GB2297786A

GB2297786A - Method and apparatus for constructing a concrete floor

Info

Publication number: GB2297786A
Application number: GB9525279A
Authority: GB
Inventors: Wen-Yuan Lee
Original assignee: Individual
Current assignee: Individual
Priority date: 1995-02-10
Filing date: 1995-12-11
Publication date: 1996-08-14
Anticipated expiration: 2015-12-11
Also published as: AU4033995A; CA2165239A1; GB9525279D0; FR2730513A1; DE19548504A1; GB2297786B

Description

2297786 METHOD FOR CONSTRUCTING A CONCRETE FLOOR OF A STRUCTURE AND

APPARATUS USED THEREIN The invention relates to a method for constructing a concrete floor of a structure, more particularly to a method for constructing a concrete f loor of an upper storey of a structure, the structure having a lower stOrey which is enclosed by surrounding walls that are formed with window openings and that confine an internal space with an open top, the method employing a floor form assembly that is formed by interconnecting a plurality of modular floor form units which can be easily dismantled when the concrete floor is formed and wh.ich can be conveniently removed from the structure via one of.the window openings for reassembly.

Usually, when constructing concrete structures such as houses and the 'like, a large amount of time and manpower is wasted on the nailing of wooden panels to assemble mold forms prior to pouring of the concrete and on the disassembly of the mold forms when the concrete hardens. Recent advancements in the field of construction have resulted in the development of reusable unitary or modular steel forms which permit fast and efficient-construction of concrete structures at a lower manpower requirement.

In the construction of reinforcedconcrete buildings, mold forms are installed to form the surrounding walls and the topmost floor of the 1 0 is buildings. The other floors are then formed in an order from the lowest floor to the topmost floor. The use of wooden panels as mold forms has become obsolete in the construction of concrete buildings. On the other hand, the use of steel mold forms requires proper planning and design to achieve ideal results. Of course, the installation and removal of the steel mold forms should be simple and easy to perform so as to attain fast and efficient construction at a low manpower requirement.

The use of unitary steel mold forms as floor forms in the construction of buildings is known in the art. Referring to Figure 1, a lower storey 9 of an unfinished building already has some partition walls 91 built therein. However, at least an entire side 92 of the lower storey 9 remains uncovered. Figure 2 illustrates how a concrete f loor of an upper storey of the building is formed. As shown, a unitary mold form 90 is hoisted to the top of the building. The unitary mold form 90 is then positioned steadily on the lower storey 9, and concrete is poured on the unitary mold form 90 to form a concrete floor 93. After the concrete floor 93 has hardened, the unitary mold form 90 is lowered and is pushed toward the uncovered side 92 of the lower storey 9. The unitary mold form 90 is then hoisted (as shown by the phantom lines) to form a concrete floor of a succeeding upper storey of the building.

2 is It is noted that the aforementioned provides an ef f icient way of f o:ming concrete f loors. However, the above method cannot be applied if the lower storey of the building has too many partition walls. In addition, at least an entire side of the lower storey should be left uncovered in order to permit removal of the unitary mold f orm. Thus, in the event that the lower storey of the building has already been enclosed by surrounding walls that are f ormed only with window and door openings, the unitary mold f orm cannot be removed unless it has been dismantled into small pieces which can be passed manually through the various openings in the surrounding walls so as to be assembled anew. This requires a lot of time and effort and is therefore uneconomical.

The object of the present invention is to provide a method for constructing a concrete f loor of an upper storey of a structure, the structure having a lower storey which is enclosed by surrounding walls that are formed with window openings and that confine an internal space with an open top, the method employing-a floor form assembly that is formed by interconnecting a plurality of modular floor form units which can be easily dismantled when the concrete floor is formed and which can be conveniently removed from the structure via one of the window openings for reassembly.

3 is Accordingly, the method of the present invention is directed to the construction of a concrete floor of an upper storey of a structure, the structure having a lower storey enclosed by surrounding walls that are formed with window openings and that confine an internal space with an open top. The method comprises the steps of:

(a) interconnecting a plurality of modular floor form units to form a floor form assembly; (b) hoisting the floor form assembly into the lower storey of.the structure through the open top, securing the floor form assembly to a ground surface of te lower storey, and pouring concrete on top of the floor form assembly to form the concrete floor of the upper storey of the structure; (c) operating a movable lifting apparatus so as to support a first one of the modular floor form units thereon once the concrete has hardened; (d) removing connection between the first one of the modular floor form units and adjacent remaining ones of the modular floor form units, connection between the first one of the modular floor form units and the ground surface, and connection between the first one of the modular floor form units and an adjacent one of the _surrounding walls, if any; (e) operating the movable lifting apparatus so as to lower the first one of the modular floor form units and 4 ( 0 c 1 1 move the first one of the modular floor form units toward one of the window openings; (f) with the use of a form moving apparatus, moving the first one of the modular floor form units from the movable lifting apparatus to an exterior of the structure via the one of the window openings; and (g) repeating steps (c) to (f) for the remaining ones of the modular floor form units.

