GB2454453A

GB2454453A - Support apparatus and formwork used in casting concrete floors

Info

Publication number: GB2454453A
Application number: GB0718512A
Authority: GB
Inventors: Tony Priddle; Thomas Finan
Original assignee: Individual
Current assignee: Individual
Priority date: 2007-09-22
Filing date: 2007-09-22
Publication date: 2009-05-13
Also published as: GB0718512D0

Abstract

The invention relates to a support apparatus for use in forming a concrete floor of a building or other structure and consists of a formwork for retaining wet concrete in position while it is setting and a tower for supporting the formwork. The formwork comprises at least one pan which is hingedly mounted for movement between an unfolded position in which it extends laterally outwards from the tower and a folded position in which it extends alongside the tower. Preferably there are nine square pans in total (A-I figure 4) arranged around a central square pan (A figure 4) mounted on the tower. The pans may be raised or lowered by gas damping springs 4 and supported in the raised position by struts 1. A later embodiment relates to a system of formwork comprising said support apparatus.

Description

SUPPORT APPARATUS

Field of the Invention

This invention relates to the prior art of concrete formwork. The piece of equipment would be classified as temporary works, in other words a single unit of this piece of equipment or a combination of numbers units up to any quantity joined together in order to form a deck at a set distance from the surface the equipment is sitting on to the deck level in order to pour concrete on to form a concrete floor suspended. When the concrete would have Set sufficiently onto vertical supports i.e. walls or columns, the formwork would then be removed, hence the classification of temporary works.

The tableform as will be described achieves the same end result as any other related piece of equipment to one skilled in the art. However, it is distinctly different in that it is a 9 square metre in plan piece of formwork that has the ability to fold down to a 1.4 square metre size without the need to dis-assemble the unit of formwork.

Background to the Invention

To one skilled in the art of formwork it would be fair to say that various systems and methods of formwork have traditionally existed within the construction industry and would be described as formwork and, more technically, as temporary works. Supporting wet concrete aloft to form a floor or in a mould to form any shape is not by any means a new concept. In fact, it is evidence as far back as Roman times. In times such as this, and even in this century, timber would have been the main supporting structure for the wet concrete. More recently the industry evolved to steel adjustable propping supports with timber on top.

The more up to date methods include component systems in aluminium or steel joined together in a set sequence in order to form the structure. All such systems would be erected on site and moved or dismantled as per the requirements of the project.

These systems, as described in present times, would normally be classified into three categories.

Category I would be the use of aluminium beams, legs and frames joined together to form a tableform and then lowered down and moved as a complete unit to the next area of the project, as illustrated in sketch 1.

Category 2 would be the use of the same equipment as described in category 1 but with one distinct difference. Because of the building shape being non-standard and with various parts of the building structure being as obstructions to the ability to move the formwork, the system would, after use, have to be dismantled and moved by hand to its new location and re-assembled as in sketch 2.

Category 3 would be a light-weight aluminium panel approximately 1 metre wide x 2 metres long which would be supported on four propping legs, one in each corner. This sequence would be repeated by joining and supporting more panels in the same manner.

Again, to move to the next area of the project all the components would have to be dismantled, moved manually and re-erected as in sketch 3.

The Invention We will now try to describe in more detail what made us design this piece of equipment, what particular problems it solves that exists in pieces of equipment currently in the marketplace.

The design for this piece of equipment has been driven by our experiences and our perceived deficiencies in similar equipment currently in use. These deficiencies, in our view, would be classified in areas of production regarding amount of labour required to dismantle, move and re-erect such systems, also in the area of safety of operatives with respect again to the need to move, dismantle and re-erect such systems.

The folding tableform is, by design and performance ability, unique, because it has the capacity to fulfil all the requirements of the previously described three categories of formwork currently in existence within the global marketplace to one skilled in the art of formwork.

The folding tableform is based on the simple principle of squareness and symmetry that affords it its unique ability. In plan, when filly opened out, the Support Apparatus is 9 metres square in area which equates to a dimensional size of 3 metres x 3 metres square.

For the purposes of this description, we will describe the units that make up the top of the tableform as pans, each pan being 1 metre x 1 metre square and the total combined unit being made up of nine of these pans giving us the 9 square metre total area. The centre pan, again 1 metre square, being supported on the main central support tower arid the remaining 8 pans being distributed evenly around the master pan. This configuration allows the 8 pans to fold evenly and symmetrically around the master pan and central support tower to form a plan area not greater than 1.4 metres square, in contrast to the original 9 square metre area when the tableform is fully opened.

