under which the walls are required to fail and bearing in mind that a change in the thickness and number of walls will alter the surface area over which the walls contact the substrate.
  • the support structure 2 is moulded in one piece directly in the shape shown in Figures 1 to 3 . Since the support structure 2 is devoid of any bulky regions, all of it is close to a surface of the mould during the moulding process and it is therefore possible to achieve a very good uniformity throughout the structure 2 of the density of the expanded material forming the structure.
  • mould portions are introduced into the cell space from opposite sides. For each cell, one half of the cell is filled by a mould portion introduced from one side and one half is filled from a mould portion introduced from the other side. The mould portions meet at a plane that is inclined to the vertical so that each mould portion is tapered towards its leading end.
  • mould portions can be introduced into the cells with clearance between them, only coming together along their interface when they reach their fully inserted positions. Similarly, when they are withdrawn after moulding, they can be moved apart in directions inclined to the adjacent moulded walls with a component of the movement away from the walls.
  • the shuttering panel shown in Figures 1 to 3 can, if required, be modified further by adding a bottom sheet similar to the top sheet which is locatable between the support structure and the substrate.
  • This bottom sheet may be made out of a sheet of a suitable rigid material similar to that of the top sheet: it may, for example, also be expanded polystyrene.
  • the surface may be bonded to the hollow support structure, for example by an impact adhesive.
  • Figure 6 illustrates an especially advantageous modification to the support structure 2.
  • the walls 7, 8 and 9 are recessed at their intersections to create recesses 20.
  • Figure 6 shows the recesses at the tops of the walls 7, 8 and 9, but it should be understood that similar recesses may be provided at the bottoms of the walls.
  • the recesses define passageways that provide fluid communication between adjacent cells, with all three cells adjoining an intersection being in communication with one another via the passageways.
  • the recesses also have the advantage of reducing the extent to which compressive loads on the structure are borne by the intersecting portions of the walls 7, 8 and 9, and of defining a relatively large space in a mould for an injector through which mould material can be injected into the walls 7, 8 and 9 during moulding.
  • the shuttering is of the kind described above with reference to Figs. 1 to 3 and the support structure has the dimensions referred to above.
  • the depth D of the walls 7, 8 and 9 when first moulded is about 215mm.
  • the support structure 2 is moulded from expanded polystyrene having a density of about 20kg/m 3 and this results in shuttering with a Safe Load of 9kN/m 2 and a Fail Load of 13kN/m 2 .
  • the Fail Load of 13kN/m 2 is applied, the support structure 2 reduces in depth by about 150mm to a depth d of about 65mm.
  • the depth D of the walls 7, 8 and 9 when first moulded is about 150mm.
  • the support structure 2 is moulded from expanded polystyrene having a density of about 30kg/m 3 and this results in shuttering with a Safe Load of 17kN/m 2 and a Fail Load of 23kN/m 2 .
  • the Fail Load of 17kN/m 2 is applied, the support structure 2 reduces in depth by about 100mm to a depth d of about 50mm.
  • the depth D of the walls 7, 8 and 9 when first moulded is about 150mm.
  • the support structure 2 is moulded from expanded polystyrene having a density of about 18kg/m 3 .
  • the shuttering is then cut in half by a hot wire to provide shuttering of depth about 75mm and this results in shuttering with a Safe Load of 7kN/m 2 and a Fail Load of 10kN/m 2 .
  • the Fail Load of 10kN/m 2 is applied, the support structure 2 reduces in depth by about 50mm to a depth d of about 25mm.

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  • Architecture (AREA)
  • Civil Engineering (AREA)
  • Structural Engineering (AREA)
  • Mechanical Engineering (AREA)
  • Life Sciences & Earth Sciences (AREA)
  • Environmental & Geological Engineering (AREA)
  • Hydrology & Water Resources (AREA)
  • General Life Sciences & Earth Sciences (AREA)
  • Mining & Mineral Resources (AREA)
  • Paleontology (AREA)
  • General Engineering & Computer Science (AREA)
  • Moulds, Cores, Or Mandrels (AREA)
  • Forms Removed On Construction Sites Or Auxiliary Members Thereof (AREA)

Claims (15)