According to another aspect of the present invention, there is provided a connecting apparatus for interconnecting adjacent modular floor form units of a floor form assembly. Each one of the modular floor form units includes a horizontal face plate, a plurality of supporting ribs secured to a bottom side of the horizontal face plate, and a plurality of girders connected transversely to the supporting ribs. The connecting apparatus comprises:

a pair of hook members to be secured respectively to connecting ends of the girders of the adjacent modular floor form units, each of the hook members having a front side formed with a horizontally extending triangular projection that forms first and second rearwardly inclining faces at the front side, each of the hook members further having a trapezoidal hook portion formed at a distal edge of the second rearwardly inclining face; 1 nb a first joining. member formed with a vertically extending central through-hole, the first joining member having a top portion and an insert portion that extends downwardly from the top portion and that has an inverted trapez o id- shaped cross section, the insert portion having inclined sides which complement and which abut respectively against the second rearwardly inclining face of the hook members, the top portion further having a bottom side formed with a pair of fastening recesses that are trapezoidal in cross section and that are disposed on two sides of the insert portion to engage respectively the hook portion of the hook members; a second joining member formed with a vertically extending central through-hole, the second joining member having a bottom portion and an insert portion which projects upwardly from the bottom portion and which has a trapezoidal cross section, the insert portion of the sec ond joining member having inclied sides which complement and which abut respectively against the first rearwardly inclining face of the hook members; and a screw fastener extending through the through-holes of the first and second joining members and causing the insert portions of the first and second joining members to abut tightly against each other.

6 $0 1 a 0 a a According to still another aspect of the present invention, there is provided a form contracting apparatus for a floor form assembly that is assembled from a plurality of interconnected modular floor form units. The form contracting- apparatus permits tight contact between a respective one of the modular floor form units and an adjacent surrounding wall of a structure that is to be formed with a concrete floor. Each of the modular floor form units includes a horizontal face plate, a vertical face plate, and an edge face plate adjacent to an edge of the horizontal face plate and connected transversely to the vertical face plate. The horizontal face plate has a plurality of supporting ribs secured to a bottom side thereof, while the vertical face plate has a plurality of vertical supports secured thereto. The form contracting apparatus comprises:

a first mounting piece formed as an elongated bar with a generally Vshaped cross section and to be mounted on a bottom side of the horizontal face plate, the first mounting piece having front and rear inclined sides; a second mounting piece formed as an elongated bar and to be mounted to the edge face plate and to the vertical face plate, the second mounting piece having a rear end formed with a wedge portion that extends rearwardly and downwardly and that complements and 7 abuts against the front inclined side of the first mounting piece, the wedge portion having a distal end f armed with an upwardly folded stop section that abuts against the rear inclined side of the f irst mounting piece; a mounting plate to be mounted to a distal end of a corresponding one of the supporting ribs secured to the bottom side of the horizontal face plate, the mounting plate having a support arm which extends upwardly and inclinedly therefrom, the support arm having an inclined edge which supports a bottom end of the second mounting piece, the mounting plate further having a locking screw which is secured threadedly thereto and which has a tip that abuts the second mounting piece, the locking screw and the inclined edge of the support arm inclining at a same angle as that of the front inclined side of the first mounting piece; and a plurality of positioning screws for interconnecting threadedly the first and second mounting pieces; whereby, when the positioning screws are loosened and the locking screw is rotated so as to move axially in a direction away from the second mounting piece, the second mounting piece slides downwardly along the inclined edge of the support arm.

According to a further aspect of the present invention, there is provided a corner leak-preventing 8 1 apparatus for a floor form assembly having two vertical face plates that form a corner therebetween. Each of the vertical face plates has a plurality of vertical supports secured thereto. The corner leak- preventing apparatus comprises: a pair of mounting plates formed as complementary plates that are to be secured respectively to one of the vertical supports on a corresponding one of the vertical face plates, each of the mounting plates having a bent distal portion which extends toward the bent distal portion of the other one of the mounting plates, the bent distal portions of the mounting plates forming a clearance therebetween; a plurality of pressing screws, each of which having a tubular sleeve secured thereto, the tubular sleeve having a periphery formed with an annular groove and being received slidably and rotatably such that the bent distal portions plates extend into the annular groove; an adjusting member formed as an elongated piece with a front side, a rear side and a plurality of spaced threaded bores that extend from the rear side to the front side to permit extension of the pressing screws therethrough; and a plug member formed as a resilient elongated strip and connected to the front side of the adjusting member, the plug member having a tapered front portion in the clearance of the mounting 9 1% is for abutting tightly edge portions of the vertical face plates to block any clearance therebetween in order to prevent leakage thereat.

Other features and advantages of the present invention will become apparent in the following detailed description of the preferred embodiment with reference to the accompanying drawings, of which:

Figure 1 illustrates a portion of an unfinished building that is to be formed with a concrete floor; Figure 2 illust37ates how the concrete floor of the unfinished building is formed in a conventional manner; Figure 3 is a front view which illustrates how a concrete floor is formed in accordance with the preferred embodiment of a floor constructing method of the present invention; Figure 4 is a side view which illustrates how the concrete floor is formed in accordance with the preferred Figure embodiment; is a top,view which illustrates how the concrete floor is formed in accordance with the preferred embodiment; Figure 6 is a partly sectional view which shows a connecting apparatus for interconnecting adjacent modular floor form units to form a floor form assembly that is employed in the preferred embodiment; Figure 7 is a bottom perspective view of a panel connecting member shown in Figure 6; c 0 Figure 8 is a front view of a hook member of the connecting apparatus shown in Figure 6; Figure 9 is a sectional view of the hook member, taken along line IX-IX in Figure 8; Figure 10 is a front view of a first joining member of the connecting apparatus shown in Figure 6; Figure 11 is a bottom view of the first joining member; Figure 12 is a top view of a second joining member of the connecting apparatus shown in Figure 6; Figure 13 is a sectional view of the second joining member, taken along line XIII-XIII in Figure 12; Figure 14 is a top view which illustrates the connection between the first joining member and positioning plates of the connecting apparatus shown in Figure 6; Figure 15 illustrates a form contracting apparatus employed in the preferred embodiment of a floor constructing method according to the present invention; Figure 16 is a perspective view which illustrates first and second mounting pieces of the form contracting apparatus shown in Figure 15; Figure 17 illustrates how a concrete floor with interior horizontal beams is formed in accordance with the preferred embodiment; Figure 18 illustrates a corner leak-preventing apparatus employed in the preferred embodiment; 11 9 is Figure 19 illustrates how a movable lifting apparatus is employed when removing a modular f loor form unit in accordance with the preferred embodiment of a floor constructing method of the present invention; Figure 20 illustrates how a form moving apparatus is' employed when moving the modular floor form unit through a window opening in accordance with the preferred embodiment; Figure 21 illustrates the form moving apparatus after moving the modular floor form unit through the window opening; F,Lgure 22 illustrates the use of a mod i fied lifting apparatus when removing a modular- floor form unit in accordance with the preferred embodiment of a floor constructing method of the present invention; Figure 23 illus.trates how the modular floor form unit is removed from the building through a window opening with the use of the modified lifting apparatus, a pair of guide rails, and a modified form moving apparatus; Figure 24 is a top view illustrating how the modular floor-form- unit i!E'-removed from the building through the window opening with the use of the modified lifting apparatus, the guide rails, and the modified form moving apparatus; and 12 Figure 25 illustrates how several modular floor form units are hoisted in preparation for another floor constructing operation.

