EP2907924B1 - Schalung für die Baubranche - Google Patents

Schalung für die Baubranche Download PDF

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Publication number
EP2907924B1
EP2907924B1 EP15153643.0A EP15153643A EP2907924B1 EP 2907924 B1 EP2907924 B1 EP 2907924B1 EP 15153643 A EP15153643 A EP 15153643A EP 2907924 B1 EP2907924 B1 EP 2907924B1
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EP
European Patent Office
Prior art keywords
support structure
walls
shuttering
depth
substrate
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Active
Application number
EP15153643.0A
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English (en)
French (fr)
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EP2907924B2 (de
EP2907924A1 (de
Inventor
Alastair SEATON
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Cordek Ltd
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Cordek Ltd
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Classifications

    • 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
    • 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
    • E02—HYDRAULIC ENGINEERING; FOUNDATIONS; SOIL SHIFTING
    • E02D—FOUNDATIONS; EXCAVATIONS; EMBANKMENTS; UNDERGROUND OR UNDERWATER STRUCTURES
    • E02D27/00—Foundations as substructures
    • E02D27/01—Flat foundations
    • E—FIXED CONSTRUCTIONS
    • E02—HYDRAULIC ENGINEERING; FOUNDATIONS; SOIL SHIFTING
    • E02D—FOUNDATIONS; EXCAVATIONS; EMBANKMENTS; UNDERGROUND OR UNDERWATER STRUCTURES
    • E02D27/00—Foundations as substructures
    • E02D27/01—Flat foundations
    • E02D27/013—Shuttering specially adapted therefor
    • E—FIXED CONSTRUCTIONS
    • E02—HYDRAULIC ENGINEERING; FOUNDATIONS; SOIL SHIFTING
    • E02D—FOUNDATIONS; EXCAVATIONS; EMBANKMENTS; UNDERGROUND OR UNDERWATER STRUCTURES
    • E02D27/00—Foundations as substructures
    • E02D27/01—Flat foundations
    • E02D27/016—Flat foundations made mainly from prefabricated concrete elements
    • 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
    • E04G9/10—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, to a method of manufacturing such shuttering and to a method of casting a slab/beam over a substrate.
  • 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 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 failed condition.
  • the depth (d) of the support structure in the second failed 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 failed 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 failed 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 walls, 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 is moulded from expanded plastics material and characterized in that the support structure has a first supporting condition in which the depth of the support structure is D and a second collapsed condition in which the depth of the support structure is d, wherein d is less than 0.38D.
  • a support structure in which the depth of the structure reduces to less than 0.38 of its original depth upon failure it becomes possible to provide an arrangement in which the amount of excavation required to provide a support structure capable of accommodating a given upward movement of a substrate is reduced, thereby reducing the cost of using the shuttering according to the invention.
  • a support structure able to accommodate about 150mm of upward movement has depth D in a first supporting condition of about 215mm and a depth d in a second failed condition of about 65mm.
  • 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 failed condition of 95mm.
  • d is less than 0.36D and more preferably d is less than 0.33D.
  • 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 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 collapsed 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 collapsed 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 collapsed 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 hollow support structure may define 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 transverse to the first direction. Whilst it is within the scope of the invention for the first and second directions in which the walls extend to be at an angle significantly away from 90 degrees, it is preferred that the second direction is perpendicular to the first direction.
  • the spacing of adjacent walls is preferably uniform across the structure, preferably in the case of both sets of walls.
  • the spacing of walls in one of the sets of walls may be the same as or different from the spacing in the other of the two directions.
