NZ196092A - Hollow insulating block:end walls with removable upper and lower inserts - Google Patents

Description

% 196092 PHot«ty Dat«{s): ; &0. .........

• Ccmpfgt® Sgecificsticn 'Filed: *!?.'(•;,?! :ufcncat3ori. Date: jO B .JILL .19,84....

:.D. -Jjoetrnai Mo: .... •.

N.Z. , No g^PATEMr^g 23 JAN 1981 NEW ZEALAND Patents Act, 1953 COMPLETE SPECIFICATION "IMPROVEMENTS IN AND RELATING TO BUILDING FORMWORK." V3e, [ e' ICORTiOT PTY .—LTD., a Victorian company of—108 Qimen." Sfe-root;—Melbourne,—arra the Ofcafee ol Victoria, Auatralia. do hereby declare the invention, for -which We pray that a Patent may be granted to us , and the method by which it is to be performed, to be particularly described in and. by-the following statement:- 19609 THIS INVENTION relates to formwork elements for building purposes and in particular relates to interlocking formwork elements of hollow block configuration produced from a hard foam resin material, and adapted to be filled with 5 concrete to provide a rigid wall or the like having high insulating properties.

Elements of this general type are known for forming a hollow wall permanent, formwork adapted to be filled with concrete. With these known elements the transverse walls of 10 the blocks are of equal height to the side walls and cross binding of the filled concrete between adjacent blocks is not possible, resulting in a considerable weakening of the concrete wall. In addition the use of horizontal steel reinforcement is not possible and if the transverse members 15 are located inwardly of the ends of the blocks to allow for cross binding of the concrete, special elements are required to enable a corner connection to be made.

It is an object of the present invention to provide a formwork block of the above general type having end trans-20 verse walls allowing strong cross binding, of the concrete, and eliminating the requirement for special elements for the interlocking of corner connections, T-connections, wall connections and wall end closures.

It is also an object of the present invention to 25 provide transverse cross pieces between the end walls for strengthening purposes and to allow a block to be cut into shorter less cavity blocks.

I 96092 Another advantage of the present invention is that instead of having to use a number of different elements, one single element only is required for providing wall connections, T-connections, corner connections and wall end closures, and allowing the installation of vertical and horizontal steel reinforcement.

According to the present invention there is provided a formwork element of lightweight insulating material comprising a hollow block member having side walls and end walls with mating grooves and tongues along the upper and lower edges of the side walls for interlocking purposes, said end walls having upper and lower portions which comprise removable inserts which interact with a central wall portion and close off said end walls at corner, wall end and T-connections.

The inserts are preferably of tongue and groove form for interlocking purposes with mating tongues and grooves in said central portions.

According to a further form of the invention there is provided transverse cross pieces in the block between the end walls, said transverse cross pieces also having upper and lower central portions adapted to receive similar removable inserts.

The elements of the invention are preferably formed from a hard foamed resin material such as polystyrol or the like.

In order that the invention and its manner of performance may be more fully described, reference will now be made to the accompanying drawings, in which 1 96 0 9 2 : v.

FIGURE 1 is a perspective view of a form element of the invention, FIGURE 2 is a perspective view of an insert frorr. the upper part of an end wall, 5 FIGURE 3 is a perspective view of an insert for the lower part of an end wall, FIGURE 4 shows a corner connection in a formwork wall illustrating the use of the inserts, FIGURE 5 is a perspective view of a further embodi- ;; 10 ment of the invention, ■ FIGURE 6 is a plan view from above of the form element of FIGURE 5, FIGURE 7 is a sectional view along the line 7-7 of FIGURE 6 in the direction of the arrows, 15 FIGURE 8 is a sectional view along the line 8-8 of FIGURE 6 in the direction of the arrows, FIGURES 9 and 10 are perspective views of an upper insert for the element of FIGURE 6, ; ' FIGURES 11 and 12 are perspective views of a lower 20 insert for the element of FIGURE 6, FIGURE 13 illustrates a curved corner element for ^ use with the embodiment of FIGURE 6, ' FIGURES 14 and 15 are a plan view from above and an end view respectively of a lintel element 25 . for use with the embodiment of FIGURE 6, and FIGURES 16 and 17 are a plan view from above and an end view respectively of a ceiling edge element for use with the embodiment of ' FIGURE 6. 1960 9 2 Referring to the embodiment of FIGURES 1 to 4, the form element or block of FIGURE 1 comprises side walls 1 and 2, each provided at the top thereof with longitudinal ridge bearers 5 and 6, corresponding cross ridge bearers 18, 19, 20 and 21 matching longitudinal mortised key seats 7 and 8, and corresponding cross mortises 9, 10, 11, 12, 23/24, 25 and 26.

Side walls 1 and 2 are joined at their ends by connecting members 13 provided at their upper edge with an upstanding ridge member 14 forming a tongue and groove at said upper edge which corresponds with the tongue and groove 15, 17 of an insert which when inserted into the butt end of the block provides a continuous and interlocking corner and end connection 18, 19, 20 and 21 at the top.