In the preferred embodiment of a method for constructing a concrete floor of an upper storey of a structure which has a lower storey that is enclosed by surrounding walls formed with window openings and confining an internal space with an open top, several modular floor form units are interconnected outdoors to form a floor form assembly. The floor form assembly is then hoisted into the structure through the open top and is secured to a ground surf ace of the lower storey before concrete is poured therean so as to form the concrete floor. Referring to Figure 3, the floor form assembly 1 forms a.generally inverted U-shaped cavity for receiving concrete and includes horizontal face plates 11 and vertical face plates 12 riveted onto top ends of the surrounding walls 110. The floor form assembly 1 is supported on a ground surface 100 (or the floor of the lower storey) by several foldable or removable props ldl. The surrounding walls 110 have been formed beforehand and are provided with window openings 111-and door openings 112 (shown in phantom lines). In this embodiment, the structure is to be provided with exterior horizontal beams 113 that can be formed by using an exterior beam form 114.

13 1 1 q.

is Referring to Figure 4, as viewed from the surrounding wall 110 with the window opening 111, three identical modular floor form units 10 constitute the floor form assembly 1. A connecting apparatus 2 joins two adjacent modular floor form units 10. ' Each modular floor form unit 10 comprises a horizontal face plate 11 on a top end for supporting concrete thereon, a plurality of supporting ribs 13 secured to a bottom side of the horizontal face plate 11, and several girders 14 of appropriate length which are connected transversely to bottom ends of the supporting ribs 13. The length of the girders 14 must be shorter than the width 'W) of the window opening k 111. In addition, the height of each modular floor form unit 10 measured from the horizontal face plate 11 to the bottom side of the girders 14, including that of the vertical face plates 12 which are secured onto the top ends of the surrounding walls 110 by means of vertical supports 121, must be shorter than the height (H) of the window opening 111. Thus, each modular floor form unit 10 may be transported out of the structure via the window opening 111.

--- -Referring to Figures 4 and 5, the three modular floor form units 10 are tightly interconnected so that the floor form assembly 1 can be used to form a concrete floor. The connecting apparatus 2 used to join adjacent modular floor form units 10 interconnects the 14 1 girders 14 at the bottom of the latter and ensure that the modular floor form units 10 have sufficient strength and load-bearing capabilities. The girders 14 are disposed on the props 101 which support the floor form assembly 1 on the ground surface 100, thereby securing the floor form assembly 1 at a desired height in the structure and enabling the floor form assembly 1 to sustain the weight of concrete to be poured thereon. Of course, the diameter, configuration, strength, number and position of the props 101 are selected through the use of simple design techniques. The Props 101, however, should be easy to detach or dismantle, should be adjustable to achieve a precise height, and should possess sufficient load-bearing capabilities.

Figure 6 illustrates the connection between adjacent modular floor form units 10. Each of the horizontal face plates 11 has a plurality of screw sockets 1101 mounted on a bottom side thereof. Screws 131 engage the screw sockets 1101,and mount the top end of the supporting ribs 13 to the horizontal face plates 11. Several panel connecting members 3 are installed at the bottom side of adjacent horizontal face plates 11 at mati:nq--e-dges 1111 -of the latter to ensure tight connection therebetween. Referring to Figure 7, each panel connecting member 3 includes two fastening rings 30 disposed respectively on two sides of the mating edges 1111 of two adjacent horizontal face plates 11.

1 4% The fastening rings 30 confine a predetermined clearance with the bottom side of the respective horizontal face plate 11. Each panel connecting member 3 further includes an L-shaped lever 31 having a first end inserted through the fastening rings 30. The Lshaped lever 31 has a generally rectangular crosssection with opposite convex sides 311 and opposite flat sides 312 adjoining the convex sides 311, the distance between the flat sides 312 being smaller than that between the convex sides 311 and corresponding with the clearance confined by the fastening rings 30 and the bottom side of the respective horizontal face pI - .ate 11. During assembly, the first end of the L shaped lever 31 is inserted through the fastening rings 30 such that the flat sides 312 are parallel to the horizontal face plates 11. The L-shaped lever 31 is then turned by a 900 angle such that the convex sides 311 abut tightly against the horizontal face plates 11 and the fastening rings 30, thereby interlocking the horizontal face plates 11. To disassemble the horizontal face plates 11, the L-shaped lever 31 is simply turned by another 900 angle. This illustrates --how the7horizontal -f-a-te plates 11 of adjacent modular floor form units 10 are conveniently and effectively coupled to one another.

Referring once more to Figure 6, girders 14 of the adjacent modular floor form units 10 are interconnected 16 1 by means of oppositely oriented upper and lower connecting apparatus 2. Each connecting apparatus 2 includes a pair of hook members 21, a first joining member 22 and a second joining member 23.