  • the centre-to-centre spacing of adjacent walls in one of the sets of walls is in the range of 148mm to 152mm.
  • the centre-to-centre spacing of adjacent walls in one of the set of walls is in the range of 158mm to 162mm.
  • the spacing of the first set of walls is in the range of 148mm to 152mm and the spacing of the second set of walls is in the range of 158mm to 162mm.
  • a spacing of about 150mm is especially suitable for a support structure that may be cut to form shuttering for beams that are 600mm wide or 450mm wide or of any other width that is an integral number of 150mm widths.
  • the planes of the support walls whilst approximately vertical, are angled to the vertical, preferably at an angle in the range of 0.5 to 5 degrees to the vertical; in an embodiment described below, the angle is about 1.3 degrees to the vertical, and larger inclinations are acceptable.
  • adjacent walls are angled in opposite directions, so that whilst one cell tapers in one direction through the thickness of the support structure the adjacent cells taper in the opposite direction. As explained below, such an arrangement facilitates moulding of the support 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, between three adjacent cells or, as in a preferred embodiment, between four 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 support structure is open on its top face and 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. When the sheet comprises a polypropylene sheet alone, it may be 5mm to 10mm thick.
  • the invention When in use a slab or beam is cast on shuttering of the invention, a structure is formed with the shuttering below. Accordingly, the invention also provides a structure including a slab or beam cast on shuttering of the first second or third aspects of the invention.
  • 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 second or third aspects 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.
  • 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 present invention still further provides a method of casting a slab/beam over a substrate, the method including the step of placing shuttering according to any of the first second or third aspects of the invention on the substrate, and casting the slab/beam on the top of the shuttering.
  • the substrate may rise after casting of the slab/beam and the shuttering may then fail. Thus excess upward pressure on the slab/beam is avoided.
  • 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 6,7.
  • the plane of each wall is substantially perpendicular to the plane of the top sheet 3.
  • the support walls 6,7 whilst substantially perpendicular, are angled to the vertical at an angle of the order of one degree.
  • Some of the support walls, referenced 6, run parallel to the long sides 4 of the top sheet, while the remaining support walls, referenced 7, run in a direction substantially parallel to the short sides of the top sheet 3 and therefore perpendicular to the long sides and to the walls 6.
  • the support walls 6 extend continuously along the length of the top sheet 3 and the support walls 7 extend continuously across the width of the top sheet 3.
  • the support walls are of a uniform thickness in order to obtain more uniform performance characteristics across the hollow support structure.
  • the support walls are spaced apart substantially regularly in both directions such that the support walls define cells 8,9.
  • the cells 8,9 defined by the support walls 6,7 are approximately square in plan.
  • 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.
  • FIGS 3 and 4 show the support structure in greater detail.
  • the cells 8,9 defined by the support walls 6,7 taper slightly between the top sheet 3 and the bottom of the hollow support structure 2.
  • the angling of the substantially perpendicular support walls has been exaggerated.
  • Some of the cells, referenced 8, defined by the support walls 6,7 have a larger cross section at the bottom of the hollow support structure 2 than at the top of the support structure 2.
  • the remaining cells, referenced 9, have a smaller cross section at the bottom of the hollow support structure 2 than at the top of the support structure.
  • the distance between adjacent walls 6,7 varies as a function of displacement from the top sheet 3 towards the substrate in a direction perpendicular to the plane of the top surface of the support structure. This tapered cell structure enables simple release of the moulded hollow support structure from the mould.