The other insert is provided with a groove 22, which on insertion into the butt end of the form element, provides a continuous and interlocking corner and end connection 23, 24, 2 5 and 26 at the bottom.

The inner and outer surfaces of side walls 1 and 2 are provided with vertical grooves 27 which allow for accurate cutting of the block into quarter pieces.

Referring to the embodiment of Figures 5 to 12, the form element 101 illustrated is a multi-cavity element having side walls 102 and 103, end walls 104 and 105 and transverse walls 106 located between the end walls. End walls 104 and 105 have cut-out portions 107 and 108 and include insert members 109 and 110 removably located in said cut-out portions. Transverse walls 106 are thicker than end walls 104 and 105 and take the form of two end walls 1 9&®92 moulded back to back for reasons and for the purpose hereinafter described.

In order that elements 101 can be assembled in interlocking form, top and bottom, the side walls 102 and 5 10 3 are provided at their upper end with continuous longitudinal ridge 111 which mates with continuous longitudinal slot 112 on the underside of the walls and slots 113, 114 and 115 on the upper end mate with tongues 116, 117 and 118.

In order to locate and match the elements 101 in end to end relationship, end y/all 104 is provided with H*. vertical grooves 119 and vertical ribs 120 mating with corresponding grooves and ribs in wall 105. For end to side location of the elements, ribs 120 mate with grooves 15 121 in side walls 102 and 103.

The upper end wall insert 122 is provided with vertical slots 123 and transverse slot 124 mating with vertical ribs 125 and horizontal transverse rib 126 respectively in the end walls 104 and 105. • 20 The lower end wall insert 127 is provided with vertical slots 128 and transverse rib 129 mating with vertical ribs 130 and groove 131 respectively in the end walls 104 and 1.05.

Both inserts 122 and 127 are provided with ribs 25 and grooves to line up with the ribs 120 and grooves 119 on the end walls. Upper insert 122 is provided with a transverse rib 132 and longitudinal ribs 133 for interlocking with transverse grooves 134 and longitudinal grooves 135 in lower insert 12 7 when the elements are interlocked in top 1 960 9 2 and bottom fashion.

For cross or T-connections with one element above another, transverse grooves 136 extending across the bottom y edge of side walls are adapted to engage over ridges 111 and i rib 132 of insert 122. Slots 112 and grooves 135 are adapted to engage over projections 137 at the upper edge of side walls 102 and 103. \ As will be seen from FIGURES 5 and 8, the transverse walls 106 are provided, in duplicate, with similar ribs and 10 grooves as in the end walls for receiving the upper and lower inserts.

By providing the transverse walls 106 in the con- ; .figuration shown, if for example a three cavity element is required, the element can be cut or sawn through the middle 15 of a transverse wall and the half of the cut transverse wall left on the three cavity element constitutes an end wall similar to end walls 104 and 105. Similarly with the single cavity element left after cutting. Grooves 138 are provided in the side walls 102 and 103 as a guide for cutting the ; " 1 elements. Grooves 139 are also provided on the side walls ; ^ as a guide if the element is to be cut to provide an open ' ended half cavity at one end thereof.

In use,in the construction of a building, the elements rt of the invention are set out on a concrete slab foundation 25 preferably to 3 course height with all elements interlocking or abutting to delineate rooms, doors, windows, vents and the like. Concrete is then poured into the elements and allowed 196 0 92 to set and further elements are added and filled until total room height has been reached. It is preferable to insert i*: ■ ^ .... - vertical reinforcing rods into the concrete slab so as to extend through the cavities of the elements and horizontal reinforcing rods can be conveniently located in grooves 140 in the end and transverse walls and tied to the vertical reinforcing rods.

In order to allow for a good crossbinding of the concrete fill along the walls,the inserts 122 and 127 are 10 removed and this also allows use of extended lengths of horizontal reinforcement. The inserts 122 and 127 must be used at corners or wall ends or in some cases at butt ■joints, to provide a full wall surface and of course to prevent the concrete running out. Preferably a filling 15 rail should be located over the top of the elements on each side to prevent the concrete entering the grooves and slots on the top of the elements. This will make the placing of subsequent elements much easier.

Large diameter pipes for plumbing and carrying 20 electrical cables may be located in the elements before filling and being fully embedded in the concrete a soundproofing effect is obtained. Small diameter pipes can be set into the sides of the elements by cutting a groove therein such as by using a soldering gun hot wire bent to U-shape. 25 This is most advantageous with hot water pipes in view of the excellent insulation properties of the material of the elements. 1960 9 2 The outside surfaces of the walls formed can be faced with bricks, cement rendering or plaster reinforced with fibre glass. Bricks can be laid directly on to the elements as the non-capiliary and high insulation properties 5 of the elements obviates the requirement of a cavity between brick and wall. Brick ties can be pushed into the elements just after filling.