The hook members 21 are secured respectively to connecting ends of the girders 14 of the adjacen. t modular floor form units 10 by means of screw fasteners 141. Alternatively, the hook members 21 may be welded onto the girders 14. Referring to Figures 8 and 9, the hook members 21 are shaped substantially as rectangular blocks and are formed respectively with a parallel pair of counterbores 210 that extend from a front side to a rear.side of the hook members 21. The entire front side of each hook member 21 is formed with a horizontally extending triangular projection 211 that forms first and second rearwardly inclining faces 212, 213 with different sizes at the front side. Each hook member 21 has a trapezoidal hook portion 214 formed at a distal edge portion of the second rearwardly inclining face 213.

Referring to Figures 10 and 11, the first joining member 22 is shaped substantially as a rectangular block -wi-th -a-flat. top portion and a vertically extending centra-through-hole 221. The flat top portion---of the first joining. member, 22 has two side edges formed with a pair of slot mortises 222 that have tapering bottom sections. An insert portion 223 extends 17 downwardly from the flat top portion and has an inverted trapezoid-shaped cross section. The insert portion 223 has inclined sides 2231 which complement and which abut respectively against the,-second rearwardly inclining face 213 of the hook members 21. The top portion has a bottom side formed with a pair of fastening recesses 224 that are trapezoidal in cross section and that are disposed on two sides of the insert portion 223. The fastening recesses 224 engage respectively the hook portion 214 of the hook members 21 to ensure tight engagement among the hook members 21 and the first joining member 22.

Referring to Figures 12 and 13, the second joining member 23 is shaped substantially as a rectangular block with a flat bottom portion and a vertically extending central through-hole 231. An insert portion 232 projects upwardly from the bottom portion and has a trapezoidal cross section. The insert Portion 232 has inclined sides 2321 which complement and which abut respectively against the first rearwardly inclining face 212 of the hook members 21.

Referring to Figures 6 and 14, each of a pair of positioning-plates 24 is formed as a generally rectangular plate-and is secured to-the top of the connecting end of,,the girder 14 of a respective one of the modular floor form units 10 by means of screw fasteners 241. Each of the positioning plates 24 has is one edge formed with a tenon 242 received in a respective one of the slot mortises 222 of the first joining member 22. A screw fastener 25 extends through the through-holes 221,. 231 of' the first and-second joining members 22, 23 and causes the insert portions 223, 232 to abut tightly against each other to secure the connecting apparatus 2. It should be noted that the positioning plates 24 only serve to position the first joining member 22 to facilitate assembly of the connecting apparatus 2 with the use of the screw fastener 25, and should not be treated as essential elements. As shown in Figure 6, the lower connecting apparatus 2 does not require positioning plates 24 when assembling the same..

It has thus been shown that the connecting apparatus 2 are simple in construction and can be easily assembled. The girders 14 of the adjacent modular floor form units 10 are tightly connected once the first and second joining memberg'22, 23 have been assembled with the use of the screw fastener 25. Interlocking of the hook portions 214 of the hook members 21 with the fastening recesses 224 of the first joining member 22 and tight-contact among the insert portions 223, 232 of the first and second- joining members 22, 23 and the first and--- second -rearward ly inclining faces 212, 213 of the hook members 21 provide the connecting apparatus 2 with radial connecting forces and ensure stable a 0 4 0 0 connection between the girders 14 of the adjacent modular floor form units 10. The connecting apparatus 2 further ensure that the floor form assembly 1 possesses ideal stress bearing capabilities to enable the latter to support properly the weight of the concrete poured thereon. In addition, since only a screw fastener 25 is required to secure each connecting apparatus 2, the connecting apparatus 2 can be quickly and easily assembled or disassembled.

In the preferred embodiment, an economical way of preventing leakage of concrete at clearances between the periphery of the floor form assembly 1 and the surrounding walls or beams would be to apply a layer of sealant, such as EVA or silica gel, at the periphery of the floor form assembly 1 after the latter has been hoisted into the structure. The sealant can be easily removed after the concrete floor has been formed.

Referring to Figure 15, a form contracting apparatus 4 is installed to permit tight contact between a respective one of the modular floor form units 10 and an adjacent surrounding wall of the structure and to facilitate removal of the modular floor form units 10 after use. As shown, a short edge face plate 120 is disposed adjacent to an edge of the horizontal face plate 11 and is connected transversely to a top edge of the vertical face plate 12. The edge face plate 120 has an inclined distal edge 1201 which inclines by a 450 06 00 a a 0 angle and which is to be disposed in tight contact with the edge of the horizontal face plate 11. The edge face plate 120 is movable by a short distance from the edge of the horizontal face plate 11 to facilitate removal of the modular floor form unit, as will be detailed in the succeeding paragraphs.

The form contracting apparatus 4 comprises a first mounting piece 41 and a second mounting piece 42. The first mounting piece 41 is formed as an elongated extruded aluminum bar with a generally V-shaped cross section. The length of the first mounting piece 41 corresponds to that of the girders 14. Referring to Figure 16, the first mounting piece 41 has opposite sides formed respectively with front and rear inclined sides 411, 412 that incline by a 450 angle. The first mounting piece 41 further has a top portion 413 which is substantially flat and which is formed with a longitudinally extending central groove 414. The central groove 414 receives therein a row of screw sockets 112 welded to the bottom side of the horizontal face plate 11, as shown in Figure 15. Screws 415 extend through the first mounting piece 41 and secure the latter to the bottom side of the horizontal face plate 11 adjacent to the inclined distal edge 1201 of the edge face plate 120.

