GB2479607A

GB2479607A - Plastic mould for forming a base for an electrical or communications cabinet, or other ground-mounted articles

Info

Publication number: GB2479607A
Application number: GB201020248A
Authority: GB
Inventors: Steven Jeffery Willis; Neil Martin Hadler
Original assignee: PERMASHUTTER Ltd
Current assignee: PERMASHUTTER Ltd
Priority date: 2010-04-14
Filing date: 2010-11-30
Publication date: 2011-10-19
Also published as: GB201020248D0; GB201006231D0

Abstract

A mould 10 for forming a base of foundation for an electrical/communications cabinet 11, wherein: the mould is formed from a plastics material and defines the shape of the base; the walls of the mould define an aperture 26 (figure 2b) for receiving a filler material, and an internal cavity for filling with the filler material 25 which may be concrete, spoil or other aggregate; and the mould incorporates one or more conduits 32, 33 (figure 6) passing through the internal cavity, through which conduits electrical or telecommunications cables 12, 13, 14, 15 may pass in use; or means for receiving and attaching one or more such conduits to one or more walls of the mould. Also provided is a method of forming a base for an electrical/communications cabinet using such a mould; and a base for an electrical/communications cabinet comprising such a mould.

Description

APPARATUS AND METHOD FOR FORMING A BASE FOR AN

ELECTRICAL OR COMMUNICATIONS CABINET,

OR OTHER GROUND-MOUNTED ARTICLES

This invention relates to apparatus and a method for forming a base for an electrical or communications cabinet, or other ground-mounted articles. An electrical or communications cabinet is often to be found on a pavement or roadside, and is typically provided by a telecommunications company to house connections between telephone wires, fibre optic cables, or other electrical or telecommunications cables.

The cabinet may also contain associated electronic or electro-optical devices such as repeaters, amplifiers or switching equipment. Such a cabinet is typically mounted on a concrete base (also referred to herein as a "foundation") that is embedded in the ground. Accordingly, the present invention is particularly suitable for, but by no means limited to, forming such a base from concrete.

Background to the Invention

As mentioned above, electrical or communications cabinets are often found on pavements or roadsides, typically to house connections between telephone wires, fibre optic cables, or other electrical or telecommunications cables. The cabinets may alternatively be situated alongside train lines, motorways, rivers, or indeed any location where telemetry or electrical services are required (i.e. in both soft and hard landscaping.) The cabinets may also contain associated electronic or electro-optical devices such as repeaters, amplifiers or switching equipment. The bases for such cabinets are usually embedded in the ground and are usually made from concrete.

Traditionally, a concrete base for such a cabinet is heavily time consuming and labour intensive to construct, typically taking several days. This is because the traditional construction procedure involves assembling a mould for the base in situ using temporary wooden shutters (typically plywood boards), which is then filled with concrete to cast the base.

More particularly, with the traditional procedure, many defined stages need to be completed in order and in situ in order to complete the construction of a concrete base. The construction procedure is lengthy and requires numerous skilled personnel, consultants, tradespeople and plant equipment. It is therefore expensive both in terms of time and employment costs. Particular care needs to be taken in order to accommodate ducts to enable electrical or telecommunications cables to pass through the base, from underground, up into the cabinet. Such ducts need to be carefully positioned so as to bring the cables into the cabinet in the correct places.

The overall traditional procedure for installing a cabinet on a concrete base (involving the use of temporary wooden shutters) is typically as follows: Erect temporary footpath barriers and signage 2 hours Remove existing paving from installation area 2 hours Excavate hole to formation level allowing enough working space to install temporary wooden formwork GL (ground level) -5 00mm 1 hour Set out position of larger 90mm ducts (2no.) 0.5 hour Excavate trench to receive larger diameter ducts (2no. 90mm) 0.5 hour Install 2no. 90mm duct bends into trench and back fill to GL-SOOmm 0.5 hour Set out position of smaller 50mm ducts and install (4no.) 1 hour Lay 175mm layer of MOT type 1 aggregate and compact to GL-325mm 0.5 hour Install timber shutters to form rectangle shape of foundation, ensuring that all ducts are configured correctly within 1 hour Install earth rod connecting cable 0.25 hour Install earth rods (2no.) 0.5 hour Place concrete into timber shutters 1 hour Finish the surface of the concrete with finishing tools (steel float) 0.25 hour Concrete curing time 168 hours Remove the timber formwork 1 hour Backfill and compact the working space area to level with the top of the foundation GL-75mm 1 hour Set out and drill holes into concrete for cabinet fixing bolts, and add bolts 1.5 hours Prepare and place sand and cement mortar bed for the perimeter of the cabinet 1 hour Bed cabinet onto mortar bed and corner fixings, and tighten up 0.25 hour Place compound resin around bolts (to prevent rusting) 0.25 hour Prepare and place resin pack 20mm thick to the surface of the concrete 2 hours Replace surfacing around the cabinet 4 hours Remove temporary footpath barriers and signage 1 hour TOTAL HOURS (minimum) 191 hours TOTAL DAYS (minimum) 10 days It will be appreciated that this is a significant length of time for installing a cabinet on a concrete base.

