NZ743594A - Building Components - Google Patents

Abstract

modular element 10 for use in the creation of a formwork for making concrete ?oor or foundation slabs. The modular element 10 is a substantially stool-like hollow body 13 formed by an upper wall 15 which has a plurality of support legs 14 downwardly extending therefrom. The legs 14 de?ne a plurality of open spaces 16. The modular element 10 is characterized by a support 25 associated with the upper wall 15 whereby reinforcing can be supported by the support 25 so that the reinforcing is located away from the surface of the upper wall 15.

Description

NEW ZEALAND Patents Act 2013 COMPLETE SPECIFICATION BUILDING COMPONENTS We, POLYMER SYSTEMS INTERNATIONAL LIMITED a New Zealand company of 15 Thames Street, Pandora, Napier 4110, New Zealand 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: Title of the Invention Building Components Related Application This complete specification is after the provisional specification No. 733146 dated the 23rd day of June 2017.

Background of the Invention This invention relates to building components and more particularly modular elements used in building construction to create formwork for concrete floor construction.

In the building industry a commonly used building material is polystyrene. For example, slabs of polystyrene are used in concrete raft floor constructions. Typically, sections of polystyrene are laid out in a grid like array with spacers being employed to keep the sections in position so that reinforcing rods can be located between the polystyrene sections. Concrete is laid over the array of polystyrene sections and reinforcing to not only form the floor slab but also beams between the polystyrene sections.

This form of raft flooring has become popular in New Zealand as it meets earthquake design requirements. However, the use of polystyrene raises environmental concerns because, amongst other things, polystyrene is non-recyclable, is non-biodegradable, the chemicals used in its manufacture are toxic and styrene (the main component) is carcinogenic.

A construction system for floor structures has been developed in Europe and uses modular construction elements made from plastic material. The modular element is essentially a stool-like component about 600 x 600 in size. An array of these modular elements can be located together to create a formwork over which concrete can be poured to form a slab floor construction. The formwork creates a space between the ground and the concrete so that air can circulate within the space. It also reduces excavation normally needed on site.

The use of plastic modular elements has advantages over the use of polystyrene sections because the environmental issues referred to above are largely obviated.

Also the plastic modular construction elements have a big advantage over polystyrene as they are much easier to freight. For example, it takes a truck load of polystyrene for an average domestic floor slab whereas only a pallet load of plastic modular elements would be used for the same floor area. The plastic modular elements can be made from non-hazardous recycled plastic.

The European modular elements, however, suffer from a number of drawbacks. One main drawback is that they tend to crack when walked on by concrete layers. Being designed for European requirements they also do not fully comply with New Zealand building regulations.

Summary of the Invention An object of the invention is to provide a modular element which can be used to create formwork for concrete slab floors/foundations which provides support for reinforcing steel mesh so that the mesh is better located within the concrete or at least provides the public with a useful choice.

Another object of the invention is to provide a modular element which can be used in the creation of formwork for concrete slab floors/foundations, the building component being able to resist damage when walked on by concrete layers or at least provides the public with a useful choice.

The modular element described herein is essentially a stool-like component which has a plurality of support legs that, in use, stand on a substantially horizontal ground surface. Thus terms used herein such as upper, top, lower, bottom, side etc. are to be interpreted in relation to the modular element when in an in use position.

In the following description the modular element will, for convenience, be simply referred to as a "pod".

Broadly in one aspect of the invention there is provided a modular element for use in the creation of a formwork for making concrete floor or foundation slabs, the modular element being a substantially stool-like structure formed by an upper wall with a plurality of support legs downwardly extending from the upper wall and defining a plurality of open spaces, the modular element being characterised by support means associated with the upper wall whereby reinforcing can be supported so that it is located away from the surface of the upper wall.

In a preferred form of the invention a reinforcing or stiffening valley is formed in the support leg.

Preferably a part of the reinforcing or stiffening valley extends into the upper wall.

In a preferred form of the invention the upper wall includes a plurality of upwardly raised areas configured to provide strengthening/stiffening of the upper wall.

In a preferred form of the invention the upper wall includes an upwardly raised area, configured to provide strengthening/stiffening of the upper wall, located between each of the adjacent parts of the reinforcing/stiffening valleys extending into the upper wall.