The second mounting piece 42 is similarly formed as an elongated extruded aluminum bar. The second mounting 21 0 46 0, 0 a 0 piece 42 has an upright portion 421 at a front end, a longitudinally extending groove 422 in a top portion, and a wedge portion 423 which extends rearwardly and downwardly at an angle of 450 at a rear end. The distal end of the wedge portion 423is formed with an upwardly folded stop section 424. The groove 422 receives therein a row of screw sockets 122 welded to the bottom side of the edge face plate 120, as shown in Figure 15. Screws 425 extend through the second mounting piece 42 and secure the latter to the bottom side of the edge face plate 120 adjacent to the inclined distal edge 1201. In addition, screw fasteners 426 extend through the upright portion 421 of the second mounting piece 42 and secure the latter to the vertical supports 121 of the vertical face plate 12. Thus, the second mounting piece 42 is secured to the edge face plate 120 and to the vertical face plate 12. Furthermore, the wedge portion 423 of the second mounting piece 42 complements and abuts against the front inclined side 411 of the first mounting piece 41. A plurality of positioning screws 427 extend uprightly through aligned screw holes 4270 in the first and second mounting pieces 41, 42 to interconnect threadedly the latter. The stop section 424 at the distal end of the wedge portion 423 complements and abuts against the rear inclined side 412 of the first mounting piece 41.

22 is If necessary, the connection between the first and second mounting pieces 41, 42 may be modified to include a longitudinally extending tenon-and- mortise joint to facilitate precise connection of the first and second mounting pieces 41, 42 in a longitudinal direction. In this way, alignment of the screw holes 42O can be accomplished easily to facilitate joining of the first and second mounting pieces 41, 42.

Referring once more to Figures 15 and 16, the rear inclined side 412 of the first mounting piece 41 is formed with an indentation 416 that has a flat bottom.

The form contracting apparatus 4 further comprises an elongated stop block 43 secured to t1-1ke rear inclined side 412 of the first mounting piece 41 by means of screw fasteners 431. Preferably, the stop block 43 has a bottom end formed with a downwardly extending tenon 432 which is adapted to engage a slot mortise (not shown) -formed in the stop section 424 in order to facilitate accurate positioning of the second mounting piece 42.

As shown in Figure 15, a mounting plate 44 is mounted to a distal end of a corresponding supporting r-ib--13-stfcUr-dd 'to -the--bbttbm-side of the horizontal face plate 11 by means of screw fasteners 441. A support arm 442 extends upwardly and inclinedly at an angle of 450 from a front end of the mounting plate 44. The support arm 442 has an inclined upper edge 4421 23 which nclines at a same angle as that of the front inclined side 411 of the first mounting piece 41 and which abuts the lower edge of the stop section 424 of the second mountihg piece 42'so as to support the latter. The mounting plate 44 further has a rectangular screw socket 45 secured thereto. The screw socket 45 is f orme d with a screw hole which inclines at a same angle as that of the inclined upper edge 4421 of the support arm 442 and which engages a locking screw 46. The tip of the locking screw 46 abuts the stop section 424.

It is noted that one set of the mounting plate 44, the screw socket 45 and the locking screw 46, or a plurality of sets thereof, may be employed to support the second mounting piece 42. In use, after the positioning screws 427 have been loosened to disconnect the first and second mounting pieces 41, 42, the locking screw 46 can be rotated so as to move axially in a direction away from the stop section 424. At this stage, the lower edge.'of the stop section 424 slides downwardly along the inclined upper edge 4421 of the support arm 442. When the locking screw 46 is rotated so as to move axially in a direction toward the stop section 424, the lower edge of the stop section 424 slides upwardly- along the -inclined upper edge 4421. The positioning screws 427 are then tightened to join the first and second mounting pieces 41, 42 together.

24 0 00 4. a 4 0 Because the second mounting piece 42 is secured to the edge face plate 120 and to the vertical face plate 12, when the stop section 424 slides downwardly along the inclined upper edge 4421 of the support arm 442, the edge face plate 120 and the vertical face plate 12 move simultaneously away from the surrounding walls of the structure to form a clearance of about 3 to 5 centimeters therewith. At this stage, the modular floor form unit 10 ceases to be pressed tightly against the adjacent surrounding wall, thereby facilitating disassembly and removal of the same.

When the positioning screws 427 are loosened to disconnect the first and second mounting pieces 41, 42, the upper side of the stop section 424 hooks with the rear inclined side 412 of the first mounting piece 41, while the lower side of the stop section 424 abuts the support arm 442 and the tip of the locking screw 46. Such connection is stable and guards against untimely separation between the first and second mounting pieces 41, 42. Thus, the edge face plate 120 and the vertical face plate 12 may be hoisted along with the modular floor form units 10.

Referring again to Figure 15, a triangular support plate 5 is secured at a predetermined location of each vertical support 121, and a positioning seat 6 is mounted to bottom ends of the supporting ribs 13. The positioning seat 6 has a bottom end that is provided with a tubular support ring 61 which is supported on the support plates 5. The support plates 5 act as an auxiliary supporting unit for providing additional support to the vertical supports 121 and the vertical f ace plate 12 in order to ensure that the f loor f orm assembly can be hoisted steadily into the structure without resulting in inward bending of the former due to excessive weight of the vertical supports 121 and the vertical face plate 12 at outer edges thereof. The support plate 5 has an inclined upper edge 51 which inclines at a same angle as that of the front inclined side 411 of the first mounting piece 41 and that of sliding movement of the second mounting piece 42 relative to the first mounting piece 41 so as to ensure that the vertical face plate 12 moves in the same direction during the form contracting operation.

