GB2282406A

GB2282406A - Method and apparatus for forming a structure of stacked concrete members

Info

Publication number: GB2282406A
Application number: GB9419693A
Authority: GB
Inventors: Edward Emrys Jones
Original assignee: Individual
Current assignee: Individual
Priority date: 1993-09-30
Filing date: 1994-09-29
Publication date: 1995-04-05
Also published as: GB9419693D0; GB9320168D0

Abstract

Concrete retaining means (10) is positioned at a location at which a concrete member is required, and concrete (32) is introduced therein, to form e.g. a garden wall. Once the concrete (32) has set to a suitable degree, the concrete retaining member (10) can be removed therefrom and used for forming the next concrete member. The concrete retaining means (10, 34) includes a pivotable end wall which allows for the ready release and removal of the concrete retaining member (10) from the set concrete member (32). A structure of stacked concrete members can thereby be advantageously formed in situ. A separator (31) may be located under the means (10), and may be of water-absorbent material. The means (10) may comprises two members hinged together to facilitate the removal of the means (10) from the set concrete. <IMAGE>

Description

METHOD AND APPARATUS FOR FORMING A STRUCTURE OF STACKED CONCRETE MEMBERS The present invention relates to a method and apparatus for forming a structure of stacked concrete members - Structures, such as buildings, garages and walls are commonly formed from stacked concrete bricks which are cemented together. The laying of such brickwork is generally considered a skilled task and particularly in view of the structural rigidity required, the costs of forming known structures reflect the use of such skilled labour.

Further, even without employing the services of a skilled bricklayer, DIY methods of forming a structure such as an ornamental garden wall are also disadvantageous due to the expense and restrictions that arise from currently available building materials. For example, the size, shape and colour of concrete blocks for forming the structure are determined solely by the choice of the particular blocks that a would-be wall builder can obtain from retail outlets. Such blocks are also disadvantageously expensive.

The present invention seeks to provide a method and apparatus for forming a structure of stacked concrete members which do not exhibit the above-mentioned restrictions and disadvantages.

According to a first aspect of the present invention there is provided a method of forming a structure of stacked concrete members, comprising locating concrete retaining means so as to define the position at which a concrete member is to be located as part of said structure, introducing unset concrete to said concrete retaining means and removing said concrete retaining means from said concrete member when said concrete has become substantially set.

The invention can therefore provide for a method in which concrete blocks of a wall, or other structure, are actually cast in situ and this is particularly advantageous in allowing the builder to determine the exact size, shape and colour of the concrete blocks. Also, it has been found that the cost of erecting a structure, for example, a retaining party or ornamental wall in accordance with this invention can be more than halved when compared with known methods.

Advantageously, each of the concrete members of the structure can be formed in situ by appropriate location of the concrete retaining means. Further, two or more of said concrete retaining means may be simultaneously employed when forming the structure. Of course, the concrete retaining means can be removed once the concrete has become sufficiently dry as to remain in shape once the retainer is removed.

The method of the present invention may also involve the location of water-absorbent means adjacent said unset concrete. In particular, said water-absorbent means can be added to the unset concrete but not mixed with it and can be located below said concrete retaining means prior to the introduction of the unset concrete. The unset concrete is advantageously retained on said absorbent means, which means serves to accelerate the setting of the concrete and thus the transition of the concrete from an unset and thus unstable state to a set and thus stable state. The water absorbent means can comprise any appropriate material such as a powder mix or a sheet material layer.

Also, the method may include the location of separator means beneath the concrete retaining means which serves to prevent the concrete bonding to one of the other concrete members of the structure upon which it is to be supported. As such, the completed structure can then be readily dismantled in part or in total as required. In a preferred embodiment, the separator means may also comprises the water-absorbent member.

The time required to form a structure can therefore be advantageously reduced by means of said water-absorbent member, and in particular, one such member per concrete member.

The invention advantageously includes the location of partition means in said concrete retaining means so that a plurality of concrete members can be formed in situ, to any particular size or shape, and within said concrete retaining means.

As an alternative, the concrete can be introduced into the concrete retaining means so as to be supported on the surface of other concrete members of the structure and to bond thereto during the transition from an unstable state to a stable state. As such a rigid structure can advantageously be formed in an inexpensive and unrestricted manner.

Preferably, once each concrete member reaches its stable state, the concrete retaining means is removed from said member by way of a sliding action relative to the then stable concrete member. The concrete retaining means is then readily reusable as and when required. In particular, the method of the present invention involves withdrawing the concrete retaining means from the stable concrete member in a substantially horizontal sliding manner. As such, the concrete locating means includes a movable side wall portion which is opened so as to allow for the substantially horizontal withdrawal of the concrete retaining means from the then stable concrete member.