(In the above schedule, and below, "MOT type 1 aggregate" is a UK Ministry of Transport specification for aggregate that has been graded to be a particular blend of fine stone dust and larger stones of approx 30mm in size. It is used underneath surfacing, in the formation of roads, car parks, footpaths, runways, railways, etc. The most popular Type 1 in the UK is produced from granite, but it may also be produced from limestone, etc.) More recently, to save some time, an alternative technique has been adopted, involving the use of pre-cast concrete (PCC) for the cabinet foundation. A typical PCC process, under comparable circumstances to the traditional process set out above, is as follows: Erect temporary footpath barriers and signage 2 hours Remove existing paving from installation area 2 hours Excavate hole to formation level allowing enough working space to install temporary wooden formwork GL-500mm 1 hour Set out position of larger 90mm ducts (2no.) 0.5 hour Excavate trench to receive larger diameter ducts (2no. 90mm) 0.5 hour Install 2no. 90mm duct bends into trench and back fill to GL-SOOmm 0.5 hour Set out position of smaller 50mm ducts and install (4no.) 1 hour Lay 175mm layer of MOT type 1 aggregate and compact to GL-325mm 0.5 hour Place PCC unit over all ducts (6no.) 1 hour Install earth rod connecting cable 0.25 hour Install earth rods (2no.) 0.5 hour Backfill and compact the working space area to level with the top of the foundation GL-75mm 1 hour Prepare and place sand and cement mortar bed for the perimeter of the cabinet 1 hour Bed cabinet onto mortar bed and corner fixings, and tighten up 0.25 hour Place compound resin around bolts (to prevent rusting) 0.5 hour Prepare and place resin pack 20mm thick to the surface of the concrete 1.5 hours Replace surfacing around the cabinet 4 hours Remove temporary footpath barriers and signage 1 hour TOTAL HOURS (minimum) 19 hours TOTAL DAYS (minimum) 3 days Although the PCC process takes significantly less time than the traditional (temporary wooden shutters) process, it is desirable to reduce the time taken still further. It is also desirable to carefully control the positions of the ducts through the base, in order to facilitate the passage of electrical or telecommunications cables, from underground, up into the cabinet in the correct places, for subsequent connection to components within the cabinet. A further disadvantage with the PCC process is that the pre-cast concrete base can be very heavy and cumbersome to manoeuvre accurately into position, and requires the use of mechanical lifting equipment.

It is therefore desired to expedite and simplify the construction of the base of an electrical/communications cabinet.

In a similar manner, it is also desired to expedite and simplify the construction of bases for other ground-mounted articles, such as (but by no means limited to) park benches, railway equipment such as signals and signs, road equipment such as traffic lights and road signs, petrol pumps, street lamps and other street furniture, playground equipment, fence posts, and so on.

Summary of the Invention

According to a first aspect of the present invention there is provided a mould as defined in Claim 1 of the appended claims. Thus there is provided a mould for forming a base for an electrical/communications cabinet, wherein: the mould is formed from a plastics material and defines the shape of the base; the walls of the mould define an aperture for receiving a filler material, and an internal cavity for filling with the filler material; and the mould incorporates one or more conduits passing through the internal cavity, through which conduits electrical or telecommunications cables may pass in use; or means for receiving and attaching one or more such conduits to one or more walls of the mould.

Such a mould may be prefabricated and supplied to the installation site ready for use, so that all that is essentially required for construction of the cabinet base is to prepare the site, place the mould into position, fit the electrical or telecommunications cables, or ducts for such cables, through the conduit(s) in the mould, and fill the mould with the filler material (e.g. concrete). Fewer quality assurance checks and items of plant are required compared with the traditional (wooden shutter) construction technique.

indeed, wooden shutters and the services of skilled carpenters are also no longer required.

Compared to the PCC process, the present mould, being made of a plastics material and substantially hollow, can quickly and easily be manoeuvred into position in the installation site, with no requirement for mechanical lifting equipment.

By incorporating one or more conduits passing through the internal cavity, through which conduits electrical or telecommunications cables pass in use, or means for receiving and attaching one or more such conduits to one or more walls of the mould, the positions of cables passing through the base can be carefully controlled. This facilitates the subsequent connection of the cables to components within the cabinet.

The conduits also mean that the cables (or ducts for the cables) within the conduits are not directly contacted or enveloped by the filler material when it is introduced into the mould, thereby protecting the cables (or ducts), and enabling them to be subsequently removed or replaced if necessary.

Using the mould, the base can be constructed and the cabinet installed in only a couple of days. The overall process is facilitated and greatly expedited, and the associated costs can be reduced.