Referring to Figure 17, if it is desired to form interior horizontal beams 115 simultaneous with the concrete floor of the upper storey of the structure, a plurality of horizontal beam form plates 7 are provided at bottom portions of the vertical face plates 12. The vertical face plates 12 and the beam form plates 7 cooperatively define a space for receiving concrete to form the interior horizontal beams 115 therein. A plurality of short ribs 71 are secured to the surrounding walls 110 and support the beam form plates 7 thereon. This procedure is similar to that 26 conventionally applied in the formation of exterior horizontal beams 113. Since the beam form plates 7 are secured to the vertical face plates 12 and the vertical supports 121, the short ribs 71 must be removed from the surrounding walls 110 before the form contracting operation can be performed when dismantling the floor form assembly 1. The vertical face plates 12 and the beam form plates 7 are movable simultaneously away from the surrounding walls 110. The support plates 5 and the positioning seat 6 ensure that the floor form assembly 1 can be hoisted steadily into the structure without resulting in inward bending of the former due to heavy load.

It has been mentioned beforehand that a layer of sealant may be applied at contact areas of the floor form assembly 1 and the surrounding walls 110 to prevent leakage of concrete at clearances therebetween. In order to prevent leakage at corners of the surrounding walls 110, a corner leakpreventing apparatus may be employed. As shown in Figure 18, a small clearance is formed between two vertical face plates 12, 121 that form a 900 corner therebetween. The corner leak-preventing apparatus 8 is used to block this clearance and comprises a pair of mounting plates 80, a plurality of pressing screws 81 (only one is shown), an adjusting member 82 and a plug member 83.

27 4 The mounting plates 80 are formed as elongated complementary plates that are secured respectively to one of the vertical supports 121 on a corresponding one of the vertical face plates 12, 121. Each mounting plate 80 has a bent distal portion that extends toward the bent distal portion of the other mounting plate 80. The bent distal portions of the mounting plates 80 form a vertical clearance 801 therebetween.

Each pressing screw 81 has a tubular sleeve 811 welded to a head portion thereof. The tubular sleeve 811 has a periphery formed with an annular groove and is received slidably and rotatably in the vertical clearance 801 such that the bent distal portions of the mounting plates 80 extend into the annular groove. The pressing screws 81 extend toward the small clearance formed between the vertical face plates 12, 121 when mounted to the mounting plates 80.

The adjusting member 82 is formed as an elongated extruded aluminum piece and is disposed uprightly in a space confined by the vertical face plates 12, 121 and the mounting plates 80. The adjusting member 82 has a front side formed with a longitudinally extending notch 821 which has a predetermined cross-section, a rear side, and a plurality of spaced threaded bores 822 (only one is shown) that extend from the rear side to the front side to permit extension of the pressing screws 81 into the notch 821.

28 04 00 A 0 The plug member 83 is an elongated strip made of a resilient material, such as silica gel, rubber or plastic. The plug member 83 has a rear end formed with an insert portion 831 received fittingly in the notch 821 of the adjusting member 82. The plug member 83 further has a hollow tapered front portion 833 which confines a longitudinal chamber 832 to enhance resiliency of the plug member 83. The front portion 833 abuts tightly edge portions of the vertical face plates 12, 121 to block the small clearance between the latter in order to prevent leakage of concrete thereat.

When the pressing screws 81 are rotated axially in a certain direction, axial movement of the pressing screws 81 is not possible due to engagement between the tubular sleeve 811 and the mounting plates 80. Thus, the adjusting member 82 moves axially relative to the pressing screws 81 to force the front portion 833 of the plug member 83 to abut tightly against the vertical face plates 12, 121 to prevent leakage. When the pressing screws 81 are rotated axially in an opposite direction, the adjusting member 82 is pulled away from the vertical face plates 12, 121 to move correspondingly the front portion 833 of the plug member 83 away from the vertical face plates 12, 121.

The preferred embodiment of a floor constructing method according to the present invention includes the following steps:

29 00 a 0 0 ' 1. Referring once more to Figures 3, 4 and 5, a plurality of modular floor form units 10 are interconnected to form the floor form assembly 1. The girders 14 of adjacent modular floor form units 10 are interconnected by means of the connecting apparatus 2. The vertical face plates 12 and the vertical supports 121 are then secured to outer edges of the interconnected modular floor form units 10.

2. The floor form assembly 1 is hoisted into the lower storey of the structure, which is enclosed by surrounding walls 110 that are formed with window openings ill and door openings 112, through an open top of confined by the surrounding walls 110. The floor form assembly 1 is secured to a ground surface of the lower storey by means of the props 101 before concrete can be poured thereon. The form contracting apparatus 4 is then operated to ensure tight contact between the floor form assembly 1 and the surrounding walls 110, as shown in Figure 15. After the floor form assembly 1 has been secured on the ground surface, reinforcing bars (not shown) for the concrete floor to be formed may be installed prior to pouring of the concrete.

3. The floor form assembly 1 is dismantled after the concrete floor has hardened. As shown in Figure 19, when dismantling the floor form assembly 1, a movable lifting apparatus 200 is employed to lower a first one of the modular floor form units 10. The movable lifting 0 0.

00 0.

apparatus 200 has appropriate dimensions, thereby permitting entry thereof into the structure via the door opening 112 of the surrounding walls 110 (see Figure 3). The movable lifting apparatus 200 is operable so as to raise a platform 210 thereof in order to support the girders 14 of the first one of the modular floor form units 10 thereon.

