GB2524472A

GB2524472A - Climbing formwork system

Info

Publication number: GB2524472A
Application number: GB1403304.7A
Authority: GB
Inventors: Stuart Bamford; Mark Taylor; Paul Leach
Original assignee: Ischebeck Titan Ltd
Current assignee: Ischebeck Titan Ltd
Priority date: 2014-02-25
Filing date: 2014-02-25
Publication date: 2015-09-30
Anticipated expiration: 2034-02-25
Also published as: GB2524472B; GB201403304D0

Abstract

A climbing formwork system (1, fig 1) comprising a support shoe or bracket 3 fastened into the wall (100, fig 1), a platform support 11 attachable to the bracket, and a guide rail (4, fig 8) that may be attached to either the platform support or the bracket to allow the formwork to climb in either a loose track (fig 1) or fixed track (fig 2) configurations. The platform support may have wheels 14 and hooks (17, fig 4) that extend either side of the guide rail to contact the wall and bracket hook engaging portions 18 respectively, and may also have guiding channels (15, fig 4) & (16, fig 5) to engage part of the guide rail that may I-shaped. The support bracket may have a guiding channel 26 to engage the other side of the guide rail.

Description

Climbing Formwork System The present disclosure relates to a climbing formwork system. More particularly to a climbing formwork system which may have multiple configurations and which may be changed between those configurations when mounted on a construction. It further relates to a method of using the climbing formwork system.

In modern construction, particularly in the construction of high rise buildings it is common to have a central core, which houses lift shafts and stair wells and which provides support to the floors of the construction, wherein the central core and floors are formed by poured concrete. Generally the central core is built up in a number of steps, with each step corresponding to one or more storeys of the building and comprising a separate pour of concrete. All of the concrete pours need to be contained, in order to hold the concrete in place until it hardens sufficiently to hold its own shape. Such containment is generally effected by use of temporary shuttering, most commonly referred to as formwork.

As the height of the building core increases, the height at which the formwork needs to be provided above ground level increases, wherein each successive pour can only take place after the preceding pour has properly set. For this purpose there exist climbing formwork systems. Climbing formwork systems generally comprise a formwork support assembly, which consists of a platform adapted to extend substantially horizontally and on which is slidably mounted, for horizontal movement, a framework which supports a vertically extending formwork panel. The platform may be located in an initial position and the formwork may be advanced horizontally to a suitable position for the pouring of concrete. After the concrete has been poured and at least partially cured the supporting framework may be moved horizontally to withdraw the formwork from the concrete. The platform, still supporting the framework and the formwork panel may then be translated vertically using a crane or hydraulic assembly to a higher position and clamped to the structure that has just been built. The formwork may then be advanced horizontally to the position to a suitable position for a subsequent pouring step.

There are three common prior art arrangements of climbing formwork system that use a crane for the vertical translation of a formwork assembly up a building: firstly, there are unguided climbing formwork systems in which a formwork support assembly is lifted by a crane (without using any guidance element) and is mounted to a bracket that is fixed to the structure that has just been built so as to clamp the formwork in place for each pour; secondly, there are guided formwork systems in which lengths of track/guide rails are secured to the structure in a vertical orientation as it is built, wherein the tracks/guide rails are arranged to guide the formwork support assembly as it is lifted by a crane and further to support the weight of the formwork support assembly when it is in position for each pour; thirdly, there are guided formwork systems in which one or more tracks/guide rails are secured to the formwork support assembly in a vertical orientation, which tracks/guide rails are arranged to engage brackets that are fixed to the structure, wherein the engagement of the tracks/guide rails by the brackets provides guidance as the formwork support assembly is lifted by a crane and supports the weight of the formwork support assembly when it is in position for each pour.

Each of these prior art arrangements has advantages and disadvantages over the other arrangements: The first arrangement, whilst providing a simple and low cost design, which may be used from ground level, is not suitable for use in the construction of high floors of a building, since wind will be liable to blow around the support platform during translation.

The second arrangement, whilst suitable for use from ground level, requires two crane operations each time the formwork support assembly is to be raised to a higher level.

A first crane operation to lift the guide rails/supports and a second crane operation to lift the formwork support assembly. A significant cause of delays in the construction of high rise buildings is down to delays due to cranes being unavailable due to high winds.