The benefits derived from this system that do not exist in systems currently in the marketplace are as follows. The system is manufactured as a complete assembled unit, in other words it arrives on site ready to be moved to the required location without the need to find the labour to put it together. this opportunity is duplicated again at the time the equipment is no longer needed on site as it does not need to be dismantled, only folded, as previously described, for transportation purposes. The ability to transport this system, the folding tableform, is a function of its size when folded which allows us to transport 20 number folded tableforms on a standard 4Oft articulated trailer, allowing us to transport square metres of formwork assembled on any delivery. This benefit of assembled formwork cures three major areas of concern for contractors; performance in production, labour requirements and safety.

With regard to performance in production, as previously described in all three previous system categories, two of the systems need to be dismantled and re-assembled between tasks, as in categories 2 and 3, while category I would need to be assembled at the beginning of the project and dismantled at the end of the project for transporting off site.

Eliminating the assembly or dismantle process will enhance the performance process as, with the folding tableform, equipment moves into the operation stage more efficiently and in turn moves off site at the end more efficiently. With regard to labour requirements for the folding tableform system, the removal from the process of the assembly or dismantling requirement reduces the need for labour for this process, allowing them to be deployed elsewhere or having a more direct impact on the lower number required in the construction phase overall. With regard to the area of safety, it stands to reason and has been proven that if you reduce the amount of activity required on site to achieve the product you are trying to build, this activity reduction reduces the amount of risks that operatives are exposed to and this in turn reduces the level of potential accidents and the frequency with which these accidents may occur.

The essential features of this invention are that the complete unit, as described previously, stays assembled at all stages of use afier the manufacturing process, even at the point of folding the tableforrn operatives to not need to remove any of the component parts from the system. The manual handling requirement is done via custom trolley to aid movement from one place to another, whilst the manual handling of the 1 metre square pans is catered for when folding by the fact that they remain attached to the central master plan also further aided by attached gas damper springs from master pan to outside pans taking 90% of the weight associated with the folding process. The design of the system has accommodated all the process of attachment of one complete 9 square metre unit to another from underneath, meaning that operatives do not need to get on top of the system, increasing the safety risks to join units together.

We have also included some important features, although not essential to the previously described functions of the equipment. The pans, being of 3 mm metal pressed to form the I x 1 metre square, are filled with a dense recycled rubber to provide the surface that the concrete would be poured onto as opposed to plywood more commonly used with systems currently in existence. This gives the system the advantage of being able to demonstrate the use of some more sustainable products in its manufacture. Also, because of the nature of the weight of concrete poured on top of the system as part of the floor casting process, we have included a quick strike apparatus on each of the four support jacks attached to the four legs forming the main central support tower. The main support legs of the tower, when joined together at the top at the location of the master pan, are closer together from centre to centre compared to the same location at the bottom connection. This configuration gives the tableform two unique qualities. 1: the legs are splayed in shape always heading diagonally towards the centre, allowing for a zone for the folding pans to fit neatly into. 2: the fact that the legs are splaying out diagonally at the bottom of the table form enhances the stability of the structure as a unit and gives it a more positive and stable centre of gravity.

Detailed description of the Invention

We will now describe the functional ability of the tableform by way of example and with reference to the accompanying drawings.

Sketch 4 shows the 9 square metre unit completely open, with the central master pan A, as previously described, attached to the central support tower as displayed in elevation on sketch 7. Sketch 4 also displays the attachment of pans B to master pan A by means of hinges attached under at locations 1. Following in a clockwise direction this connection process repeats where pan D is connected to master pan A by means of hinges attached under at locations 2. Pan F is connected to master pan A by means of hinges attached under at locations 3. This connection process to master pan A completes where pan H is connected to master pan A by means of hinges attached under at locations 4.

Sketch 4 then proceeds to show the second phase of connections starting from pan B and again moving in a clockwise direction. As previously described, pans B,D,F and H are all connected to the master pan A. The remaining pans C,E,G and I are connected to the previously mentioned pans and in the order notated. Pan C is connected to pan B by means of hinges under at locations 6. Pan G is connected to F by means of hinges under at locations 7. Last in the sequence is pan I connected to pan H by means of hinges at locations 8.