Alternatively, the concrete locating means can be arranged for upward lifting movement for removal from the concrete member.

In particular, the concrete locating means can be released from said concrete member by mutual pivoted motion of portions thereof. The mutual pivoted motion thereof is advantageously achieved by the use of scissor-action lever members engaged to respective portions of the concrete locating means.

In accordance with another aspect of the present invention, there is provided apparatus for forming a structure of stacked concrete members according to the above method.

According to a further aspect of the present invention, there is provided concrete casting apparatus for forming a structure of stacked concrete members, comprising frame means having side wall means for retaining unset concrete in a position at which a member is to be formed as part of said structure, said frame member defining a first opening through-which unset concrete is introduced thereto and a second opening through-which said unset concrete contacts a surface upon which said member is to be supported as part of said structure.

The apparatus is advantageous in allowing for the accurate location of the concrete for forming a member of said structure, while the concrete is in an unset form, and so the user can determine the size, shape and colour of the member as required.

Preferably, the apparatus includes partition means arranged to extend in said frame means and between side wall means for forming a plurality of discreet concrete members within said frame means. Such a feature is particularly advantageous in that the size and the shape of the concrete members to be formed can be varied in accordance with the builder's particular tastes or special requirements.

According to a further advantageous feature, the apparatus includes water-absorbent means for location beneath said frame means prior to the introduction of said unset concrete thereto. The water-absorbent means then serves to accelerate the setting of the concrete and thus the transition from an unset and thus unstable state to a set and thus stable state. Preferably said absorbent means comprises a layer of water-absorbent material.

Further, said apparatus can include spacer means for location beneath said frame means prior to the introduction of the unstable concrete so as to prevent the concrete then introduced into the frame means from bonding to the surface of a member of said structure upon which it is supported.

Such spacer means advantageously serve to allow for the dismantling of said structure. Of course, it will be appreciated that the water-absorbent means may also comprise said spacer means. Further, a separate waterabsorbent means and/or spacer means may of course be provided for supporting each of the concrete members of said structure.

According to a particularly advantageous feature, the side wall means of said frame means comprises a moveable portion which can be moved so as to assist withdrawal of the frame member from the stable concrete member. The movable portion may comprise one or more side wall members of said frame means.

The movable portion may be arranged to pivot relative to the remainder of said frame means and, as such, may include a handle member to assist such pivoting motion.

Alternatively, each portion of the frame means may be pivotable relative to the concrete member.

Preferably the movable side wall portion is arranged to be pivotable about an axis which extends substantially horizontally when said frame means is located so as to have said unstable concrete introduced thereto.

In one particular embodiment, said frame means comprises a plurality of side wall members, wherein said moveable portion comprises one of said side wall members.

In particular the pivotable side wall is pivotably mounted at each point of engagement to adjacent side wall means.

The apparatus may further comprise handle means for assisting the removal of the frame means from the stable concrete member formed therein.

In particular, the frame means may comprise two mutually pivotable portions each associates with respective handle means. The respective handle means may further be arranged to extend from junction regions between said portions.

The handle means may advantageously comprise lever means which are engaged for scissor-action pivotal motion so as to open said frame means for release from said concrete member.

As will be appreciated from the above, the present invention is advantageous in reducing the cost of erecting a structure formed from a stack of concrete members, which reduction may be as much as 50W as compared with a similar structure formed from pre-cast concrete blocks as is currently known. As such a structure can be readily formed in a DIY manner to any particular design without the need for known expensive materials and the services of a qualified craftsman. Use of the spacer members in the finished structure allows for ready dismantling at a later stage due to the vertical separation achieved between adjacent concrete members of the structure. However, the invention is particularly advantageous in that, although formed of such discreet members, the structure remains robust and sturdy.Further, the advantage of allowing for a would-be builder to mix the concrete allows for the colour of the final structure to be determined according to the builder's tastes or other requirements. Also, the surface of a concrete member can be deformed in some manner so as to provide for any require outward appearance or texture. For example, the surfaces can be chipped after some three to five hours from formation so as to create a rock-face texture.

Further, the side-wall means of the frame member may be curved. The curvature may be in a horizontal and/or vertical plane when the frame is in use. If the curvature is in the vertical plane alone, the movable portion of the side-wall means is particularly effective in permitting removal of the frame by sliding in a horizontal direction.

The stable concrete members formed according to one embodiment of the present invention can then have at least one side face that is curved in a horizontal and/or vertical plane. A shallow barrel-shaped concrete member can then be formed if required.