Preferable, optional, features are defined in the dependent claims.

Thus, preferably the upper surface of the mould incorporates means (for example threaded bolts) for engaging with an electrical/communications cabinet. This facilitates subsequent alignment and attachment of the cabinet to the base.

Alternatively the said engaging means may be arranged to engage with a collar, upstand or raising-piece, to which the cabinet is then attached.

Preferably the mould further comprises fastening means (e.g. threaded studs, bolts or threaded holes) for attaching the cabinet thereto in use.

Preferably the mould further comprises means for forming a seal between the upper surface of the mould and an electrical/communications cabinet. This helps to prevent moisture/dampness, gas or insects from getting up into the cabinet, where they could potentially interfere with the operation of the electrical/telecommunications components therein.

Preferably the mould is formed and configured to incorporate integral structural reinforcement. This is beneficial in order to resist deformation of the mould during filling, and in order to be able to support the weight of a heavy cabinet in use.

Particularly preferably the integral structural reinforcement is arranged vertically, in positions corresponding to the corners of the cabinet. As those skilled in the art will appreciate, integral structural reinforcements may also be provided elsewhere, as necessary.

Alternatively, or in addition, a plurality of support means may be provided within the mould, arranged to support the cabinet in use. These support means are preferably metal posts, arranged vertically within the mould, and which may be positioned to coincide with the corners of the cabinet. Moreover, each post may be attached to a base plate, each base plate being shaped and configured to locate in a correspondingly-shaped recess in the underside of the mould. Preferably the upper end of each post is provided with fastening means for attaching the cabinet thereto.

Together, the base plate and the fastening means serve to improve the security of the cabinet (i.e. the strength of attachment of the cabinet to the base) when installed.

Preferably the walls of the mould are formed and configured to receive and provide support for one or more reinforcing members spanning the internal cavity. Such reinforcing members also help to prevent (or at least limit) deformation of the mould during filling.

Particularly preferably the reinforcing members comprise crenellated metal braces, although other designs of reinforcing members are also possible.

The mould may further comprise a cap to close the said aperture.

The mould may further comprise a channel recessed within one of the walls of the mould and arranged to link two conduits together. This is particularly advantageous in the underside of the mould, in order to enable a pair of earth cables or earth rods (one in each of the said two conduits) to be electrically connected together.

The mould may further comprising a plurality of pimples, protrusions or ribs on one or more ground-engaging outer surfaces of the mould, to enhance the engagement of the mould with the ground and to help stop the mould from moving about during filling.

According to a second aspect of the present invention there is provided a base for an electrical/communications cabinet, the base comprising a mould in accordance with the first aspect of the invention.

Preferably the base further comprises filler material within the internal cavity of the mould. The filler material preferably comprises concrete, although sand, stone, earth, spoil from the installation site itself, or other aggregates may be used instead, as those skilled in the art will appreciate.

According to a third aspect of the present invention there is provided a method of forming a base for an electrical/communications cabinet using a mould in accordance with the first aspect of the invention, the method comprising the steps of: positioning the mould in the installation site; passing one or more electrical or telecommunications cables, or one or more ducts for such cables, through the conduit(s); and filling the internal cavity of the mould with a filler material.

Preferably the method further comprises inserting one or more reinforcing members through the mould before filling the internal cavity with the filler material.

The method may further comprise passing one or more earth rods and/or earth cables through conduits in the mould; and/or fitting a cap to close the said aperture in the mould.

The method may then comprise attaching an electrical/communications cabinet to the mould (optionally with a seal between the upper surface of the mould and the cabinet); or first attaching a collar, upstand or raising-piece to the mould, and then attaching an electrical/communications cabinet to the collar, upstand or raising-piece (again optionally with seals therebetween).

Some of the principles mentioned above are more broadly applicable than just to providing bases for electrical/communications cabinets. Thus, according to a fourth aspect of the invention there is provided a mould for forming a base for a ground-mounted article, wherein: the mould is formed from a plastics material and defines the shape of the base; the walls of the mould define an aperture for receiving a filler material, and an internal cavity for filling with the filler material; and the mould incorporates fastening means for attaching the article thereto in use. The article in question may be, for example, a park bench, an item of railway equipment such as a signal or sign, an item of road equipment such as a set of traffic lights or a road sign, a petrol pump, a street lamp or other item of street furniture, a piece of playground equipment, a fence post, and so on. This list is given by way of example only, and is by no means exhaustive, as those skilled in the art will appreciate.

The mould may further incorporate one or more conduits passing through the internal cavity, through which conduits cables or pipes may pass in use; or means for receiving and attaching one or more such conduits to one or more walls of the mould.

Alternatively, or in addition, the mould may incorporate any of the optional features mentioned above in relation to the first aspect of the invention.