We will now describe the folding sequence of all the pans taking a 9 square metre unit to a size of 1.4 square metres, following the eight stages as drawn in sketch 5 and 6.

Step 1, as displayed in sketch 5, shows pans B and C as displayed in sketch 4 folding downwards together by means of hinges at locations I connected to master pan A. Step 2, as displayed in sketch 5, shows pans D and E as displayed in sketch 4 folding downwards together by means of hinges at locations 2 connected to master pan A. Step 3, as displayed in sketch 5, shows pan C folding over on top of previously folded down pan D by means of hinges at locations 5 in sketch 4 and sketch 5.

Step 4, as displayed in sketch 5, shows pans F and G as displayed in sketch 4 folding downwards together by means of hinges at locations 3 connected to master pan A. Step 5, as displayed in sketch 6, shows pan E folding over on top of previously folded down pan F by means of hinges at locations 6 in sketch 4 and sketch 6.

Step 6, as displayed in sketch 6, shows pans H and I as displayed in sketch 4 folding downwards together by means of hinges at locations 4 connected to master pan A. Step 7, as displayed in sketch 6, shows pan 0 folding over on top of previously folded down pan H by means of hinges at locations 7 in sketch 4 and in sketch 6.

Step 8, as displayed in sketch 6, shows pan I folding over on top of previously folded down pan B by means of hinges at locations 8 in sketch 4 and in sketch 6.

At this stage the unit would stand at the same height but the plan area, as described in step 8 of sketch 6, would be 1.4 metres square as opposed to the plan area of 9 square metres in sketch 4.

The operation of opening the tableform back out would require one to undo all the previously described sequences starting in reverse from step 8 back to step 1.

As displayed in sketch 7 and 8, we have shown steel struts number 1, these pairs of struts numbered 1 would sit in pairs around the four sides of the central support tower accounting for eight struts per tableform.

The connection of the struts to the pans is made by means of hinged connection at location 2 in sketch 7 and the struts being connected to pans B,D,F and H only, as displayed in sketch 4.

The connection of the struts at the other end to the central support tower is made at locations 3 by means of a connecting sleeve joining the supporting legs. This sleeve at location 4 in sketch 7 has got rotation ball connections at location 3 in sketch 7 which allows the struts numbered 1 to pass through without the need to remove the struts as part of the folding sequence.

This operation can be further clarified in sketch 8 which demonstrates one pan B folded for clarity. What it demonstrates is the pan B folded down and struts number I passing through the rotating ball sleeve at location 3, allowing the strut I to move down and fold neatly inside the folded pan B without the need to remove any components.

The sequence would repeat for all other pans folding downwards as is the case for pans D,F and H. As previously described, in the sequence the struts would not have any connection to the four outside corner pans C,E,G and I in sketch 4 as they would simply fold over pans D,F,H and B respectively by means of hinges 5,6,7 and 8 respectively.

The supporting of these pans C,E,G and I without struts attached would happen by means of joining other identical units of tableform together at location 9 on sketch 4. Where four pans at this location 9 from 4 separate tableforms would converge they would be supported vertically by means of an independent prop, but in no way influencing or disrupting the ability of a single tableform to fold up or to open back out.

As previously briefly described, we mentioned the attachment of gas damper spring pans in order to absorb 90% of the weight as operatives move to fold the tableform up and again as operatives try to open it back up.

As displayed in sketch 7 and 8, the item labelled 4 is the gas damper spring. In use in every tableform there would be four gas damper springs attached centrally to the master pan A and in turn attached to pans B,D,F and H as displayed by item 4 in sketch 7 and 8.

These previously mentioned springs, item 4 in sketch 7 and 8, are part of the function of folding the table down and opening it back up by virtue of the fact that they accommodate 90% of all the moving weight away from the operatives using the equipment.

As shown in sketch 9, part labelled 1 can be described as an alignment waling member which allows for the connection of any pan i.e. B,C,D,E,F,G,H and I in a tableform to any corresponding pan they become attached to in another tableform. In simple terms, these members 1 would align and stabilize two tableforms together.

Also to describe is the clear area created when two separate tableforms are joined together. This clear area is created on all four sides of the central support tower and facilitates the movement of materials, another folded tableform or operatives through the clear access created.