The invention as described further hereinafter, by way of example only, with reference to the accompanying drawings in which: Fig. 1 is a perspective view of concrete casting apparatus embodying the present invention; Fig. 2 is a perspective view of the apparatus of Fig 1 in position on a structure being formed in accordance with an embodiment of the present invention; Fig. 3 is a perspective view of the apparatus and structure of Fig 2 illustrating a further step in the construction of the structure of Fig 2; Fig. 4 is a perspective view of the uncompleted structure of Figs 2 and 3 with the apparatus of Fig. 1 removed; Fig. 5 is a perspective view of another embodiment of concrete casting apparatus according to the present invention; and Fig. 5 is a perspective view of the apparatus of Fig. 5 in an open or release state.

Fig. 1 is a perspective view of a frame member 10 for retaining unstable concrete in a position in which it is to form one of the concrete blocks of the structure shown in Fig. 2 and 3. The frame 10 comprises four side walls 1218. The side walls can be formed from any required material such as wood, plastic or metal or a combination thereof. The frame 10 is rectangular in nature and thus the length of one pair of opposite side walls 12,16, is greater than the length of the remaining pair 14,18. As can be seen, handles 20 extend upwardly from the opposite side walls 12,16.

One of the side walls 18 is pivotably mounted at respective ends thereof to opposite side portions of the walls 12,16. As such, the wall 18 forms an end flap member of the frame 10. Wall 18 has a handle 22 extending therefrom by which the wall 18 can be pivoted upwardly as will be described later.

The structural rigidity of the frame 10 is enhanced in the region of the flap end 18 by the provision of a cross bar member 24. The handle 22 has a crank portion (not shown in drawings) such that when the flap wall 18 is pivoted upwardly, as later described, the cross bar member 24 does not interfere with the required movement of the handle 22 and thus the flap wall 18.

The apparatus of the illustrated embodiment may also comprise at least one partition wall member (not shown) which can be arranged to extend within the frame 10 and between at least two of the walls 12-18 so that a plurality of concrete blocks, of a particular size and shape, can be formed within the single frame pen.

Fig.2 shows an ornamental garden wall 26 in the process of construction according to an embodiment of the present invention. The wall 26 comprises a plurality of stacked concrete blocks 28. As shown in Fig.2, the next block to be provided in the process of constructing the wall 26 is in the process of being formed by way of the frame 10 of Fig. 1.

An upper surface 30 of the part formed wall 26 provides a surface upon which the next layer of blocks are to be formed and the frame 10 is shown in the process of forming part of this next layer.

Prior to location of the frame 10 on the layer 30 a layer of water absorbent~material 31 is placed on the surface 30. The frame 10 is then located on the absorbent material 31 and in the appropriate position according to the stacking pattern of the wall 26 and unset concrete can be poured into the frame 10. Such recently poured concrete 32 is illustrated in Fig.2 and is retained in the appropriate position by way of the side walls 12-18 of the frame 10. The frame 10 remains in position until such time as the concrete 32 has become sufficiently dry, and thus stable. Once stable, the concrete 32 remains in position as a concrete block without requiring the retaining function of the walls 12-18 of the frame 10.The waterabsorbent material 31 assist in accelerating the setting of the concrete by readily absorbing the water content thereof.

The water absorbent material need not necessarily be formed as a layer. The water absorbent material 31 can comprise a powder mix which can be added to the unset concrete by gouging out a 'birds nest" in the centre of the concrete and introducing the powder into the hollow.

Once the concrete 32 is set the frame 10 is then removed so that it can be used for forming the next concrete block in the layer.

As can be seen from Fig. 3, the removal of the frame 10 is first achieved by tilting the handle 22 in the direction of the concrete 32 so as to pivot the flap wall 18 upwardly and away from the concrete 32 in the direction of arrow A. Once the flap wall 18 has pivoted into a substantially horizontal position, as shown in Fig.3, the frame 10 can be drawn outwardly and away from the concrete 32 in the direction of arrow B. The concrete 32 then remains in position as one of the concrete blocks of the wall 26 and this process can be repeated so as to form the remaining blocks of the wall 26.

Fig. 4 shows the state of the structure once the frame 10 has been removed to reveal set concrete block 32.

Fig. 5 is a perspective view of another embodiment of concrete casting apparatus 34 according to the present invention. The apparatus 34 comprises a first substantially rectilinear frame portion 36 and a second substantially rectilinear frame portion 38 which have side walls in engagement at a junction 40 so as to form a substantially square frame member. In a region of the junction 40, each frame portion 36, 38 has respective mounting plates 42, 44 fixedly secured to the frame portions 36, 38 by way of screws 46. Each of the mounting plates 42, 44 extends upwardly from the frame portions 36, 38 to form respective handle levers 46, 48 which are mutually pivotally engaged by way of a pivot joint 50.