According to a fifth aspect of the present invention there is provided a base for a ground-mounted article, the base comprising a mould in accordance with the fourth aspect of the invention. As with the second aspect of the invention mentioned above, preferably the base further comprises filler material within the internal cavity of the mould.

According to a sixth aspect of the present invention there is provided a method of forming a base for a ground-mounted article using a mould in accordance with the fourth aspect of the invention, the method comprising the steps of: positioning the mould in the installation site; filling the internal cavity of the mould with a filler material; and fastening the article to the mould.

With all the aspects of the invention, preferable, optional, features are defined in the dependent claims.

Brief Description of the Drawings

Embodiments of the invention will now be described, by way of example only, and with reference to the drawings in which: Figure 1 illustrates an exploded view of a mould in accordance with a first embodiment of the invention, together with an electrical/communications cabinet, and associated ducts for electrical or telecommunications cables; Figure 2a illustrates the mould of Figure 1 embedded in the ground beneath a pavement, filled with concrete; Figure 2b is an alternative representation of Figure 2a, before being filled with concrete; Figure 3 is an isometric view of the mould of Figure 1 from above; Figure 4 is an isometric view of the underside of the mould of Figure 1; Figure 5 comprises plan views of the mould of Figure 1 fioni above (at the top of Figure 5) and below (at the bottom of Figure 5), a side view (the other side corresponds), and end views; Figure 6 illustrates cross-sectional views through the mould of Figure 1, according to lines J-J, K-K and L-L indicated in Figure 5 on the plan view of the mould from above; Figure 7 is an isometric view from above of a mould in accordance with a second embodiment of the invention; Figure 8 is an isometric view of the underside of the mould of Figure 7; Figure 9 comprises plan views of the mould of Figure 7 from above (at the top of Figure 9) and below (at the bottom of Figure 9), a side view (the other side corresponds), and end views with cross-sectional detail taken along lines M-M and N-N; and Figure 10 illustrates cross-sectional views through the mould of Figure 7, according to lines J-J, K-K and L-L indicated in Figure 9 on the plan view of the mould from above.

n the figures, like elements are indicated by like reference numerals throughout.

Detailed Description of Preferred Embodiments

The present embodiments represent the best ways known to the Applicant of putting the invention into practice. However, they are not the only ways in which this can be achieved.

Initial overview (first embodiment) Currently-preferred embodiments of the present invention are illustrated in the figures. By way of an initial overview of a first embodiment, and with reference to Figures 1, 2a and 2b, a prefabricated plastic mould 10 is provided which, in use, is used to form a base or foundation for an electric/communications cabinet 11 (Figure 1). The mould 10 has a hollow internal cavity. In the installation site (Figure 2a), the mould 10 is embedded in the ground and filled with a filler material 25, which is poured into the mould 10 through aperture 26 (Figure 2b) so as to fill the internal cavity. The filler material provides strength, weight and rigidity to the base, and is preferably concrete, although sand, stone, earth, spoil from the installation site itself, or other aggregates may be used instead. Once filled, the mould 10 remains in place as part of the cabinet base.

The mould 10 is prefabricated in a factory and supplied to the installation site ready for use. Each such mould is typically manufactured in two or more parts that are assembled in the factory. The mould may be produced by forming, injection moulding or rotation moulding. With injection moulding, molten plastic material is forced into a mould cavity, where it cools and hardens, conforming to the contours of the mould cavity. Rotation moulding, on the other hand, is a technique in which plastic is introduced into a mould which is then spun on all three axes at a high temperature, such that molten plastic is spun to the outside of the mould to form the required product.

The plastics material from which the mould 10 is made may be reinforced. For example, it may be made of fibreglass, or any other suitable plastics materials that will be readily apparent to those skilled in the art.

As shown in Figure 2a, in use the prefabricated plastic mould 10 is embedded in the ground 24. The upper surface of the mould 10 may be arranged to be level with the upper surface of a pavement 20 (the paving slabs typically being supported by a bed 22 of sand, concrete or mortar), or, more usually, may be set 75mm below the surface of the pavement.

Once the mould ifi has been installed in the ground and filled to form the base, the cabinet 11 may be fitted directly on top of the mould/base. Alternatively, as those skilled in the art will appreciate, a metal collar, upstand, raising-piece or so-called "root" (not illustrated) may be fitted between the base and the cabinet, to raise the cabinet above the base by a few inches. In such a way, the base may be completely buried within the ground, and the collar/upstand/raising-piece protrudes from the ground to support the cabinet.

Conduits through the mould Before the mould is filled with the filler material 25, ducts 12, 13, 14 and 15 for electrical or communications cables may be arranged to pass up through the mould, from underground, so as to enable the cables to be connected to the appropriate components within the cabinet 11. The ducts 12, 13, 14 and 15 may be located through corresponding conduits through the mould 10, as will now be described in detail: As illustrated in Figures 3, 4, 5 and 6, the mould incorporates integral conduits 32 and 33 that are configured to receive small 50mm-diameter ducts 14 and 15 respectively.