4. The connections between the first one of the modular floor form units 10 and the adjacent remaining ones of the modular floor form units 10, between the first one of the modular floor form units 10 and the props 101 which support the former on the ground surface, and between the first one of the modular floor form units 10 and the adjacent surrounding walls 110, such as the short ribs 71 shown in Figure 17, are then removed. The screw fasteners 25 of the connecting apparatus 2 and the panel connecting members 3 which connect the horizontal face plates 11 of adjacent modular floor form units 10 are removed to disconnect the first one of the modular floor form units 10 from the adjacent remaining ones of the modular floor form units 10. In addition, a form contracting operation should be performed if a form contracting apparatus 4 is disposed at an outer edge of the first one of the modular floor form units 10 to prevent the adjacent ones of the surrounding walls 110 from hindering removal of the former. The form contracting operation 31 9 can be easily accomplished by simply loosening the positioning screws 427 and the locking screw 46 of the f orm contracting apparatus 4, thus f orming a clearance between the edge face plate 120 and the vertical face plate 12 and the surrounding walls 110 of the structure.

5. The movable lifting apparatus 200 is then operated so as to lower the platform 210 and the first one of the modular floor form units 10 thereon and so as to move the first one of the modular floor form units 10 toward one of the window openings 111.

6. Referring to Figure 20, a form moving apparatus 400 is employed to move the first one of the modular floor form units 10 from the platform 210 of the movable lifting apparatus 200 to an exterior of the structure via the window opening 111. The form moving apparatus 400 is provided on a scaffold 300 that is secured to a lower storey of the structure, and includes a laterally movable load bearing unit 410. The load bearing unit 410 is extendible into the structure via the window opening 111 so as to permit transfer of the first one of the modular floor form units 10 from the lifting apparatus 200 to the load bearing unit 410 of the form moving apparatus 400. Referring to Figure 21, the first one of the modular floor form units 10 is removed from the structure when the load bearing unit 410 is extended out of the window opening ill of the 32 0 structure. At this time, a magnetic hoist 500 may be employed to lift the first one of the modular floor form units 10 in preparation for another floor form assembly operation.

7. Finally, the steps 3 to 6 are repeated for the remaining modular floor form units 10. After all of the modular floor form units 10 have been removed from the structure, the floor form assembly 1 is reassembled in preparation for a floor constructing operation of another upper storey of the structure.

Referring to Figure 22, a modified lifting apparatus 200a and form moving apparatus 400a may be employed in the floor constructing method of the present invention. As shown, legs 142 are secured to two sides of the bottom ends of the girders 14 of the first one of the modular floor form units 10 before supporting the same on the lifting apparatus 200a. The legs 142 are provided with a respective wheel 143. A pair of rails 220 are provided on two sides of the top end of the lifting apparatus 200a and support the wheels 143 thereon. A pair of horizontally extending guide rails 420 (only one is shown) extend from an interior of the structure through the exterior of the structure via the window opening 111 and are supported in the structure by a pair of supports 421. The form moving apparatus 400a is provided on a scaffold 300 that is secured to a lower storey of the structure, and has a pair of guide 33 6 rails 430 which can be aligned with the guide rails 420. The wheels 143 are grooved wheels which are capable of engaging rotatably the rails 220 and the guide rails 420.

Referring to Figure 23, after the lifting apparatus 200a has been operated so as to lower the first one of the modular floor form units 10 and move the latter toward one of the window openings ill, the first one of the modular floor form units 10 is then transferred to the guide rails 420 so as to be moved outside the structure via the window opening 111. As shown in Figure 24, the first one of the modular floor form units 10 on the guide rails 420 is then transferred to the guide rails 430 of the form moving apparatus 400a. Preferably, a plurality of form moving apparatus 400a are disposed on the scaffold 300, thereby permitting the interconnection of a plurality of modular floor form units 10 thereon so as to form the floor form assembly 1, as shown in Figure 25. The floor form assembly 1 is then lifted with the use of the magnetic hoist 500 in preparation for another floor constructing operation. Performing the procedure illustrated in Figures 22 to 25 increases the efficiency of the floor constructing operation.

Since the features of the floor constructing method of the present invention do not reside in the particular construction of the lifting apparatus 200, 34 A 0 0 a 200a, the form moving apparatus 400, 400a and the scaffold 300, a detailed description of the latter will be omitted herein.

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Claims

CLAIMS:

1. A method for constructing a concrete floor of an upper storey of a structure, the structure having a lower storey enclosed by surrounding walls that are formed with window openings and that confine an internal space with an open top, the method comprising the steps of:

(a) interconnecting a plurality of modular floor form units to form a floor form assembly; (b) hoisting the floor form assembly into the lower storey of the structure through the open top, securing the floor form assembly to a ground surface of the lower storey, and pouring concrete on top of the floor form assembly to form the concrete floor of the upper storey of the structure; (c) operating a movable lifting apparatus so as to support a first one of the modular floor form units thereon once the concrete has hardened; (d) removing connection between the first one of the modular floor form units and adjacent remaining ones of the modular floor form units, connection between the first one of the modular floor form units and the ground surface, and connection between the first one of the modular floor form units and an adjacent one of the surrounding walls, if any; (e) operating the movable lifting apparatus so as to lower the first one of the modular floor form units and 36 is move the first one of the modular floor form units toward one of the window openings; (f) with the use of a form moving apparatus, moving the first one of the modular floor form units from the movable lifting apparatus to an exterior of the structure via said one of the window openings; and (g) repeating steps (c) to (f) for the remaining ones of the modular floor form units.

2. The method for constructing a concrete floor of an upper storey of a structure as claimed in claim 1, further comprising the step of, prior to step (e), performing a form contracting operation to prevent adjacent ones of the surrounding walls from hindering removal of the first one of the modular floor form units.