The casting apparatus 34 can be manoeuvred and manipulated by way of the handle lever 46, 48 and, as will be described with reference to Fig. 6, the handle levers 46, 48 are arranged to be moved together in a pivotal manner so as to open, or release, the casting apparatus 34.

As will be appreciated, the embodiment of the present invention illustrated in Figs. 5 and 6 is particularly suited to the construction of a formation which involves removal of the casting apparatus in a generally upward manner rather than in a generally horizontal sliding manner. In view of the opening, or release, of the casting apparatus 34 that can be achieved by way of the handle levers 46, 48, the internal surface 52 of the frame portions 36, 38 can be formed with any particular shaped profile so as to provide an appropriate shaped profile on the concrete member being formed. In particular, the inner surface 52 of the frame portion 36, 38 can be provided with somewhat scalloped or concave profile.

With reference to Fig. 6, the casting apparatus 34 of Fig. 5 is illustrated with the handle levers 46, 48 having been pivoted around the pivot joint 50 in the directions of arrows A. This pivotal motion, by way of the mounting plates 42, 44, serves to open the casting apparatus 34 and therefore release the apparatus 34 from a concrete member formed therein. The particular location of the handle levers 46, 48 is advantageous in that the handles can be used not only to effect the aforementioned releasing function but also to allow for ready manipulation of the casting apparatus 34 and the lifting thereof from the formed concrete member.

As regards the profiled form of the inner surface 52 of the frame portions 36, 38, the inner surface 52 can be provided with a concave portion extending along the upper region thereof so as to form concrete members having correspondingly rounded convex upper peripheral portions.

A particularly advantageous form of the present invention provided by the embodiments of Figs. 5 and 6 is in itself enhanced by forming the frame portions 36, 38 of equal dimensions and the pivotal axis of the pivot joint 50 in a manner so that it extends parallel to the longitudinal axis of opposite sides of the casting apparatus 34.

It will of course be appreciated that, in use, concrete is introduced into the casting apparatus 34 when in the form illustrated in Fig. 5 and, once the concrete is suitably set, the casting apparatus 34 can be readily removed from the concrete member once opened or released, as shown in Fig. 6. The opening of the casting apparatus 34 as illustrated in Fig. 6 advantageously allows for the apparatus 34 to be lifted from the suitably set concrete member.

It will be clearly understood that the invention is particularly advantageous in that the shape, texture and colour of the concrete block is simply a matter of choice for the builder and thus these features are not dependent upon the supply of standardized blocks. In particular, the casting of two or more concrete blocks by way of two or more frames 10, and with absorbent material present, provides for an advantageously quick construction method.

The invention is not restricted at the details of the foregoing embodiments. For example, any one or more walls of the frame 10 can be moveable so as to allow for the withdrawal of the frame from the concrete block. Also the relative spacial locations of the wall members 12-18 themselves can be varied so as to vary the shape and size of the concrete blocks formed. As such, and as one of many possibilities, the end wall 14 can also be arranged to extend between the walls 12, 16 at a point some half way along the length of the walls 12, 16. The embodiment of Figs. 5 and 6 can also be provided with inner partitions for varying the shape, size and number of concrete members formed within the frame means.

As will be appreciated, the absorbent material can be provided in any appropriate form such as a sheet material or powdered material. In the latter case the powdered material may be formed as a layer between adjacent concrete members or introduced into the body of a concrete member.

The frame means can be formed of any required material such as wood, plastic or metal or a combination thereof.

It will be appreciated that other modifications and variations may be made to the embodiments described and illustrated within the scope of the present application.

Claims

1. A method of forming a structure of stacked concrete members, comprising locating concrete retaining means so as to define the position at which a concrete member is to be located as part qf said structure, introducing unset concrete to said concrete retaining means and removing said concrete retaining means from said concrete member when said concrete has become substantially set.

2. A method as claimed in claim 1, wherein each of the concrete members of the structure is formed in situ by appropriate location of the concrete retaining means.

3. A method as claimed in claim 1 or 2, wherein waterabsorbent means is located adjacent said unset concrete.

4. A method as claimed in claim 3, wherein said waterabsorbent means is located below said concrete retaining means prior to the introduction of the unset concrete.

5. A method as claimed in any one of claims 1 to 4, wherein water absorbent means is introduced into the body of the unset concrete.