As illustrated in section J-J of Figure 6, conduit 32 passes down through the internal cavity of the mould 10 and across to the left hand side as illustrated. Conduit 33 passes down through the internal cavity of the mould 10 and across to the right hand side, as illustrated in section K-K of Figure 6. Conduits 32 and 33 are preferably sized such that ducts 14 and 15 can be contained within the profile of the mould and do not protrude beneath it.

The mould also incorporates two vertical conduits 34 and 36, which pass straight down through the internal cavity of the mould 10. Furthermore, as illustrated in Figure 4 (which shows the underside of the mould 10) and the plan view from below in Figure 5, conduits 34 and 36 are connected by a channel 35 recessed within the bottom wall of the mould 10. Conduits 34 and 36 are intended to accommodate earth rods (approximately 14 mm in diameter) which may be inserted down conduits 34 and 36 and embedded in the ground, in order to provide earth grounding for the electrical equipment within the cabinet 11. Additionally, or alternatively, earth cables 38 and 39, connected to the earth rods, can pass up conduits 34 and 36, as illustrated in Figures 2a and 2b. The earth cables 38, 39 may each be terminated by an eyelet to facilitate connection to the electrical equipment inside the cabinet 11. The cabinet 11 may be divided into two compartments, and consequently separate earth cables 38, 39 may be provided for each compartment. The recessed channel 35 on the underside of the mould enables the two earth cables 34, 36 to be electrically connected together, by connecting an electrical cable along the channel 35, thereby enabling both earth cables to be served by a single earth rod.

In alternative embodiments, instead of (or in addition to) providing integrally-moulded conduits through the mould, the mould may be user-configurable. That is to say, an installation engineer may fit tubular conduits through the interior of the mould, as desired, linking apertures in different (e.g. opposing) walls of the mould.

The apertures may be pre-formed in the walls of the mould, or may be punched-out by the installation engineer in positions as desired, and in sizes as desired. In such a manner, the installation engineer may fit conduits in a variety of diameters, as desired, in a variety of positions within the mould.

In the embodiment illustrated, apertures 28 and 29 are not linked by a conduit, but instead large 90mm-diameter ducts 12 and 13 are simply inserted through the apertures prior to filling the mould 10 with the filler material. In alternative embodiments, one or two conduits could readily be installed connecting apertures 28 and 29, through which conduit(s) the ducts 12 and 13 would pass.

The provision of conduits (e.g. 32 and 33) through the internal cavity of the mould advantageously means that the ducts 14 and 15 do not become directly coated with the filler material when it is introduced, and so can be removed if necessary. The conduits 32 and 33 also cause the ducts 14 and 15 to be precisely located relative to the cabinet 11, thereby facilitating subsequent connections within the cabinet.

Structural rein trceinent Being made of plastic, the walls of the mould 10 are susceptible to deforming when the internal cavity of the mould is filled with the filler material (e.g. concrete). Tn order to prevent (or at least limit) such deformation from happening, the long sidewalls of the mould 10 are provided with slots 30 and 31, and corresponding slots (not visible in the drawings) on the opposing sidewall of the mould. The slots are configured to receive crenellated steel reinforcing braces 16, 17 as illustrated in Figure 1. Each reinforcing brace 16, 17 is inserted through a slot in one sidewall of the mould, pushed through the internal cavity of the mould, and then through the corresponding slot in the opposite sidewall of the mould. Each brace 16, 17 is then rotated through 90° to adopt the configuration shown in Figures 2a and 2b, such that the ends of the braces 16, 17 locate in recesses or detents 48, 49 (Figure 3) to lock them in place. The crenellated shape of the braces enables them to be locked in position around the walls of the mould. The braces 16, 17 fix the separation of the opposing sidewalls of the mould, and prevent the mould from flexing or distorting when it is filled with concrete or other filler material. II will be appreciated that, when the internal cavity of the mould is filled, the filler material envelops the braces.

The slots 30, 31 and the corresponding slots on the opposing sidewall of the mould are located at the bottom of recessed channels 44, 45, 46 and 47 respectively. These recessed channels provide further structural rigidity and stiffness to the walls of the mould. They also facilitate manufacture of the mould, since they enable the two parts of a manufacturing tool to be easily separated.

Additional structural reinforcement may be integrally incorporated within the material of the mould -for example arranged vertically and positioned to correspond with the corners of the cabinet 11 -in order to provide adequate support the weight of the cabinet (which may be of the order of 280 kg in weight). Such reinforcements enable the cabinet to be placed on top of the base immediately after the mould 10 has been put in position and filled (i.e. without needing to wait for the concrete to set, if concrete is used as the filler material), thus saving a considerable amount of time compared to traditional techniques.