Claims

I. Support apparatus for use in forming a concrete floor of a building or other structure, said apparatus comprising formwork for retaining wet concrete in position while it is setting and a tower for supporting the formwork, the formwork including at least one pan mounted for movement between an unfolded position in which it extends laterally outwards from the tower and a folded position in which it extends alongside the tower.
2. Support apparatus according to Claim 1, wherein the formwork includes a pan mounted directly on the tower and one or more further pans mounted for said movement.
3. Support apparatus according to Claim 2, wherein each pan provides a square or rectangular concrete support surface.
4. Support apparatus according to Claim 3, wherein there are nine square pans arranged in a square with the central pan mounted directly on the tower.
5. Support apparatus according to any of the preceding claims, wherein when fully opened it measures 3 metres x 3 metres or 9 square metres in area on plan where each pan is 1 metre square starting with the master pan centrally attached to the centre support tower and in turn surrounded evenly and symmetrically by eight No 1 metre square pans, each one having the ability to fold inwards towards the central support tower, reducing the total tableform area from 9 square metres to just 1.4 square metres.
6. Support apparatus according to any of the preceding claims, where the folding means is provided by a series of moving hinges located symmetrically under the pans.
7. Support apparatus according to Claim 6, wherein its ability to fold from a maximum plan area size of 9 square metres to a minimum plan size of 1.4 square metres is facilitated by the design based on the principle of squareness and symmetry.
8. Support apparatus according to Claim 7, wherein when fully opened up, the complete plan area is filled in i.e. there are no voids to fill in manually.
9. Support apparatus according to any of the preceding claims, wherein when raising or lower the pans attached to the central master pan, the weight of the pans is taken up by gas damping springs.
10. Support apparatus according to Claim 9, wherein the pans are raised or lowered, this is facilitated by the hinged struts attached to the pans and passing through the ball rotating support brace, allowing the tableform to be raised or lowered without the need to remove any parts.
11. Support apparatus according to any of the preceding claims, wherein after the initial manufacture and assembly process, the unit never needs to be dismantled as part of the construction process or moving from project to project.
12. Support apparatus according to any of the preceding claims, wherein four no round steel legs forming the central support tower splay outwards diagonally enhancing the tableform's centre of gravity and in turn its ability to stand as a single unit or collectively as a group of folding tableforms.
13. Support apparatus according to Claim 12, wherein the diagonally splayed out legs at the base of the central support tower provide the means and the area at the top of the central support tower for the folding pans to fit into, without the pan square metre area at the top, when folded, exceeding the plan area of the tower at the bottom.
14. Support apparatus according to Claim 13, wherein the folded area at the top does not exceed the support area at the bottom, facilitates the transportation of completely assembled formwork on a normal articulated truck without the need for any special transportation licence.
15. Support apparatus according to any of the preceding claims, wherein the sequence of folding with regard to one pan to another remains constantly the same and is a function of the symmetry in design.
16. Support apparatus according to Claim 12, where the four steel legs splayed but joined together by a series of fixed braces provide for loading to be transferred to the central support tower.
17. Support apparatus according to any of the preceding claims, wherein the lowering process is facilitated by threaded jacks attached to the bottom of the four steel legs.
18. Support apparatus according to Claim 17, wherein attached to the threaded jacks is a quick release mechanism for removing the majority of the weight allowing for the rest to be removed manually.
19. Support apparatus according to any of the preceding claims, wherein the individual units do not get moved from place to place manually.
20. Support apparatus according to any of the preceding claims, wherein the full 360 degrees around the central master pan receives completed pans after raising.
21. A system of formwork comprising a plurality of items of support apparatus as described in any of the preceding claims, wherein one unit of the tableform meets another and having the requirement to be attached to each other, the aligning and attachment process in the design is all done from underneath enhancing the safety of operatives.
22. A system according to Claim 21, wherein one unit is attached and aligned to another by means of a v-shaped waler under.
23. A system of formwork according to Claim 21 or Claim 22, wherein one unit or more than one completely assembled unit can be moved from one floor level to another by means of hoisting.
24. Support apparatus according to Claim I and substantially as herein described.
25. Support apparatus substantially as described with reference to the accompanying drawings.
26. A system according to Claim 21 and substantially as herein described.
27. A system of formwork substantially as described with reference to the accompanying drawings.