6. A method as claimed in claim 5, wherein said water absorbent means comprises a powder material.

7. A method as claimed in any one of the preceding claims, wherein a separator member is located beneath the concrete retaining means and which serves to prevent the concrete bonding to one of the other concrete members of the structure upon which it is to be supported.

8. A method as claimed in any one of claims 1 to 6, wherein the concrete is introduced into said concrete retaining means so as to be supported on the surface of other concrete members of the structure and to bond thereto during the transition from an unstable state to a stable state.

9. A method as claimed in any one of the preceding claims, wherein partition means is located in said concrete retaining means so that a plurality of concrete members can be formed in situ, to any particular size or shape, and within said concrete retaining means.

10. A method as claimed in any one of the preceding claims, wherein once a concrete member reaches its stable state, said concrete retaining means is removed from said member by way of a sliding action relative to the stable concrete member.

11. A method as claimed in claim 10, wherein the concrete retaining means is withdrawn from the stable concrete member in a substantially horizontal sliding manner.

12. A method as claimed in claim 11, wherein a movable side wall portion of said concrete locating means is opened so as to allow for the substantially horizontal withdrawal of said concrete retaining means from said stable concrete member.

13. A method as claimed in any one of claims 1 to 9, wherein once a concrete member reaches its stable state, said concrete retaining means is removed from said member by way of upward lifting motion.

14. A method as claimed in claim 13, wherein removal of said concrete retaining means includes release of said concrete retaining means from the concrete member by a pivotal motion relative to a portion of the concrete retaining means.

15. A method as claimed in claim 14, wherein said concrete retaining means comprises two portions of substantially similar dimensions.

16. A method as claimed in claim 15, wherein the pivotal motion between the two portions is achieved by way of respective lever means arranged for scissor-action pivotal motion.

17. Concrete casting apparatus for forming a structure of stacked concrete members, comprising frame means having side wall means for retaining unset concrete in a position at which a member is to be formed as part of said structure, said frame member defining a first opening through-which unset concrete is introduced thereto and a second opening through-which said unset concrete contacts a surface upon which said member is to be supported as part of said structure.

18. Apparatus as claimed in Claim 17 and including partition means arranged to extend in said frame means and between side wall means for forming a plurality of discreet concrete members within said frame means.

19. Apparatus as claimed in claim 17 or 18, and including water-absorbent means for location beneath said frame means prior to the introduction of said unset concrete thereto.

20. Apparatus as claimed in claim 19, wherein said absorbent means comprises a sheet of water-absorbent material.

21. Apparatus as claimed in claim 19 or 20, wherein said water absorbent means comprises powdered material.

22. Apparatus as claimed in claim 19 or 20, wherein said water absorbent means comprises a water absorbent member.

23. Apparatus as claimed in any one of claims 15 to 22, and including spacer means for location beneath said frame means prior to the introduction of the unstable concrete so as to prevent the concrete then introduced into the frame means from bonding to the surface of a member of said structure upon which it is supported.

24. Apparatus as claimed in any one of claims 15 to 23, wherein side wall means of said frame means comprises a moveable portion which can be moved so as to assist withdrawal of the frame member from the stable concrete member.

25. Apparatus as claimed in claim 24, wherein said movable portion is arranged to pivot relative to the remainder of said frame means and includes a handle member to assist such pivoting motion.

26. Apparatus as claimed in claim 25, wherein said movable side wall portion is arranged to be pivotable about an axis which extends substantially horizontally when said frame means is located so as to have said unstable concrete introduced thereto.

27. Apparatus as claimed in claim 25 or 26, wherein said frame means comprises a plurality of side wall means and said pivotable side wall means is pivotably mounted at each point of engagement to adjacent side wall means.

28. Apparatus as claimed in any of claims 15 to 27, and including handle means for assisting the removal of the frame means from the stable concrete member formed therein.

29. Apparatus as claimed in claim 28, wherein said frame means comprises two mutually pivotable portions each associated with a respective handle means.

30. Apparatus as claimed in claim 29, wherein said respective handle means extend from junction regions between said portions.

31. Apparatus as claimed in claim 30, wherein said handle means comprise lever means mutually engaged for scissoraction pivotal motion.

32. Apparatus as claimed in any one of claims 15 to 31, wherein said side-wall means of said frame member have a curved profile.

33. Concrete casting apparatus for forming a structure of stacked concrete members according to a method as claimed in any one of claims 1 to 16.

34. A method of forming a structure of stacked concrete members substantially as hereinbefore described with reference to, and as illustrated in the accompanying drawings.

35. Concrete casting apparatus for forming a structure of stacked concrete members substantially as hereinbefore described with reference to, and as illustrated in, the accompanying drawings.