Completion of the base Once the mould 10 has been filled with the filler material, a cap (not illustrated) may be snap-fitted into aperture 26 to create a smooth sealed upper surface to the finished base. A rubber gasket 18 may be fitted into recess 42 provided around the upper surface of the mould, to create a watertight seal between the base and the cabinet 11 (or between the base and a collar/upstand/raising-piece) when it is brought into position. A rubber seal may also be fitted around the larger ducts 12, 13 passing through aperture 28. The cap on aperture 26, the gasket 18, and any additional seals, help to prevent moisture/dampness, gas or insects from getting up into the cabinet 11, where they could potentially interfere with the operation of the electrical/telecommunications components.

As those skilled in the art will appreciate, additional sealing material (for example expanding foam or such like) may be applied around any of the ducts or cables, to seal any gaps between them and the base as they pass through it.

Attachment of the electrical cabinet Once the base has been installed, the cabinet 11 is then lowered into place and connected to the base using threaded bolts 40 or other suitable fastening means. The electrical/communications cables passing along the ducts 12, 13, 14 and 15, and the earth connections 38 and 39, are then connected to the appropriate components within the cabinet 11.

Alternatively, a metal collar, upstand, raising-piece or so-called "root" (not illustrated) may first be attached to the base, and then the cabinet attached to the collar/upstand/raising-piece. The collar/upstand/raising-piece raises the cabinet above the base by a few inches, and enables the base to be completely buried within the ground. The collar/upstand/raising-piece may be made of cast iron or steel, and incorporates vertical openings through which the electrical cables or ducts can pass.

Second embodiment A second embodiment of the invention is illustrated in Figures 7, 8, 9 and 10, which show a mould 50 having many similar structural features as the mould 10 of the first embodiment described above. The similarities are reflected by the use of common reference numerals in the figures, and need not be repeated in detail here. The method of manufacture and method of installation of the mould 50 are also substantially the same as for the first embodiment.

One of the principal differences between the first and second embodiments is that, with the second embodiment, in each corner of the mould 50 there is provided a metal post 61 with a base plate 60 attached. With reference in particular to Figure 8, each post 61 is inserted through the underside of the mould 50, such that the attached base plate 60 locates in a correspondingly-shaped recess provided within the underside of the mould. Each post and base plate assembly (60/6 1) may be added to and configured within the plastic mould 50 at the factory, or inserted on-site.

By virtue of the base plates being square (or some other non-circular shape), each post and base plate assembly (60/6 1) is prevented from rotating once installed in the mould 50. Moreover, as a result of the engagement of each base plate 60 in the underside of the mould 50, the pullout force necessary to pull out the corresponding post 61 from the foundation is much greater than if the post was only moulded into the plastic of the mould (i.e., as illustrated, each base plate and post assembly would need to be pulled completely through the underside of the mould 50 and its filling material, which in practice would be extremely difficult to do).

The metal post and base plate assemblies have two main purposes. Firstly, they provide additional support to the cabinet 11 installed thereon (particularly if the mould is not filled with concrete, but instead with some less dense aggregate or other material). Secondly, if the top of each metal post 61 is threaded (or incorporates some other kind of fastening means) then they may provide a fixing connection between the base and the cabinet 11, or between the base and a collar/stand/raising-piece or "root" on which the cabinet is then mounted.

Together, the base plate 60 and the fastening means at the top of each metal post 61 serve to improve the security of the cabinet 11 (i.e. the strength of attachment of the cabinet to the base) when installed.

Another difference between the second embodiment and the first is that the mould 50 has longer and more pronounced recessed channels 52, 53, 54, 55, 56 and 57 formed within the side walls of the mould. These recessed channels enhance the structural rigidity and stiffness of the walls of the mould (as with the first embodiment), and also improve the degree of engagement of the mould with the ground when installed.

The engagement of the mould with the ground is also enhanced by the provision of a number of pimples or protrusions on the underside of the base, as illustrated for example in Figure 8. These pimples or protrusions also help to stop the mould from moving about during filling, and to key the mould to the ground underneath. Tnstead of pimples or protrusions as illustrated, a series of ribs may be provided on the underside of the mould, to carry out the same purpose.

To facilitate the filling of the mould 50 and the compaction of the filler material therein, the aperture 26 of the mould 50 has been made as large as possible.

A further noteworthy feature is that, instead of the single apertures 28 and 29 through which ducts 12 and 13 pass in the first embodiment (see Figures 2b, 3 and 4), in the second embodiment the single aperture 28 is replaced by two separate apertures 28a and 28b arranged to individually receive and retain ducts 12 and 13 in use.

It should be emphasised that those features shown or described above as being particular to the mould 50 of the second embodiment may be applied to and incorporated in the mould 10 of the first embodiment, and vice-versa.