  • FIG. 6 and 7 The manner in which the shuttering panel 1 is used in laying a floor slab of a building is illustrated in Figures 6 and 7 .
  • 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 5 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.
  • heaving movement occurs in the substrate, a vertical compressive force is exerted on the support walls 6,7. Initially creep occurs in the expanded polystyrene material and, if the heaving movement of the substrate is extensive, the support walls 6,7 begin to compress. If the compressive force on the support walls 6,7 is such that it exceeds a predetermined limit, the moulding will fail. The resistance of the support walls 6, 7 to further compression will actually reduce and thus the resistance to further heaving movement reduces. Of course, if the heaving movement were to continue beyond the amount that the shuttering is designed to accommodate, the resistance to heaving movement would then increase beyond the original resistance level.
  • Figure 7 shows the situation where there has been some heaving movement but not as much as the shuttering is designed to accommodate.
  • Figure 7 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 breakup of the support walls 6,7 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.
  • Other dimensions of the shuttering will be described in more detail below with reference to some particular examples.
  • the centre-to-centre spacing of the walls 6 is 150mm and the centre-to-centre spacing of the walls 7 is 160mm.
  • the dimensions referred to are particularly advantageous as the most commonly used widths, 450mm to 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, number, height and/or layout of the support walls 6,7 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 size of the cells defined by the walls can be decreased by increasing the number of shorter support walls 7 and/or increasing the number of longer support walls 6.
  • the support structure 2 is moulded in one piece directly in the shape shown for example in Figure 5 .
  • Alternate cells are formed by projecting parts of appropriate halves of the mould and the tapering of the cells assist the withdrawal of the mould halves from the support structure after moulding. 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.
  • the shuttering panel shown in Figures 1 and 2 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 8 illustrates an especially advantageous modification to the support structure 2.
  • the walls 6 and 7 are recessed at their intersections to create recesses 20.
  • Figure 8 shows the recesses at the tops of the walls 6 and 7, 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 four 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 6 and 7, and of defining a relatively large space in a mould for an injector through which mould material can be injected into the walls 6 and 7 during moulding.
  • the depth D of the walls 6 and 7 when first moulded is about 215mm.
  • the support structure 2 is moulded from expanded polystyrene having a density of about 19kg/m 3 and this results in shuttering with a Safe Load of 9kN/m 2 and a Fail Load of 13kN/m 2 When in testing, 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 6 and 7 when first moulded is about 150mm.
  • the support structure 2 is moulded from expanded polystyrene having a density of about 28kg/m 3 and this results in shuttering with a Safe Load of 17kN/m 2 and a Fail Load of 23kN/m 2 When in testing, the Fail Load of 23kN/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 6 and 7 when first moulded is about 150mm.
  • the support structure 2 is moulded from expanded polystyrene having a density of about 22kg/m 3
  • the structure is then cut in half by a hot wire to provide two structures of depth about 75mm and this results in shuttering with a Safe Load of 13kN/m2 and a Fail Load of 18kN/m 2 .
  • the Fail Load of 18kN/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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  • Engineering & Computer Science (AREA)
  • Civil Engineering (AREA)
  • Structural Engineering (AREA)
  • Architecture (AREA)
  • Life Sciences & Earth Sciences (AREA)
  • Mining & Mineral Resources (AREA)
  • General Life Sciences & Earth Sciences (AREA)
  • Paleontology (AREA)
  • General Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Environmental & Geological Engineering (AREA)
  • Hydrology & Water Resources (AREA)
  • Moulds, Cores, Or Mandrels (AREA)
  • Forms Removed On Construction Sites Or Auxiliary Members Thereof (AREA)