  1. Coffrage destiné à être utilisé pour la coulée d'une brame ou d'une poutrelle (14) sur un substrat, comprenant une structure de support creuse (2) comportant une pluralité de parois de support (7, 8, 9) espacées les unes des autres et définissant entre elles des cellules (6), la structure de support (2) pouvant être placée sur le substrat pour soutenir la brame ou la poutrelle (14) pendant la coulée, dans lequel la structure de support est formée avec ses parois espacées par un procédé de moulage et à partir d'une matière plastique expansée, caractérisé en ce que les cellules (6) sont d'une forme sensiblement hexagonale.
  2. Coffrage selon la revendication 1, dans lequel chaque cellule (6) sensiblement hexagonale présente la forme d'un hexagone irrégulier.
  3. Coffrage selon la revendication 2, dans lequel au moins une paire de parois opposées (7, 8, 9) de la cellule sensiblement hexagonale sont sensiblement parallèles entre elles.
  4. Coffrage selon la revendication 3, dans lequel le coffrage est un panneau de forme rectangulaire et une paire de parois sensiblement parallèles (7) s'étendent de façon sensiblement parallèle à des bords d'extrémité plus courts du panneau.
  5. Coffrage selon la revendication 4, dans lequel ladite une paire de parois sensiblement parallèles (7) sont espacées l'une de l'autre d'une distance inférieure à l'espacement des autres parois opposées de la cellule sensiblement hexagonale.
  6. Coffrage selon l'une quelconque des revendications 3 à 5, dans lequel les trois paires de parois opposées (7, 8, 9) sont sensiblement parallèles entre elles.
  7. Coffrage selon l'une quelconque des revendications précédentes, dans lequel les parois (7, 8, 9) ont une épaisseur inférieure à 15 mm.
  8. Coffrage selon l'une quelconque des revendications précédentes, dans lequel la structure de support (2) présente un premier état de support dans lequel la profondeur de la structure de support est D et un second état de défaillance dans lequel la profondeur de la structure de support est d, d étant inférieur à 0,38D.
  9. Coffrage selon l'une quelconque des revendications précédentes, dans lequel les parois sont en retrait dans les régions d'au moins certains de leurs croisements.
  10. Coffrage selon la revendication 9, dans lequel les retraits (20) définissent des passages entre des cellules (6) adjacentes.
  11. Procédé de fabrication d'un coffrage destiné à être utilisé pour la coulée d'une brame ou d'une poutrelle (14) sur un substrat, le procédé comprenant l'étape consistant à mouler une structure de support (2) à partir d'un polystyrène expansé pour fournir un coffrage (1) selon l'une quelconque des revendications précédentes.
  12. Procédé selon la revendication 11, comprenant l'étape consistant à introduire de la matière dans le moule à des emplacements correspondant aux croisements des parois de support.
  13. Procédé selon la revendication 11 ou 12, dans lequel durant le moulage, une cellule hexagonale (6) est créée dans la structure de support (2) par la combinaison d'une première partie de moule insérée dans la cellule depuis un premier côté de la structure de support et d'une seconde partie de moule insérée dans la cellule depuis le côté opposé de la structure de support.
  14. Procédé selon la revendication 13, dans lequel les première et seconde parties de moule ont des faces en regard et inclinées de façon complémentaire qui se rejoignent au milieu d'une cellule hexagonale lorsque la matière plastique expansée est introduite dans le moule.
  15. Procédé selon l'une quelconque des revendications 11 à 14, comprenant l'étape qui consiste à découper le produit moulé en deux moitiés le long d'un plan à mi-chemin entre la partie supérieure et la partie inférieure de la structure de support.
EP11804769.5A 2010-12-23 2011-12-21 Coffrage Active EP2655762B1 (fr)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
GB1021915.2A GB2486723B (en) 2010-12-23 2010-12-23 Shuttering
PCT/GB2011/052545 WO2012085570A2 (fr) 2010-12-23 2011-12-21 Coffrage

Publications (2)

Publication Number Publication Date
EP2655762A2 EP2655762A2 (fr) 2013-10-30
EP2655762B1 true EP2655762B1 (fr) 2018-07-04

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Family Applications (1)

Application Number Title Priority Date Filing Date
EP11804769.5A Active EP2655762B1 (fr) 2010-12-23 2011-12-21 Coffrage

Country Status (4)

Country Link
EP (1) EP2655762B1 (fr)
ES (1) ES2686552T3 (fr)
GB (1) GB2486723B (fr)
WO (1) WO2012085570A2 (fr)

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EP3495584A1 (fr) * 2017-12-11 2019-06-12 Eurojoint Squelette pour élément de construction, élément de construction comprenant un tel squelette et procédé de réalisation associé

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AU2016203082A1 (en) * 2015-05-29 2016-12-15 Airformer Pty Ltd Apparatus and elements for use in building construction

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GB1605136A (en) * 1977-08-10 1982-02-10 Applied Surfaces Ltd Collapsible structure and method of building using such a structure
GB2095740B (en) * 1981-03-27 1985-01-30 Magnex Ltd Method of building
GB2130524B (en) * 1982-04-21 1986-04-03 Magnex Ltd Collapsible structure and method of using such a structure
GB2120167B (en) * 1982-04-21 1986-07-09 Beldale Investments Ltd A deformable structure and method of using such a structure
GB2241976B (en) 1987-06-29 1992-01-08 Cordek Ltd Shuttering for use in casting slabs or beams
GB8715178D0 (en) 1987-06-29 1987-08-05 Cordek Ltd Shuttering
CA2053087A1 (fr) * 1991-10-09 1993-04-10 Thomas C. Smerchanksi Cadre de soutien pour poutre de mur porteur
US6649110B1 (en) * 2000-05-31 2003-11-18 Ols Consulting Services, Inc. Method for manufacturing molded panels
DE20106810U1 (de) * 2001-03-30 2001-10-04 Max Frank GmbH & Co. KG, 94339 Leiblfing Schalungselement für den Betonbau
GB2417283B (en) 2002-07-02 2007-02-07 Cordek Ltd Shuttering for use in casting slabs or beams
WO2005045158A1 (fr) * 2003-10-07 2005-05-19 M.A.S. Systeme Gesellschaft für Kunststoffprodukte mbH Panneau de coffrage a noyau alveolaire
FR2899839B1 (fr) * 2006-04-12 2011-01-14 Tonelli France Sas Materiau en carton alveolaire perfore pour le coffrage de parois

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EP3495584A1 (fr) * 2017-12-11 2019-06-12 Eurojoint Squelette pour élément de construction, élément de construction comprenant un tel squelette et procédé de réalisation associé

Also Published As

Publication number Publication date
GB2486723A (en) 2012-06-27
WO2012085570A3 (fr) 2012-10-26
GB2486723B (en) 2017-08-23
GB201021915D0 (en) 2011-02-02
ES2686552T3 (es) 2018-10-18
WO2012085570A2 (fr) 2012-06-28
EP2655762A2 (fr) 2013-10-30

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