The filler material, and filling the mould As noted above, with both embodiments the filler material is preferably concrete, although sand, stone, earth, spoil from the installation site itself, or other aggregates may be used instead. By enabling the installing contractor to fill the mould with what he has excavated from the installation site, this saves on the import of concrete and the removal of spoil. n many cases the cabinets/foundations are intended to be installed on footpaths, which are constructed using type 1 stone material; this can also be used as the filler material.

It should be noted that, as concrete is denser than sand or stone, the internal volume of the mould may need to be increased if sand or stone is used as the filler material, in order to give the same overall mass.

Another design consideration is that the fitting aperture 26 should be large enough to ensure that the filler material can be effectively placed and compacted within the mould using a hand tool. This is to ensure that no voids are left inside the moulding.

Accordingly, in further variants, the mould may have a completely removable lid or a lid that may be hinged or clipped in some way.

Installation method and typical timescale The process of installing a cabinet on a concrete base formed using one of the present prefabricated moulds (e.g. mould 10 or mould 50), under comparable circumstances to the traditional and PCC processes set out above, is as follows: Erect temporary footpath barriers and signage 2 hours Remove existing paving from installation area 2 hours Excavate hole to formation level allowing enough working space to install the plastic mould formwork. GL-600mm 1 hour Set out position of larger 2no. 90mm ducts 0.5 hour Excavate trench to receive larger diameter ducts (2no. 90mm) 0.5 hour Install 2no. 90mm duct bends into trench and back fill to GL-SOOmm 0.5 hour Clip 4no. 50mm ducts into bottom of plastic mould formwork 0.1 hour Lay 100mm layer of MOT type 1 aggregate and compact to GL-400mm 0.5 hour Place plastic mould formwork over 90mm ducts (2no) 0.11 hour Install 2no. earth rods 0.5 hour Fill plastic mould formwork with concrete 1 hour Backfill and compact the working space area to level with the top of the foundation GL-75mm 1 hour Place cabinet onto gasket (optionally with collar/upstand) and corner fixings and tighten up 0.25 hour Replace surfacing around the cabinet 4 hours Remove temporary footpath barriers and signage 1 hour TOTAL HOURS (minimum) 14.95 hrs TOTAL DAYS (minimum) 2 days Thus, it can be seen that the present invention enables a significant time saving to be realised, compared either to the use of temporary wooden shutters to cast a concrete base (191 hours / 10 days), or to the use of a pre-cast concrete base (19 hours / 3 days).

Mouldsforforming bases for other ground-mounted articles The principles described above may readily be extended to provide moulds for forming bases for other ground-mounted articles, such as (but by no means limited to) park benches, railway equipment such as signals and signs, road equipment such as traffic lights and road signs, petrol pumps, street lamps and other street furniture, playground equipment, fence posts, and so on.

In such cases, the mould is formed from a plastics material and defines the shape of the base, and the walls of the mould define an aperture for receiving a filler material, and an internal cavity for filling with the filler material. The mould also incorporates fastening means for attaching the article thereto in use.

Optionally, if the article requires electrical, fibre-optic or pipe connections (e.g. for water, petrol, gas or oil) thereto, then the mould may further incorporate one or more conduits passing through the internal cavity, through which conduits cables or pipes may pass in use; or means for receiving and attaching one or more such conduits to one or more walls of the mould.

Alternatively, or in addition, the mould may incorporate any of the features mentioned above in relation to the electrical/communications cabinet base embodiments.

In use, the mould is inserted into the installation site, filled with filler material (as per the examples described above), and left in situ as part of the base to which the article is then attached.