Claims (15)

  1. Schalung zur Verwendung beim Gießen von einer Platte oder einem Balken über einem Substrat, wobei die Schalung eine hohle Trägerstruktur (2) aufweist, welche eine Vielzahl von voneinander beabstandeten Wänden (6, 7) aufweist, wobei die Trägerstruktur (2) auf dem Substrat angeordnet werden kann, um die Platte oder den Balken während des Gießens zu tragen, wobei die Trägerstruktur (2) mit ihren voneinander beabstandeten Wänden (6, 7) mit einem Formgebungsprozess geformt ist und aus expandiertem Kunststoffmaterial geformt ist,
    dadurch gekennzeichnet,
    dass die Trägerstruktur (2) einen ersten tragenden Zustand, in welchem die Tiefe der Trägerstruktur (2) einen Wert D besitzt, und einen zweiten kollabierten Zustand aufweist, in welchem die Tiefe der Trägerstruktur (2) einen Wert d besitzt, wobei d kleiner als 0,38D ist.
  2. Schalung nach Anspruch 1,
    wobei die Tiefe D der Trägerstruktur (2) in dem ersten tragenden Zustand im Bereich von 200 mm bis 220 mm liegt und die Tiefe d der Trägerstruktur (2) in dem zweiten kollabierten Zustand um mehr als 140 mm geringer als die Tiefe D im ersten tragenden Zustand ist.
  3. Schalung nach Anspruch 1 oder 2,
    wobei die Tiefe D der Trägerstruktur (2) in dem ersten tragenden Zustand im Bereich von 140 mm bis 160 mm liegt und die Tiefe d der Trägerstruktur (2) in dem zweiten kollabierten Zustand um mehr als 90 mm geringer als die Tiefe D in dem ersten tragenden Zustand ist.
  4. Schalung nach einem der vorhergehenden Ansprüche,
    wobei die Tiefe D der Trägerstruktur in dem ersten tragenden Zustand im Bereich von 70 mm bis 80 mm liegt und die Tiefe d der Trägerstruktur (2) in dem zweiten kollabierten Zustand um mehr als 45 mm geringer als die Tiefe D in dem ersten tragenden Zustand ist.
  5. Schalung nach einem der vorhergehenden Ansprüche,
    wobei die hohle Trägerstruktur (2) eine Vielzahl von vierseitigen Zellen bildet, die durch einen ersten Satz von Wänden (6) begrenzt sind, welche sich längs der Struktur in einer ersten Richtung erstrecken, und einen zweiten Satz von Wänden (7) begrenzt sind, welche sich längs der Struktur in einer zweiten Richtung quer zu der ersten Richtung erstrecken.
  6. Schalung nach Anspruch 5,
    wobei der Abstand von benachbarten Wänden (6, 7) der Trägerstruktur (2) gleichmäßig über die Struktur ausgebildet ist und der Abstand von Mittezu-Mitte von benachbarten Wänden (6, 7) in einem der Sätze von Wänden im Bereich von 148 mm bis 152 mm liegt und/oder der Abstand von Mittezu-Mitte von benachbarten Wänden (6, 7) in einem der Sätze von Wänden in dem Bereich von 158 mm bis 162 mm liegt.
  7. Schalung nach einem der vorhergehenden Ansprüche,
    wobei die Ebene von jeder Stützwand (6, 7) ungefähr vertikal ist, aber gegenüber der Vertikalen geneigt ist.
  8. Schalung nach einem der vorhergehenden Ansprüche,
    wobei die Wände (6, 7) in den Bereichen von mindestens einigen von ihren Kreuzungen mit Aussparungen versehen sind, wobei die Aussparungen Durchgänge zwischen benachbarten Zellen bilden.
  9. Schalung nach einem der vorhergehenden Ansprüche,
    die ferner einen oberen Flächenkörper (3) aus einem Material an der Oberseite der Trägerstruktur (2) aufweist.
  10. Schalung nach einem der vorhergehenden Ansprüche,
    wobei die Dicke der Wände (6, 7) weniger als 15 mm beträgt.
  11. Struktur mit einer Platte oder einem Balken, der auf der Schalung nach einem der vorhergehenden Ansprüche gegossen ist.
  12. Verfahren zum Herstellen einer Schalung zur Verwendung beim Gießen von einer Platte oder einem Balken über einem Substrat,
    wobei das Verfahren einen Schritt aufweist, bei dem eine Trägerstruktur (2) aus expandiertem Polystyrolmaterial geformt wird, um eine Schalung gemäß einem der Ansprüche 1 bis 10 zu bilden.
  13. Verfahren nach Anspruch 12,
    das einen Schritt aufweist, bei dem ein Material in die Form an Orten eingeführt wird, welche Kreuzungen der Tragwände (6, 7) entsprechen.
  14. Verfahren nach Anspruch 12 oder 13,
    das einen Schritt aufweist, bei dem das geformte Produkt in zwei Hälften geschnitten wird, und zwar längs einer Ebene, die zwischen der Oberseite und der Unterseite der Trägerstruktur liegt.
  15. Verfahren zum Gießen einer Platte oder eines Balkens über einem Substrat, wobei das Verfahren einen Schritt umfasst, bei dem eine Schalung (12) gemäß einem der Ansprüche 1 bis 10 auf dem Substrat angeordnet wird, und einen Schritt, bei dem die Platte oder der Balken (13) auf der Oberseite der Schalung gegossen wird.
EP15153643.0A 2010-12-23 2011-12-21 Schalung für die Baubranche Active EP2907924B2 (de)

Applications Claiming Priority (3)