The third arrangement, whilst only requiring a single crane operation, cannot be used from ground level, since the tracks/guide rails are permanently attached to the climbing bracket and extend to a level significantly below the level of the platform.

The present invention arose in a bid to provide an improved climbing formwork system.

According to the present invention in a first aspect, there is provided a climbing formwork system, comprising: a formwork support assembly, which is adapted to be mountable on and translatable along a construction; a support bracket that is arranged to be fixed to the construction; and a guide rail; wherein formwork support assembly attachment means are provided for removably attaching the formwork support assembly to the support bracket, and guide rail attachment means are provided for removably attaching the guide rail to the formwork support assembly or the support bracket.

Preferably, the support bracket is arranged to support the weight of the formwork support assembly, and the guide rail attachment means are arranged such that the guide rail may be attached to and/or detached from the formwork support assembly or the support bracket whilst the formwork support assembly is attached to the support bracket.

By virtue of the present invention, as defined above, there is provided a climbing formwork system that uniquely offers the advantages of all of the first, second and third prior art arrangements described above and which may be converted between three modes of operation at any stage during construction, 1) by detachment of the guide rail from both the formwork support assembly and the support bracket, 2) by attachment of the guide rail to the support bracket only or 3) by attachment of the guide rail to the formwork support assembly only, allowing a single climbing formwork system to be used throughout a build and in a manner to suit the conditions encountered on the build at any point in time.

By attachment of the guide rail to the formwork support assembly the guide rail is fixed to the formwork support assembly such that it is translated up the construction with the formwork support assembly. By attachment of the guide rail to the support bracket, the guide rail is fixed to the construction and remains stationary as the formwork support assembly is translated up the construction. In both arrangements the guide rail extends vertically.

The guide rail, uniquely, does not bear the weight of the formwork support assembly. No vertical load is transmitted through the guide rail. The guide rail provides guidance only, during translation of the formwork support assembly along the construction.

The only load transmitted through the guide rail is horizontal loading as a result of wind forces or otherwise. A lightweight guide rail may be utilized. The guide rails may be lifted using a hand winch or otherwise. No crane is required.

According to the present invention in a further aspect, there is provided a climbing formwork system, comprising: a formwork support assembly, which is adapted to be mountable on and translatable along a construction; and a guide rail; wherein formwork support assembly attachment means are provided for removably attaching the formwork support assembly to the construction, and guide rail attachment means are provided for removably attaching the guide rail to the formwork support assembly or the construction.

Preferably, the guide rail attachment means are arranged such that the guide rail may be attached to and/or detached from the formwork support assembly or the construction whilst the formwork support assembly is attached to the construction.

Further preferred features are presented in the dependent claims.

Non-limiting embodiments will now be described, by way of example only, with reference to the accompanying drawings, in which: Figures la to if show, in perspective view, an operation sequence of the climbing formwork system of the present invention in a loose track configuration and Figures ig to 11 show the same operation sequence in side view; Figures 2a to 2d show, in perspective view, an operation sequence of the climbing formwork system of the present invention in a fixed track configuration and Figures 2e to 2h show the same operation sequence in side view; Figure 3 shows a part of a platform support framework, which forms part of the formwork support assembly; Figure 4 shows a formwork support assembly attachment means; Figure 5 shows a wheeled support element; Figure 6 shows a support bracket; Figure 7 shows an intermediate guide bracket; Figure 8 shows a guide rail; Figure 9 shows a guide rail attachment element for use in attaching the guide rail to the support bracket; Figure 10 shows a guide rail attachment element for use in attaching the guide rail to the formwork support assembly; and Figure 11 shows an anti-uplift bracket.

With reference to Figures 1 and 2, a climbing formwork system 1 is shown which comprises a formwork support assembly 2, which is adapted to be mountable on and translatable along a construction, a support bracket 3 that is arranged to be fixed to the construction, and a guide rail 4. The formwork support assembly attachment means 5 is arranged so that the formwork support assembly may be removably attached to the support bracket. The support bracket is arranged to support the weight of the formwork support assembly. Guide rail attachment means 6, 7 are provided for removably attaching the guide rail to the formwork support assembly or the support bracket.

The formwork support assembly preferably comprises a platform 9 adapted to extend substantially horizontally, in use, and on which is mounted, for horizontal movement, a vertically extending formwork panel 10. The platform is supported by a platform support framework 11 (part of which is shown in Figure 3), which comprises the formwork support assembly attachment means 5 and a support element 12, which is spaced below the formwork support assembly attachment means and is arranged to contact the construction.

In the arrangement shown, the formwork support assembly attachment means 5 comprises a pair of hook assemblies 13. A hook assembly is shown most clearly in Figure 4.

The arrangement further comprises a pair of guide rails 4. A guide rail is shown most clearly in Figure 8. Each of the hook assemblies is associated with a corresponding one of the guide rails. At any time during use of the climbing formwork system, regardless of the operation mode, at least one support bracket 3 is in vertical alignment with each hook assembly, or substantially so. A pair of support elements 12 are provided. A support element is shown most clearly in Figure 5. Each support element is in vertical alignment with a corresponding one of the hook assemblies. The support elements in the present arrangement comprise S wheels 14 (see Figures 3 and 5), which are arranged to contact and roll along the construction during translation. The formwork support assembly is further provided with one or more guide members 15, 16 (see Figures 4 and 5), which are arranged to slidably engage the guide rails to limit or substantially prevent horizontal movement of the formwork support assembly relative to the guide rails. There is preferably a guide member 15 associated with each of the hook assemblies 13 and a guide member associated with each of the support elements 12. It should be noted that more or less hook assemblies/guide rails/support elements/guide members may be provided in dependence of the size/structure/configuration of the formwork support assembly. The invention is not to be limited to the exemplary arrangement shown.

With reference to Figures land 2, the operation of the climbing formwork system will now be described. Note that in Figures la to lf and 2a to 2d the formwork panel is omitted for clarity. The formwork panel is shown in Figures lg to 11 and 2c to 2h.

Figure 1 shows an operation sequence of the climbing formwork system in a loose track configuration. In the loose track configuration, the guide rail (track) is loose in the sense that it is not fixed to the formwork support assembly. The guide rail may be moved independently of the formwork support assembly.

Figures la and lg show the formwork support assembly mounted to a pair of support brackets 3, prior to a pouring step. The support brackets are fixed to the construction 100. They may be fixed by bolting or otherwise. The support brackets may be fixed to anchors that are cast into the construction. Each of the hook assemblies 13 engages a respective one of the support brackets 3. The support brackets support the weight of the formwork support assembly 2. The wheels 14 are in contact with the construction. The formwork panel is in a retracted position. The guide rails 4 are detached from both the support brackets 3 and the formwork support assembly 2.

Figures lb and ih illustrate a pouring step in which the formwork panel has been advanced horizontally (from the retracted position of Figures ia and ig) to a suitable position for the pouring of concrete. The concrete is poured with the formwork panel retained in place.

Figures lc to if and ii to 11 illustrate the vertical translation of the formwork support assembly up the building in the loose track configuration. In Figures lc and ii, the formwork panel is retracted following the sufficient setting of the concrete pour of Figures lb and lh and further support brackets are fixed to the freshly poured and set section of the construction. The further support brackets are each provided higher up the construction and in vertical alignment with a corresponding one of the support brackets to which the formwork support assembly is attached in Figures la to id and ig to ii. In Figures id and lj the guide rails are introduced, which will provide guidance to the formwork support assembly as it is translated vertically along the construction. The guide rails are lowered into position. They may be lowered using a hand winch or otherwise. Figures ie and 1k show the guide rails in position to guide the formwork support assembly during its vertical translation along the construction. The guide rails are each attached to a corresponding one of the further support brackets. The further support brackets support the weight of the guide rails. The guide rails each extend vertically (i.e. their longitudinal axes extend vertically) and in vertical alignment with a corresponding one of the hook assemblies. The guide members i5 associated with the hook assemblies i3 and the guide members 16 associated with the support members i2 are now in slidable engagement with the guide rails. As the formwork support assembly is lifted by crane or otherwise, the sliding engagement of the guide members 15, 16 with the guide rails substantially prevents horizontal movement of the formwork support assembly. Lifting of the formwork support assembly will continue until the hook assemblies 13 are brought into engagement with the further support elements 3 and are attached thereto, as shown in Figures if and 11. At this point the further support elements support the weight of the formwork support assembly and the formwork panel is thereby maintained at the correct vertical height for the next pour.

Figure 2 shows an operation sequence of the climbing formwork system in a fixed track configuration. In the fixed track configuration, the guide rail (track) is fixed in the sense that it is fixed to the formwork support assembly. The guide rail is moved with the formwork support assembly and thereby is moved relative to the fixed bracket.

Figures 2a and 2e show the formwork support assembly mounted to a pair of support brackets 3. The arrangement is the same as that shown in Figures la and ig with the exception that the guide rails are attached to the formwork support assembly.

Figures 2b and 2f illustrate a pouring step in which the formwork panel is advanced horizontally to a suitable position for the pouring of concrete and is retained in place.

Figures 2c to 2d and 2g to 2h illustrate the vertical translation of the formwork support assembly up the building in the fixed track configuration. In Figures 2c and 2g, the formwork panel is retracted following the sufficient setting of the concrete pour of Figures 2b and 2f and further support brackets 3 are fixed to the freshly poured and set section of the construction. The further support brackets are each provided higher up the construction and in vertical alignment with a corresponding one of the support brackets to which the formwork support assembly is attached in Figures 2a to 2c and 2e to 2g. In addition, intermediate guide brackets 19 (shown most clearly in Figure 7) are fixed to the freshly poured and set section of the construction. An intermediate guide bracket is provided between each pair of support brackets and in vertical alignment therewith. The intermediate guide brackets provide guidance to the guide rail as it moves between the support brackets with vertical translation of the formwork support assembly along the construction. It should be noted that the intermediate guide brackets could be omitted or there could be additional intermediate guide brackets provided between each vertically aligned pair of support brackets. Next, the formwork support assembly is lifted from the position shown in Figures 2c and 2g to the position shown in Figures 2d and 2h, again using a crane or similar. During lifting, the guide rails 4, which are attached to the formwork support assembly and are translated vertically with the formwork support assembly, are guided firstly by the support members and then the intermediate guide brackets. Lifting of the formwork support assembly will continue until the hook assemblies 13 are brought into engagement with the further support elements 3 and are attached thereto, as shown in Figures 2d and 2h. At this point the further support elements support the weight of the formwork support assembly and the formwork panel is thereby maintained at the correct vertical height for the next pour.

S

Since the weight of the formwork support assembly is supported by the support brackets when the formwork support assembly is positioned for each concrete pour, and no vertical load is transmitted through the guide rails, the guide rails may readily be detached from or attached to either of the formwork support assembly or the support brackets at any point during construction, allowing the climbing formwork system to be swapped between the loose track and fixed track configurations as desired during the construction.

The component parts of the climbing formwork system of Figures land 2 will now be detailed.

Figure 3 shows a frame 20 comprising part of the platform support framework 11, which forms part of the formwork support assembly 2. The platform support framework 11 of the arrangement of Figures land 2 comprises two frames, however, it should be appreciated that the formwork support assembly may comprise more than two frames or an alternative structure. The platform 9 is mounted to an upper surface 21 of the frame. The frame defines a vertically extending channel 22, which provides an opening through which the guide rail 4 or at least a portion thereof may pass vertically. The formwork support assembly attachment means 5, which as discussed comprises a hook assembly 13, is attached to an upper portion of the frame adjacent the platform. The wheeled support means 12, which is arranged to contact the construction is attached to a lower portion of the frame at the base of the formwork support assembly. The hook assembly 13 and the wheeled support means are in vertical alignment with one another. Whilst the support means is provided with wheels in the present arrangement, it should be appreciated that the support means may alternatively be provided with one or more rollers, slides, skis or low friction elements arranged to contact the construction.

The hook assembly 13 is shown in detail in Figure 4. The hook assembly comprises a hook element 17, which comprises a split hook. The split hook may be considered to provide an opening 23 through which the guide rail 4 or at least a portion thereof may vertically pass. The hook element is pivotally mounted and resiliently or gravity biased into the position shown in Figure 4.

The wheeled support means 12 is shown in detail in Figure 5. The projection of the wheels 14 from the support means may be considered to provide an opening 24 formed between the construction and the support means and through which the guide rail 4 may vertically pass, as seen in Figure 2.

Both the hook assembly 13 and the support means 12 are provided with guide means 15, 16, which are vertically aligned with one another and are arranged to slidably engage the guide rail 4 and to prevent relative movement between the guide rail and the formwork support assembly.

Figure 6 shows the support bracket 3, which is provided with holes 25 to allow it to be fixed to the construction 100. The support bracket comprises a pair of hook engaging elements 18 that are arranged to engage with the split hook of the hook assembly 13 and to thereby support the formwork support assembly. The support bracket is provided with a guide channel 26 of gradually reducing width from the bottom towards the top of the support bracket, which channel aids in guidance of the guide rail 4 when it is attached to the formwork support assembly during use of the climbing formwork system in the fixed track configuration. The support bracket may comprise one or more lugs 27, as shown, which may form part of the guide rail attachment means for attaching the guide rail to the support bracket. The support bracket 3 defines an opening 28 through which the guide rail 4 or at least a portion thereof may vertically pass.

By virtue of the arrangement of the support bracket 3 and the hook assembly 13, when the hook element 17 is brought into engagement with the support bracket during vertical translation of the formwork support assembly, the hook element is deflected downwardly by the hook engaging element 18 against the biasing force, so that the hook element may pass the support bracket and, once it is past the support bracket, the resilient biasing force may return the hook element 17 to its position shown in Figure 4 for engagement with the support bracket. The hook element 17 is arranged to hang on the hook engaging element 18.

Figure 7 shows the intermediate guide bracket 19, which is provided with holes 29 to allow it to be fixed to the construction. The intermediate guide bracket comprises a vertically extending through hole 30 that has a gradually decreasing open area from its bottom towards its top and a guide channel 31 of gradually reducing width from its bottom towards its top, these features together aid in guiding the guide rail 4 towards the support bracket above when it is attached to the formwork support assembly during use of the climbing formwork system in the fixed track configuration. Furthermore, the through hole defines an opening through which the guide rail 4 or at least a portion thereof may vertically pass.

Figure 8 shows an exemplary guide rail 4, which comprises an I-beam. The guide rail may comprise one or more lugs 32, as shown, which provides one means of attachment of the guide rail to the support bracket 3 or the formwork support assembly 2. When the lug is present it will face inwards, i.e. towards the construction, when the climbing formwork system is used in the fixed rail configuration, and will be attached to the lugs 27 of the support bracket. It will face outwards when the climbing formwork system is used in the loose rail configuration, and will be attached to suitable corresponding attachment means provided on the formwork support assembly. When the lug is not present alternative fixing means will be provided. In particular the guide rail may be provided with a number of holes 33, as shown, which may be attached to suitable brackets or fixing means provided on the support bracket 3 or the formwork support assembly 2, such as, but not limited to, the guide rail attachment means 6, 7 shown in Figures 9 and 10 and discussed below.

Figures 9 and 10 show further guide rail attachment means 6, 7. Attachment means 6 comprises a bracket for attachment to or adjacent to the support bracket 3, which is arranged to allow a guide rail without an attachment lug to be attached to the support bracket 3. The attachment means 6 may be considered to form part of the support bracket 3. The attachment means 6 is provided with threaded holes 35 for receiving bolts that pass through the holes 33 provided in the guide rail 4. Attachment means 6 may be attached to the construction 100, or to the construction 100 and the support bracket 3, using bolts.

Attachment means 7 comprises a bracket for attachment to the frame 20 to allow S attachment of the guide rail thereto by bolting or similar. Bolts 36 are provided in the arrangement shown for fixing the bracket to the frame 20 and bolts 37 are provided to be received by the holes 33 in the guide rail for attaching the guide rail to the bracket.

As will be readily appreciated by those skilled in the art, there will be numerous means possible for the attachment of the guide rail to the support bracket 3 or the formwork support assembly 2 and the present invention is not to be limited to the example guide rail attachment means discussed herein.

It should be noted that the term bracket support, as used throughout the specification and in the claims, is used to define any element or assembly that may be fixed to a construction and may have a formwork support assembly removably attached thereto.

It should further be noted that the term support bracket is intended to cover bracket assemblies formed from multiple parts that may be attached to and detached from one another, or which may not contact one another.

Figure 11 shows an anti-uplift bracket 34, which may be attached to the support bracket 3 once the hook element 17 has fully engaged the hook engaging element 18.

Claims

Claims 1. A climbing formwork system, comprising: a formwork support assembly, which is adapted to be mountable on and translatable along a construction; a support bracket that is arranged to be fixed to the construction; and a guide rail; wherein formwork support assembly attachment means are provided for removably attaching the formwork support assembly to the support bracket, and guide rail attachment means are provided for removably attaching the guide rail to the formwork support assembly or the support bracket.
2. A climbing formwork system as claimed in Claim 1, wherein the support bracket is arranged to support the weight of the formwork support assembly, and the guide rail attachment means are arranged such that the guide rail may be attached to and/or detached from the formwork support assembly or the support bracket whilst the formwork support assembly is attached to the support bracket.
3. A climbing formwork system as claimed in Claim 1 or 2, wherein the formwork support assembly and/or the formwork support assembly attachment means and the support bracket comprise openings, which, in use, are arranged to allow the vertical travel of the guide rail therethrough.
4. A climbing formwork system as claimed in Claim 3, wherein the openings in the formwork support assembly and/or the formwork support assembly attachment means and the support bracket are arranged such that they co-operate with one another when the formwork support assembly is attached to the support bracket, such that the guide rail may pass vertically through the formwork support assembly and/or the formwork support assembly attachment means and the support bracket.
5. A climbing formwork system as claimed in any preceding claim, wherein the formwork support assembly is provided with one or more guide members, which are arranged to slidably engage with the guide rails.
6. A climbing formwork system as claimed in Claim 5, wherein the one or more guide members are arranged to allow the vertical travel of the guide rail therethrough.
7. A climbing formwork system as claimed in Claim 5 or 6, wherein the one or more guide members are arranged to limit or substantially prevent horizontal movement of the formwork support assembly relative to the guide rails.
8. A climbing formwork system as claimed in any preceding claim, wherein the formwork support assembly attachment means comprise a hook element, which is arranged to engage a corresponding hook engagement element on the support bracket.
9. A climbing formwork system as claimed in Claim 8, wherein the hook element is pivotally mounted to the formwork support assembly.
10. A climbing formwork system as claimed in Claim 8 or 9, wherein the hook element is resiliently or gravity biased and is arranged such that when the hook element and the hook engaging element are brought into engagement with one another by translation of the formwork support assembly along the construction, the hook element is deflected by the hook engaging element against the biasing force.
11. A climbing formwork system as claimed in any of Claims 8 to 10, wherein the hook element comprises a split hook.
12. A climbing formwork system as claimed in any of Claims 8 to 11, wherein means are provided for limiting or preventing the upward movement of the formwork support assembly when the hook is engaged with the hook engagement element.
13. A climbing formwork system as claimed in any preceding claim, wherein two of the support brackets are provided, which are in vertical alignment with one another, and, between the two support brackets and in vertical alignment therewith, there is provided one or more intermediate guide brackets.
14. A climbing formwork system as claimed in Claim 13, wherein the one or more intermediate guide brackets are arranged to slidably engage with the guide rails.
15. A climbing formwork system as claimed in Claim 13 or 14, wherein the one or more intermediate guide brackets are arranged to allow the vertical travel of the guide rail therethrough.
16. A climbing formwork system as claimed in any of Claims 13 to 15, wherein the one or more intermediate guide brackets are arranged to limit or substantially prevent horizontal movement of the guide rails.
17. A climbing formwork system as claimed in any of Claims 13 to 16, wherein the one or more intermediate guide brackets comprises a vertically extending through hole that has a gradually decreasing open area from its bottom towards its top.
18. A climbing formwork system as claimed in any preceding claim, wherein the formwork support assembly further comprises a support element, which, in use, is spaced vertically below the formwork support assembly attachment means and is arranged to contact the construction.
19. A climbing formwork system as claimed in Claim 18, wherein the support means is provided with one or more wheels, rollers, slides, skis or low friction elements arranged to contact the construction.
20. A climbing formwork system as claimed in any preceding claim, wherein the formwork support assembly comprises a platform adapted to extend substantially horizontally, in use, and on which is mounted, for horizontal movement, a vertically extending formwork panel, and wherein the platform is supported by a platform support framework, which comprises the formwork support assembly attachment means.
21. A climbing formwork system substantially as hereinbefore described with reference S to, and as illustrated by, the accompanying drawings.