The inside surfaces may be faced with plaster board, tiles, timber panelling and the like. 10 By providing walls of the material of the elements> most effective insulation properties are obtained. Equally there is exceptional soundproofing. The preferred material,, . * - ' ■■=■:■ ■-polystyrol, is a non-combustable and self extinguishing material.

Referring to Figure 13 there is illustrated an element for use on curved corners or doorways of buildings. The element of this embodiment has similar constructional and interlocking features as the element of FIGURES 5 to 12. The curved outer surface of this element is provided with:a 20 number cutting guide grooves so that a curved part having less, than 90° can be obtained.

FIGURES 14 and 15 illustrate another embodiment of the invention wherein the element comprises a lintel member having the upper and side parts of the side members similar 25 in form to the element of FIGURES 5 to 12, but including a. closed bottom 141 and dovetail shaped ribs 142, to enhance locking of the concrete therein, and no transverse walls. 1 960 9 2 In use this lintel member is set across a door opening on top of existing wall elements and supported whilst being filled with concrete. The lintel element is dimensioned so that further courses of the basic formwork elements can be added thereto and interlocked by reason of the mating configuration of the upper edge of the lintel side member.

Figures 16 and 17 illustrate a ceiling edge element 143 which is used at room height level to support a concrete plate or plates forming a ceiling. The side wall 144 is of similar configuration to the element of FIGURES 5 to 12 as is the top edge of side wall 144, the lower part 145, and the bottom part 146 has grooves and ribs to allow interlocking with a basic element. The bottom part 146 has cavities 147 and 148 which are filled with concrete. In use this ceiling edge element is interlocked on the walls constituted by the basic elements of FIGURES 5 to 12 and after the concrete filling has set, the ceiling plate or plates is or are placed in position resting on the ledge afforded by element 143.

Support members are located throughout the area of the ceiling plates and a further concrete fill is made up to the top of side wall 144. Reinforcement members can be inserted' in the concrete fill.

After the concrete fill has set, further floors of the building can be developed in like manner to the first floor and the basic formwork elements can interlock and be built up from the side wall 144 of the ceiling edge member and the concrete fill therein.

As shown in FIGURE 16 grooves 149 are formed in the element as a guide to cutting, the diagonal grooves allowing for accurate cutting of mitred ends of the element. 186092

Claims (15)

WHAT WE CLAIM IS:

1. A formwork element of lightweight insulating material comprising a hollow block member having side walls and end walls with mating grooves and tongues along the upper and lower edges of the side walls and end walls for interlocking purposes, said end walls having upper and lower portions which comprise removable inserts which interact with a central wall portion and close off said end walls at corner, wall end and T-conhections.

2. A formwork element according to claim 1 wherein said inserts have grooves and tongues mating with grooves and tongues in said central portions for interlocking purposes.

3. A formwork element according to claim 1 or claim 2 wherein the lightweight insulating material is a hard foamed resin material.

4. A formwork element according to claim 3 wherein said resin material is polystyrol.

5. A formwork element according to any one of the preceding claims and including spaced-apart transverse wall members extending between the side walls and spaced from said end walls, said transverse wall members each having a central wall portion able to interact with similar removable inserts. 186002

6. A formwork element according to claim 5 wherein the transverse wall members constitute the thickness of two end walls moulded back to back so that when an element can be cut along at least one of said transverse wall members, the central portion of which can be closed off by said similar removable inserts so as to provide two or more closed end smaller elements.

7. A formwork element according to claim 6 wherein the side walls are provided with aligned vertical grooves to facilitate accurate cutting of the elements at the centre of the thickness of the transverse wall members and at locations intermediate said transverse wall members and intermediate said end walls and said transverse wall members.

8. A formwork element according to any one of claims 5 to 7, said central portion of the transverse wall members including grooves for locating horizontal reinforcing rods.

9. A wall comprising a plurality of courses of interlocked elements of the type defined in any one of claims 1 to 8, the at least one cavity in said elements being filled with concrete.

10. A wall according to claim 9, wherein vertical and horizontal reinforcing rods are embedded in the concrete fill.

11. A building incorporating walls as defined in claim 9 or claim 10. - 13 - I 96092

12. A building according to claim 11 and including lintel members substantially as hereinbefore described with reference to Figures 14 and 15 of the accompanying drawings.

13. A building according to claim 11 or claim 12 and including ceiling edge elements substantially as hereinbefore described with reference to Figures 16 and 17 of the accompanying drawings.

14. A wall according to claim 9 or claim 10 and including curved wall elements substantially as hereinbefore described with reference to Figure 13 of the accompanying drawings.

15. A formwork element substantially as hereinbefore described with reference to Figures 1, 2 and 3 or Figures 5, 6, 7, 8, 9, 10, 11 and 12, of the accompanying drawings. W- ICORAOT PTY. LTD. By Their Attorneys HENRY HUGHES LIMITED By: