IES20120419A2 - Permanent formwork system for reinforcing concrete structures - Google Patents

Permanent formwork system for reinforcing concrete structures

Info

Publication number
IES20120419A2
IES20120419A2 IES20120419A IES20120419A IES20120419A2 IE S20120419 A2 IES20120419 A2 IE S20120419A2 IE S20120419 A IES20120419 A IE S20120419A IE S20120419 A IES20120419 A IE S20120419A IE S20120419 A2 IES20120419 A2 IE S20120419A2
Authority
IE
Ireland
Prior art keywords
wall
connectors
sheets
connector
distance
Prior art date
Application number
IES20120419A
Inventor
Gerald Hurley
Francis Macdara Forde
Original Assignee
Gerald Hurley
Francis Macdara Forde
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Gerald Hurley, Francis Macdara Forde filed Critical Gerald Hurley
Priority to IES20120419A priority Critical patent/IES20120419A2/en
Publication of IES86124B2 publication Critical patent/IES86124B2/en
Publication of IES20120419A2 publication Critical patent/IES20120419A2/en
Priority to PCT/EP2013/069182 priority patent/WO2014044644A1/en

Links

Classifications

    • EFIXED CONSTRUCTIONS
    • E04BUILDING
    • E04BGENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
    • E04B2/00Walls, e.g. partitions, for buildings; Wall construction with regard to insulation; Connections specially adapted to walls
    • E04B2/84Walls made by casting, pouring, or tamping in situ
    • E04B2/86Walls made by casting, pouring, or tamping in situ made in permanent forms
    • E04B2/8635Walls made by casting, pouring, or tamping in situ made in permanent forms with ties attached to the inner faces of the forms
    • EFIXED CONSTRUCTIONS
    • E04BUILDING
    • E04BGENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
    • E04B2/00Walls, e.g. partitions, for buildings; Wall construction with regard to insulation; Connections specially adapted to walls
    • E04B2/84Walls made by casting, pouring, or tamping in situ
    • E04B2/86Walls made by casting, pouring, or tamping in situ made in permanent forms
    • E04B2002/8676Wall end details
    • EFIXED CONSTRUCTIONS
    • E04BUILDING
    • E04CSTRUCTURAL ELEMENTS; BUILDING MATERIALS
    • E04C2/00Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels
    • E04C2/30Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by the shape or structure
    • E04C2/34Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by the shape or structure composed of two or more spaced sheet-like parts
    • E04C2002/3477Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by the shape or structure composed of two or more spaced sheet-like parts spaced apart by tubular elements parallel to the sheets
    • EFIXED CONSTRUCTIONS
    • E04BUILDING
    • E04CSTRUCTURAL ELEMENTS; BUILDING MATERIALS
    • E04C5/00Reinforcing elements, e.g. for concrete; Auxiliary elements therefor
    • E04C5/16Auxiliary parts for reinforcements, e.g. connectors, spacers, stirrups
    • E04C5/20Auxiliary parts for reinforcements, e.g. connectors, spacers, stirrups of material other than metal or with only additional metal parts, e.g. concrete or plastics spacers with metal binding wires
    • E04C5/201Spacer blocks with embedded separate holding wire or clips

Landscapes

  • Engineering & Computer Science (AREA)
  • Architecture (AREA)
  • Physics & Mathematics (AREA)
  • Electromagnetism (AREA)
  • Civil Engineering (AREA)
  • Structural Engineering (AREA)
  • Forms Removed On Construction Sites Or Auxiliary Members Thereof (AREA)

Abstract

A wall connector (100) for locating between two parallel sheets of fibre cement formwork boards (100,102) maintains the sheets in a parallel arrangement with other like wall connectors. Each wall connector comprises an oblong shaped body having two pairs of mutually opposed side walls (104,106,108,110)and a pair of open ends. The first pair of mutually opposed side walls (104, 106) is spaced apart from one another by a first distance "Y" and the second pair of mutually opposed side walls (108,110) is spaced apart from one another by a second distance "Z" which is greater than or less than the first distance "Y" but not equal to the first distance. Each of the respective pairs of side walls is securable to the sheets so as to maintain the sheets apart by either the first or second distance "Y" or "Z". The ends of the obling body are substantially open to allow for the flow of concrete, cement or other setting material.

Description

PERMANENT FORMWORK SYSTEM FOR REINFORCING CONCRETE STRUCTURES The present invention relates to a permanent formwork system for reinforcing concrete structures and in particular to a system utilising lightweight hollow panels which are pre5 manufactured, erected on site and filled with concrete to form the structure. The lightweight hollow panels may also be insulated panels having a sheet of insulation on one or both faces.
The panels are generally formed from sheets of fibre cement board which themselves form the outer wall surfaces of the actual formwork structure. The sheets of fibre cement board are kept apart in a mutually parallel arrangement by a plurality of connectors which are evenly distributed in the space between the sheets to allow for an even distribution and flow of concrete. The connectors and any strengthening bars supported by the connectors are incorporated into the final structure.
Typical prior art connectors come in many forms and can be made from metal, timber or plastics material. AH have to be of identical size so that the boards are kept spaced apart in a mutually parallel arrangement.
The disadvantage associated with prior art connectors in particular is that different sized connectors are required for walls of different thickness and it is necessary to carry a large inventory of different sized connectors.
The object of the invention is to alleviate the above disadvantage.
The present invention provides a wall connector for locating between two parallel sheets of fibre cement formwork boards, for maintaining the sheets in a parallel arrangement with other like wall connectors, each wall connector comprising an oblong shaped body having two pairs of mutually opposed side walls and a pair of open ends, with the first pair of mutually opposed side walls being spaced apart from one another by a first distance and the second pair of mutually opposed side walls being spaced apart from one another by a second distance which is greater than or less than the first distance but not equal to the first distance, each of the respective pairs of side walls being securable to the sheets so as to maintain the sheets IE1204 19 S86124 apart by either the first or second distance, and the ends of the oblong body being substantially open to aliow for the flow of concrete, cement or other setting material.
Advantageously, the edges of each of the four side wails of the connectors are provided with at least one open ended opening for receiving at least one vertical reinforcing bar for a structure, with the openings in each wall connector being arranged in a staggered layout when secured to a sheet, so that the vertical reinforcing bar can extend through alternate openings in a column of wail connectors, and with an inner wail being provided within the body and one or more openings being provided in the inner wal! to accommodate at least one horizontal reinforcing bar, or alternatively the connectors are arranged in a non-staggered layout in which the horizontal reinforcing bar rests on the U channels in a row of wall connectors and the vertical reinforcing bar extends through the openings in the inner walis of the connectors.
The open ended openings may comprise U-shaped channels.
Conveniently, the wall connectors are manufactured from a material such as a high impact polystyrene (HIPS).
The present invention aiso provides a method of assembling a formwork structure from two parallel sheets of fibre cement formwork boards and a plurality of wal! connectors as herein defined comprising laying a first sheet on an assembly jig, marking the location of the connectors on the first sheet using a marking template to provide a staggered arrangement for the connectors; applying a deposit of bonding agent or glue to each location; placing a side wall of a connector on each deposit of bonding agent or glue; applying a further deposit of bonding agent or glue to the opposite side wal! of each connector; and then laying a second sheet on the connectors so that the second sheet is bonded to the connectors to complete an assembled formwork panel.
The invention will hereinafter be described with reference to the accompanying drawings which show, by way of example only, two embodiments of a wall connector used in a formwork system according to the invention and also three jigs for use in assembling the formwork system. In the drawings: IE 1 2 ο 4 19 Figure 1 is a perspective view from one side and from above of a first embodiment of wail connector for use in assembling a wall connector according to the invention; Figure 2 is a perspective view from one end of the first embodiment of wall connector as shown in Figure 1; Figure 3 is an end view of the wall connector located between two sheets of material or boards, with the shorter sides of the connector being used to space apart the sheets or boards; Figure 4 is an end view of the wall connector similar to Figure 3 but with the longer sides being used to space apart the sheets or boards; Figure 5 is a perspective view of an assembled wall structure with the front wall removed and showing a plurality of wall connectors secured to the rear wall and retaining a series of horizontal and vertical reinforcing bars for the reinforcement of concrete which will be poured into the structure; Figure 6 is a plan view of the assembled formwork wall structure showing a number of wall connectors, a horizontal reinforcing bar and two vertical reinforcing bars; Figure 7 is an end elevation showing end views of two wali connectors, a vertical reinforcing bar and two horizontal reinforcing bars; Figure 8 is a perspective view from one side end from above of a second embodiment of wall connector for use in assembling a wall connector according to the invention; Figure 9 is a perspective view from one end of the second embodiment of wall connector as shown in Figure 8; IE 1 2 Ο 4 19 Figure 10 is an end view of the wali connector iocated between the two sheets of material or boards, with the shorter sides of the connector being used to space apart the sheets or boards; Figure 11 is an end view of the wall connector similar to Figure 10 but with the longer sides being used to space apart the sheets or boards; Figures 12 to 15 are a series of four perspective views of a panel assembly jig for assembling and stacking assembled formwork wall panels in accordance with the invention, illustrating the sequential assembling and stacking of wall panels as shown in Figure 15; Figures 16 and 17 are perspective views of the panel assembly jig rearranged for the assembly and stacking of different shaped and different sized wail panels respectively; Figure 18 is a perspective view of a corner assembly jig used to form corner connections for fixing to two wall panels which end at a corner; Figure 19 is an exploded perspective view of the key elements of the corner assembly jig; Figure 20 is a further exploded perspective view of a corner connection and its components being assembled on the corner assembly jig; Figure 21 is an end view of the corner assembly jig showing an alternative setting for a different sized corner connection; Figure 22 is a perspective view of the end-trim jig used to form end-trim panels to close off the end section of an exposed wall panel; Figure 23 is an exploded perspective view of an end-trim panel and its components being 30 assembled on the end-trim jig; Figure 24 is a perspective end view of the upper components of the end-trim jig; and ΙΕί 2 Ο 4 19 Figure 25 is an exploded perspective view of the end-trim jig as shown in Figure 24.
Referring to the drawings and initially to Figures 1 to 7, the first embodiment of a wall connector 100 according to the invention is used for spacing apart, with a plurality of other similar waif connectors, two sheets of fibre cement boards 101 and 102 (see Figures 3 and 4) to maintain both sheets apart an equal and uniform distance prior to the pouring of a wet concrete materia! between the sheets 101, 102 which act as a permanent formwork for the wafi structure.
The wall connector 100 is a three dimensional oblong construction having a length X, a width Ύ and a height Z. It has two side walls 104, 106 each of which is securable to the formwork sheets 101, 102 separated by an upper wall 108, and a lower wall 110 as shown in Figure 3 so that the sheets are maintained apart by the distance Ύ. However, as shown in Figure 4, the wait connector may be orientated through 90’, so that the upper walls 108 and 110 are securable to the formwork sheets 101, 102 with the distance Z of the side walls 104, 106 being the spaced apart distance between the sheets 101, 102. In a non-limiting example, the distance Y is 75mm and the distance Z is 100mm. This distance determines the reinforced concrete wall thickness.
Located in the central region of the wall connector 100 as shown in Figure 3, is an inner wall 115 which gives structural rigidity to the wall connector 100 which is further strengthened by eight ribs 117 extending from both sides of the inner wall 115 in between a series of air hoies 116. At the centre of the inner wall 115 is a central orifice 118 having four rounded corners 120. Formed at each end ofthe wall connector 100 in the side wails 104, 106, the top wall 108 and the bottom wall 110 are four U-shaped channels or receivers 124.
With reference to Figure 2, located in the side walls 104, 106, upper and lower walls 108, 110 are a series of triangular shaped air holes 126 which facilitate the flow of concrete when poured into the formwork. These holes 126 also can assist in the adhesion of the walls 104, 106 or 108 to 110 to the sheets 101, 102 of fibre cement board.
The use of the connectors 100 will now be explained in relation to Figures 5 to 7. The connectors 100 are mounted in regular and alternately staggered rows 130 and 131. In IE 1 2 Ο 4 19 practice a first sheet of fibre cement board is laid out flat on a working surface of jig 300 and the connectors 100 are bonded to the sheet by a strong bonding agent or giue following a template marked up on the first sheet. Each side wail 106 of the connectors is pressed firmly against the deposit of glue at each particular location according to the staggered layout.
After alt the connectors 100 are located in situ, a deposit of the bonding agent or giue is provided on the side wall 104 of each connector 100.
The second sheet of fibre cement board is then laid down on the plurality of connectors 100 and firmly sandwiched together to form a completed wall panel on the jig 300. The next panel is then assembled on the jig 300 by laying another first sheet on the assembled panel, applying the giue according to the template, laying down the connectors, applying glue to the connectors and laying a second sheet on top of the connectors.
When the panels are erected on site to be used as structural formwork, reinforcing bars are inserted into the waif panels as shown in Figures 5 to 7 according to an engineer's specification for the particular structure. Horizontaf reinforcing bars 140 are threaded through the central orifice 118 of each connector 100, so that the reinforcing bars 140 rest on the lowermost corners 120. Vertical reinforcing bars 150 are then threaded through each alternate forward and rearward facing U-shaped channels 124 on each of the staggered rows 130and131.
The amount of stagger between the rows 130 and 131 of the connectors 100 can be varied so as to vary the size of the included hole formed by the offset U-shaped channels 124 on each alternate row. This can make it easier to thread a reinforcing bar through the U-shaped channels 124. A tighter included hole may be more useful on a short panel so that the reinforcing bar is not located at an angle.
In an alternative arrangement not shown in the drawings, the connectors 100 are turned through 90° and are aligned without any stagger, thereby providing a large vertica! channel between the connectors allowing for the insertion of additional elements such as multipie conduits for services. In this way the horizontal reinforcing bars are seated in the U-shaped channels 124 and the vertical reinforcing bars extend through the central orifices 118.
IE 1 2 Ο 4 1 9 Referring now to Figures 8 to 11, the second embodiment of a wall connector 200 according to the invention is used for spacing apart, with a plurality of other similar wall connectors, two sheets of fibre cement boards 201 and 202 (see Figures 10 and 11) to maintain both sheets apart an equal and uniform distance prior to the pouring of a wet concrete material between the sheets 201, 202 which act as a permanent formwork for the wall structure.
The wall connector 200 is a three dimensional oblong construction having a length X-X, a width Y-Y and a height Z-Z. It has two side walls 204, 206 each of which is securable to the formwork sheets 201, 202 separated by an upper wall 208, and a lower wall 210 as 1D shown in Figure 10 so that the sheets are maintained apart by the distance Y-Y. However, as shown in Figure 11, the wall connector may be orientated through 90’, so that the upper walls 108 and 210 are securable to the formwork sheets 201, 202 with the distance Z-Z of the side walls 204, 206 being the spaced apart distance between the sheets 101, 102. In a non-limiting example, the distance Y-Y is 125mm and the distance Z-Z is 150mm. In a non-limiting example, if the sheets are 6mm thick, then the total thickness of the finished wall will be 137mm or 162mm. In a further non-limiting example, if the sheets are 9mm thick, the first wall thickness will be 143mm or 168mm.