3. A connecting apparatus for interconnecting adjacent modular floor form units of a floor form assembly, each one of the modular floor form units including a horizontal face plate, a plurality of supporting ribs secured to a bottom side of the horizontal face plate, and a plurality of girders connected transversely to the supporting ribs, said connecting apparatus comprising:

a pair of hook members to be secured respectively to connecting ends of the girders of the adjacent modular floor form units, each of said hook members having a front side formed with a horizontally extending 37 triangular projection that forms first and second rearwardly inclining faces at said front side. each of said hook members further having a trapezoidal hook portion formed at a distal edge of said second rearwardly inclining face; a first joining member formed with a vertically extending central through- hole, said first joining member having a top portion and an insert portion that extends downwardly from said top portion and that has an inverted trapezoid-shaped cross section, said insert portion having inclined sides which complement and which abut respectively against said second rearwardly inclining face of said hook members, said top portion further having a bottom side formed with a pair of fastening recesses that are trapezoidal in cross section and that are disposed on two sides of said insert portion to engage respectively said hook portion of said hook members; a second joining member formed with a vertically extending central through-hole, said second joining member having a bottom portion and an insert portion which projects upwardly from said bottom portion and which has a trapezoidal cross section, said insert portion of said second joining member having inclined sides which complement and which abut respectively against said first rearwardly inclining face of said hook members; and 38 a screw fastener extending through said throughholes of said first and second joining members and causing said insert portions of said first and second joining members to abut tightly against each other.

4. The connecting apparatus as claimed in Claim 3, wherein said top portion of said first joining member has two side edges formed with a pair of slot mortises, said connecting apparatus further comprising a pair of positioning plates to be secured respectively to the connecting ends of the girders of the adjacent modular floor form units, each of said positioning plates having one edge formed with a tenon received in a respective one of said slot mortises of said first joining member.

5. A form contracting apparatus for a floor form assembly that is assembled from a plurality of interconnected modular floor form units, the form contracting apparatus permitting tight contact between a respective one of the modular floor form units and an adjacent surrounding wall of a structure that is to be formed with a concrete floor, each of the modular floor form units including a horizontal face plate, a vertical face plate, and an edge face plate adjacent to an edge of the horizontal face plate and connected transversely to the vertical face plate, the horizontal face plate having a plurality of supporting ribs secured to a bottom side thereof, the vertical face 39 plate having a plurality of vertical supports secured thereto, said form contracting apparatus comprising:

a first mounting piece formed as an elongated bar with a generally Vshaped cross section and to be mounted on a bottom side of the horizontal face plate, said first mounting piece having front and rear inclined sides; a second mounting piece formed as an elongated bar and to be mounted to the edge face plate and to the vertical face plate, said second mounting piece having a rear end formed with a wedge portion that extends rearwardly and downwardly and that complements and abuts against said front inclined side of said first mounting piece, said wedge portion having a distal end formed with an upwardly folded stop section that abuts against said rear inclined side of said first mounting piece; a mounting plate to be mounted to a distal end of a corresponding one of the supporting ribs secured to the bottom side of the horizontal face plate, said mounting plate having a support arm which extends upwardly and inclinedly therefrom, said support arm having an inclined edge which supports a bottom end of the second mounting piece, said mounting plate further having a locking screw which is secured threadedly thereto and which has a tip that abuts the second mounting piece, said locking screw and said inclined edge of said support arm inclining at a same angle as that of said front inclined side of said first mounting piece; and a plurality of positioning screws for interconnecting threadedly said f irst and second mounting pieces; whereby, when said positioning screws are loosened and said locking screw is rotated so as to move axially in a direction away from said second mounting piece, said second mounting piece slides downwardly along said inclined edge of said support arm.

6. The form contracting apparatus as claimed in claim 5, further comprising:

a support plate to be mounted to a corresponding one of the vertical supports secured to the vertical face plate, said support plate having an inclined edge which inclines at a same angle as that of said front inclined side of said first mounting piece; and a positioning seat to be mounted to one end of the supporting ribs secured to the bottom side of the horizontal face plate and supported on said inclined edge of said support plate.

7. The form contracting apparatus as claimed in Claim 5, wherein said stop section of said second mounting piece is formed with a slot mortise, said rear inclined side of said first mounting piece being formed with a stop block which is provided with a tenon that engages said slot mortise to facilitate positioning of said 41 second mounting piece.

8. A corner leak-preventing apparatus f or a f loor f orm assembly having two vertical face plates that form a corner therebetween, each of the vertical face plates having a plurality of vertical supports secured thereto, said corner leak-preventing apparatus comprising: a pair of mounting plates formed as complementary plates that are to be secured respectively to one of the vertical supports on a corresponding one of the vertical face plates, each of said mounting plates having a bent distal portion which extends toward said bent distal portion of the other one of said mounting plates, said bent distal portions of said mounting plates forming a clearance therebetween; a plurality of pressing screws, each of which having a tubular sleeve secured thereto, said tubular sleeve having a periphery formed with an annular groove and being received slidably and rotatably in said clearance such that said bent distal portions of said mounting plates extend into said annular groove; an adjusting member formed as an elongated piece with a front side, a rear side and a plurality of spaced threaded bores that extend from said rear side to said front side to permit extension of said pressing screws therethrough; and 42 a plug member formed as a resilient elongated strip and connected to said front side of said adjusting member, said plug member having a tapered front portion for abutting tightly edge portions of the vertical face plates to block any clearance therebetween in order to prevent leakage thereat.

9. The method for constructing a concrete floor of an upper storey of a structure substantially as hereinbefore described with reference to and as illustrated in Figures 3 to 25 of the accompanying drawings.

10. The connecting apparatus for interconnecting adjacent modular floor form units of a floor form assembly substantially as hereinbefore described with reference to and as illustrated in Figures 3 to 25 of the accompanying drawings.

11. The form contracting apparatus for a floor form assembly that is assembled from a plurality of interconnected modular floor form units substantially as hereinbefore described with reference to and as illustrated in Figures 3 to 25 of the accompanying drawings.

12. The corner leak-preventing apparatus for a floor form assembly substantially as hereinbefore described with reference to and as illustrated in Figures 3 to 25 of the accompanying drawings.

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