Claims

CLAIMS1. A mould for forming a base for an electrical/communications cabinet, wherein: the mould is formed from a plastics material and defines the shape of the base; the walls of the mould define an aperture for receiving a filler material, and an internal cavity for filling with the filler material; and the mould incorporates one or more conduits passing through the internal cavity, through which conduits electrical or telecommunications cables may pass in use; or means for receiving and attaching one or more such conduits to one or more walls of the mould.
2. A mould as claimed in Claim 1, wherein the upper surface of the mould incorporates means for engaging with an electrical/communications cabinet.
3. A mould as claimed in Claim 2, further comprising fastening means for attaching the cabinet thereto in use.
4. A mould as claimed in any preceding claim, further comprising means for forming a seal between the upper surface of the mould and an electrical/communications cabinet.
5. A mould as claimed in any preceding claim, wherein the mould is formed and configured to incorporate integral structural reinforcement.
6. A mould as claimed in Claim 5, wherein the integral structural reinforcement is arranged vertically, in positions corresponding to the corners of the cabinet.
7. A mould as claimed in any preceding claim, further comprising a plurality of support means within the mould, arranged to support the cabinet in use.
8. A mould as claimed in Claim 7, wherein the support means comprise metal posts, arranged vertically within the mould.
9. A mould as claimed in Claim 8, wherein each post is attached to a base plate, each base plate being shaped and configured to locate in a correspondingly-shaped recess in the underside of the mould.
10. A mould as claimed in Claim 8 or Claim 9, wherein the upper end of each post is provided with fastening means for attaching the cabinet thereto in use.
11. A mould as claimed in any preceding claim, wherein the walls of the mould are formed and configured to receive and provide support for one or more reinforcing members spanning the internal cavity.
12. A mould as claimed in Claim 11, further comprising one or more reinforcing members spanning the internal cavity.
13. A mould as claimed in Claim 12, wherein the reinforcing members comprise crenellated metal braces.
14. A mould as claimed in any preceding claim, further comprising a cap to close the said aperture.
15. A mould as claimed in any preceding claim, further comprising a channel recessed within one of the walls of the mould and arranged to link two conduits together.
16. A mould as claimed in any preceding claim, further comprising a plurality of pimples, protrusions or ribs on one or more ground-engaging outer surfaces of the mould.
17. A base for an electrical/communications cabinet, the base comprising a mould as claimed in any preceding claim.
18. A base as claimed in Claim 17, further comprising filler material within the internal cavity of the mould.
19. A base as claimed in Claim 18, wherein the filler material comprises concrete.
20. A base as claimed in Claim 18, wherein the filler material comprises sand, stone, earth, or another aggregate.
21. A base as claimed in Claim 18, wherein the filler material comprises spoil from the installation site.
22. A method of forming a base for an electrical/communications cabinet using a mould as claimed in any of Claims 1 to 16, the method comprising the steps of: positioning the mould in the installation site; passing one or more electrical or telecommunications cables, or one or more ducts for such cables, through the conduit(s); and filling the internal cavity of the mould with a filler material.
23. A method as claimed in Claim 22, wherein the filler material comprises concrete.
24. A method as claimed in Claim 22, wherein the filler material comprises sand, stone, earth, or another aggregate.
25. A method as claimed in Claim 22, wherein the filler material comprises spoil from the installation site.
26. A method as claimed in any of claims 22 to 25, further comprising inserting one or more reinforcing members through the mould before filling the internal cavity with the filler material.
27. A method as claimed in any of claims 22 to 26, further comprising passing one or more earth rods and/or earth cables through conduits in the mould.
28. A method as claimed in any of claims 22 to 27, further comprising fitting a cap to close the said aperture in the mould.
29. A method as claimed in any of claims 22 to 28, further comprising attaching an electrical/communications cabinet to the mould.
30. A method as claimed in Claim 29, further comprising applying means for forming a seal between the upper surface of the mould and the cabinet, prior to attaching the cabinet.
31. A method as claimed in any of claims 22 to 28, further comprising attaching a collar, upstand or raising-piece to the mould, and then attaching an electrical/communications cabinet to the collar, upstand or raising-piece.
32. A method as claimed in Claim 31, further comprising applying means for forming a seal between the mould and the collar/upstand/raising-piece, and/or between the collar/upstand/raising-piece and the cabinet.
33. A mould for forming a base for a ground-mounted article, wherein: the mould is formed from a plastics material and defines the shape of the base; the walls of the mould define an aperture for receiving a filler material, and an internal cavity for filling with the filler material; and the mould incorporates fastening means for attaching the article thereto in use.
34. A mould as claimed in Claim 33, further incorporating one or more conduits passing through the internal cavity, through which conduits cables or pipes may pass in use; or means for receiving and attaching one or more such conduits to one or more walls of the mould.
35. A base for a ground-mounted article, the base comprising a mould as claimed in Claim 33 or Claim 34.
36. A base as claimed in Claim 35, further comprising filler material within the internal cavity of the mould.
37. A base as claimed in Claim 36, wherein the filler material comprises concrete.
38. A base as claimed in Claim 36, wherein the filler material comprises sand, stone, earth, or another aggregate.
39. A base as claimed in Claim 36, wherein the filler material comprises spoil from the installation site.
40. A method of forming a base for a ground-mounted article using a mould as claimed in Claim 33 or Claim 34, the method comprising the steps of: positioning the mould in the installation site; filling the internal cavity of the mould with a filler material; and fastening the article to the mould.
41. A method as claimed in Claim 40, wherein the filler material comprises concrete.
42. A method as claimed in Claim 40, wherein the filler material comprises sand, stone, earth, or another aggregate.
43. A method as claimed in Claim 40, wherein the filler material comprises spoil from the installation site.
44. A mould substantially as herein described with reference to and as illustrated in any combination of the accompanying drawings.
45. A base for an electrical/communications cabinet or another ground-mounted article, the base comprising a mould substantially as herein described with reference to and as illustrated in any combination of the accompanying drawings.
46. A method of forming a base for an electrical/communications cabinet or another ground-mounted article substantially as herein described with reference to and as illustrated in any combination of the accompanying drawings.