Application Number Priority Date Filing Date Title
GB1021914.5A GB2486722B (en) 2010-12-23 2010-12-23 Shuttering for use in the construction industry
PCT/GB2011/052544 WO2012085569A2 (en) 2010-12-23 2011-12-21 Shuttering for use in the construction industry
EP11804768.7A EP2655749B8 (de) 2010-12-23 2011-12-21 Schalung für flachgründung

Related Parent Applications (2)

Application Number Title Priority Date Filing Date
EP11804768.7A Division EP2655749B8 (de) 2010-12-23 2011-12-21 Schalung für flachgründung
EP11804768.7A Division-Into EP2655749B8 (de) 2010-12-23 2011-12-21 Schalung für flachgründung

Publications (3)

Publication Number Publication Date
EP2907924A1 EP2907924A1 (de) 2015-08-19
EP2907924B1 true EP2907924B1 (de) 2016-09-14
EP2907924B2 EP2907924B2 (de) 2019-10-09

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Application Number Title Priority Date Filing Date
EP15153643.0A Active EP2907924B2 (de) 2010-12-23 2011-12-21 Schalung für die Baubranche
EP11804768.7A Active EP2655749B8 (de) 2010-12-23 2011-12-21 Schalung für flachgründung

Family Applications After (1)

Application Number Title Priority Date Filing Date
EP11804768.7A Active EP2655749B8 (de) 2010-12-23 2011-12-21 Schalung für flachgründung

Country Status (4)

Country Link
EP (2) EP2907924B2 (de)
ES (2) ES2603081T5 (de)
GB (1) GB2486722B (de)
WO (1) WO2012085569A2 (de)

Families Citing this family (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JP6416239B2 (ja) * 2013-06-11 2018-10-31 ファビオ・パロディＦａｂｉｏ ＰＡＲＯＤＩ コンクリートスラブ形成方法及び支持要素

Citations (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
GB2206637A (en) 1987-06-29 1989-01-11 Cordek Ltd Collapsible shuttering to absorb ground heave
US5339578A (en) 1991-10-09 1994-08-23 Aerofoam Chemicals, Division Of Border Chemical Company Support form for a grade beam or slab
US5352064A (en) 1991-04-26 1994-10-04 Plasti-Fab Ltd. Collapsible spacer
GB2390390A (en) 2002-07-02 2004-01-07 Cordek Ltd Collapsible shuttering for use in casting slabs or beams

Family Cites Families (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
GB2241976B (en) * 1987-06-29 1992-01-08 Cordek Ltd Shuttering for use in casting slabs or beams
CA2282109C (en) * 1999-09-14 2005-12-20 Robert Eugene Vasseur Apparatus for creating a void under a structural concrete slab
GB2384010A (en) * 2002-01-09 2003-07-16 Kay Metzeler Ltd A starch based compressible fill for use in reducing the effects of ground heave
AU2009201776A1 (en) * 2008-05-05 2009-11-19 Francesco Antonio Martino A footing levelling mould for transportable buildings

Patent Citations (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
GB2206637A (en) 1987-06-29 1989-01-11 Cordek Ltd Collapsible shuttering to absorb ground heave
US5352064A (en) 1991-04-26 1994-10-04 Plasti-Fab Ltd. Collapsible spacer
US5339578A (en) 1991-10-09 1994-08-23 Aerofoam Chemicals, Division Of Border Chemical Company Support form for a grade beam or slab
GB2390390A (en) 2002-07-02 2004-01-07 Cordek Ltd Collapsible shuttering for use in casting slabs or beams

Also Published As

Publication number Publication date
ES2603081T3 (es) 2017-02-23
EP2655749A2 (de) 2013-10-30
WO2012085569A2 (en) 2012-06-28
ES2603081T5 (es) 2020-05-28
GB2486722A (en) 2012-06-27
GB201021914D0 (en) 2011-02-02
WO2012085569A3 (en) 2013-05-10
EP2907924B2 (de) 2019-10-09
GB2486722B (en) 2017-10-04
EP2655749B1 (de) 2015-02-11
EP2907924A1 (de) 2015-08-19
ES2536642T3 (es) 2015-05-27
EP2655749B8 (de) 2015-04-22

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