Located in the central region of the wall connector 200 is an inner wall 215 which gives structural rigidity to the wall connector 200. Ribs (not shown) may also be provided to give extra structural rigidity to the connector 200. At the centre of the inner wall 215 are two central orifices 218 having four rounded corners 220 as well as a number of air holes 216. Formed at each end of the wall connector 200 in the side walls 204, 206, the top wall 208 and the bottom wall 210 are eight U-shaped channels or receivers 224.
Located in the side walls 204, 206, upper and lower walls 208, 210 are a series of triangular shaped air holes 226 which facilitate the flow of concrete when poured into the formwork.
The connectors 200 are used in a similar fashion as the connectors 100 except that the horizontal reinforcing bars may be inserted through one or both of the central orifices 218 and the vertical reinforcing bars may be inserted through one or both ofthe central orifices.
IE 1 2 Ο 4 19 In an alternative embodiment, the connectors 200 are turned ninety degrees, the amount of stagger between the two rows of the connectors is reduced to zero, thereby providing a large vertical channel between the connectors allowing for the insertion of additional elements such as multiple conduits for services. In this way the horizontal reinforcing bars are seated in the U-shaped channels 224 and the vertical reinforcing bars extend through the central orifices 218.
Referring now to Figures 12 to 17, panel assembly jig 300 is utilised for assembling a stack of completed rectangular formwork panels 310, irregular shaped formwork panels 320 and small sized panels 330. panel assembly jig 300 comprises a box section frame 340, which is open at one side 341, and includes an elongate side section 342 and two end sections 343 located about two adjustable platforms 345 between which is Socatable a pallet 346. Extending upright from the elongate side sections 342 are two locating upright arms 350 mounted on sleeves 351 having lateral side arms 352. Mounted on each lateral side are 352 is a movable and pivotable sleeve 354 from which extends an upright locating arm 360 which can be positioned as shown in Figure 12, 14 and 15 to keep the formwork panels in position and parallel to one another or as shown in Figure 13 moved away to allow access to a stack of assembled panels 310. The panels 310 may be assembled one on top of another until the uppermost panel 310 reaches the top of the locating arms 350 and 360. A weight may also be placed on top of the stack to assist in the gluing process.
In Figures 16 and 17 the arms 350 and 360 are adjusted to accommodate an angled wall panel 320 and a smaller wall panel 330. This enables the panel assembly jig 300 to be used to align and secure stacks of the angled wall panels 320 and the smaller wall panels 330.
The formation of corner units is achieved utilising the corner assembly jig 400 shown in Figures 18 to 21. When the two panels 310 meet at a right angle, it is necessary to close off the open corner with a corner unit 450 which is assembled on the corner assembly jig 400. The corner unit comprises a right angled strip of metal or any other suitable material 452 to which is attached two elongate sheets of fibre cement board 454 of the desired width which are screwed into position on the strip 452 along the corner support 420 of the jig. The cut outs 422 along the open of the support 420 allow clearance for the screws. The location of the cut outs 422 are also marked on the lower edge 424 of the support. The movable IE 1 2 04 19 supports 430 are adjustable to allow for the different widths of the sheets 454 even when two separate different widths are needed as shown in Figure 21.
End-trim jig 500 is shown in Figures 22 to 25 and is utilised in the formation of end-trim panel to close off each section of an exposed wall panel. When it is desired to close off the end of a wal! panel, use is made of an end-trim panel 550 which comprises two right angle members 552 to which is attached an elongate sheet of fibre cement board 554. The right angle members 552 are located in position on the end support 520 which has an end stop 522 which is adjustable in the different dimensional slots 525. It is also possible to locate the end stop 552 in one of the slots 525 so that the elongate sheet of fibre cement board 554 overhangs the right angle members 552 by an amount equal to the thickness of the board 554 so as to close off the edges of the completed wall panel exactly.
It is to be understood that the invention is not limited to the specific details described herein which are given by way of exampie only and that various modifications and alterations are possible without departing from the scope of the invention as defined in the appended claims.

Claims (5)

CLAIMS:
1. A wall connector for locating between two parallel sheets of fibre cement formwork boards, for maintaining the sheets in a parallel arrangement with other like wall connectors, 5 each wall connector comprising an oblong shaped body having two pairs of mutually opposed side wails and a pair of open ends, with the first pair of mutually opposed side walls being spaced apart from one another by a first distance and the second pair of mutually opposed side walls being spaced apart from one another by a second distance which is greater than or less than the first distance but not equal to the first distance, each of the respective pairs of 10 side walls being securable to the sheets so as to maintain the sheets apart by either the first or second distance, and the ends of the oblong body being substantially open to allow for the flow of concrete, cement or other setting material.
2. A waif connector as claimed in Claim 1, in which the edges of each of the four side 15 walls are provided with at least one open ended opening for receiving at least one vertical reinforcing bar for a structure, with the openings in each wall connector being arranged in a staggered layout when secured to a sheet, so that the vertical reinforcing bar can extend through alternate openings in a column of wall connectors, with an inner wail being provided within the body and one or more openings being provided in the inner wall to accommodate 20 at least one horizontal reinforcing bar or alternatively the connectors are arranged in a nonstaggered layout in which the horizontal reinforcing bar rests on U-shaped channels in a row of wall connectors and the vertical reinforcing bar extends through the openings in the inner wall of the connectors. 25
3. A wall connector as claimed in Claim 2, in which the open ended openings comprise U-shaped channels.
4. A method of assembling a formwork structure from two parallel sheets of fibre cement formwork boards and a plurality of wall connectors as claimed in any one of Claims 1 to 3 30 comprising laying a first sheet on a panel assembly jig, marking the location of the connectors on the first sheet using a marking template to provide a staggered arrangement for the connectors; applying a deposit of bonding agent or glue to each location; placing a side wall of a connector on each deposit of bonding agent or glue; applying a further deposit of IE 1 2 Ο 4 19 bonding agent or glue to the opposite side wall of each connector; and then laying a second sheet on the connectors so that the second sheet is bonded to the connectors to complete an assembled formwork panel.
5. 5. A wail connector, a method of assembling a formwork structure and/or and an apparatus for assembling a formwork structure, substantially in accordance with any of the embodiments, as herein described with reference to and as shown in the accompanying drawings.
IES20120419A 2012-09-21 2012-09-21 Permanent formwork system for reinforcing concrete structures IES20120419A2 (en)

Priority Applications (2)

Application Number Priority Date Filing Date Title
IES20120419A IES20120419A2 (en) 2012-09-21 2012-09-21 Permanent formwork system for reinforcing concrete structures
PCT/EP2013/069182 WO2014044644A1 (en) 2012-09-21 2013-09-16 Permanent formwork system for reinforcing concrete structures

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
IES20120419A IES20120419A2 (en) 2012-09-21 2012-09-21 Permanent formwork system for reinforcing concrete structures

Publications (2)

Publication Number Publication Date
IES86124B2 IES86124B2 (en) 2013-01-16
IES20120419A2 true IES20120419A2 (en) 2013-01-16

Family

ID=47595226

Family Applications (1)

Application Number Title Priority Date Filing Date
IES20120419A IES20120419A2 (en) 2012-09-21 2012-09-21 Permanent formwork system for reinforcing concrete structures

Country Status (2)

Country Link
IE (1) IES20120419A2 (en)
WO (1) WO2014044644A1 (en)

Families Citing this family (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN113107112A (en) * 2015-04-29 2021-07-13 B·丁塞尔 Building element

Family Cites Families (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
AU656846B2 (en) * 1992-10-01 1995-02-16 Fiberslab Pty Limited Improvements in foundation construction
AU2009101212B4 (en) * 2009-05-05 2010-02-04 Safari Heights Pty Ltd Wall spacer and method of installation
US20120011799A1 (en) * 2009-10-28 2012-01-19 Ian Reginald Beaumont Support element for a reinforcing rod

Also Published As

Publication number Publication date
IES86124B2 (en) 2013-01-16
WO2014044644A1 (en) 2014-03-27

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