In a preferred form of the invention there is also provided a modular element in combination with at least one cover element coupled to the modular element to close off a said open space.

In a preferred form of the invention there is also provided a modular element in combination with at least one connector element coupled to the modular element to extend an open space beyond the periphery of the modular element.

In a preferred form of the invention there is also provided a modular element in combination with a cover element coupled to the connector element to close off the extended open space.

In a preferred form of the invention there is also provided a modular element in combination with a plurality of connector elements coupled together to form an elongate connector.

In a preferred form of the invention the elongate connector is coupled at one end to the modular element and coupled at an opposite end to a cover element.

In a preferred form of the invention the modular element is coupled to another modular element by a connector element or an elongate connector whereby open spaces of the modular elements are coupled together.

In a preferred form of the invention the modular element is moulded from a plastics material.

In a preferred form of the invention the support means is a circular wall extending upwardly from an outer surface of the upper wall.

Preferably the circular wall is located substantially centrally in the upper wall.

In a preferred form of the invention a laterally extending land or flange is provided at the lowermost extremity of each leg.

In a preferred form of the invention the connector element is a substantially arch- shaped body.

In a preferred form the modular element is of a hollow form whereby a plurality of modular elements can be stacked together.

In a preferred form the modular element further includes connection means whereby modular elements located adjacent one another can be connected together.

Preferably the connection means are located at or adjacent a foot end of the support legs.

In a preferred form of the invention the connection means are located with an outwardly facing rim associated with each pair of adjacent support legs and a part of the upper wall located between each pair of adjacent support legs. preferably the cover element(s) and the connector element(s) as mentioned above also include connection means adapted to interconnect with the connection means of the modular element.

In a preferred form of the invention a plurality of modular elements are connected together by the connection means to form a block of modular units.

According to a second broad aspect of the invention there is provided a plurality of modular elements, cover elements and connector elements coupled together to form a formwork for creating a concrete floor or foundation slab.

Brief Description of the Drawings In the following more detailed description of the present invention there will be described building construction components including a pod and reference will be made to the accompanying drawings in which:- Figure 1 is an isometric view from above of a pod according to one form of the invention, Figure 2 is an underside isometric view of the pod shown in Figure 1, Figure 3 is a top plan view of the pod shown in Figures 1 and 2, Figure 4 is an isometric view of a cover element that can be connected to a pod to cover an aperture in the pod as is, for example, illustrated in Figures 1 and 3, Figure 5 is a further isometric view of the cover element shown in Figure 4 but as viewed from the reverse side thereof, Figure 6 is an isometric view of the pod with the cover element coupled thereto, Figure 7 is an isometric view of a connector element that can be clipped to a pod, Figure 8 is a further isometric view of the connector element shown in Figure 7 but as viewed from the reverse side thereof, Figure 9 is an isometric view of a pod, a plurality of connector elements and a cover element connected to the pod, Figure 10 is a view similar to Figure 9 but showing a reinforcing support coupled to the cover element, Figure 11 is an isometric view of a plurality of pods (as shown in Figure 1, 2 and 3) when combined together in a stack of pods, Figure 12 is an isometric view of how preassembled blocks of four pods can be nestled together for storage, transportation and on site handling purposes, Figure 13 is an isometric view of a modified form of the pod, Figure 14 is an isometric view of a pipe protrusion flange component for use with the embodiment of the pod shown in Figure 13, and Figure 15 is a view similar to Figure 14 but showing a different form of the flange component.

Description of Preferred Embodiments of the Invention In the drawings there is shown one embodiment of a pod 10 together with cover and connector elements 11 and 12 respectively. A plurality of pods 10 together with cover elements 11 and connector elements 12 can be selectively combined to create a formwork for a reinforced concrete floor slab or foundation slab. It will be appreciated by the skilled addressee that these building components (i.e. pod, cover and connector elements) according to the invention and the use thereof can be achieved by way of embodiments which differ from those described and illustrated in the present specification.

In the drawings a pod 10 is shown by way of example in order to describe the construction and use of a pod according to the present invention.

The pod 10 is, in its preferred form, moulded from a plastics material. The pod is of the type that would typically be used in the construction of rib raft type flooring.

Typically the pods 10 will be located on a membrane (not shown) which has been laid on the surface of the ground on which the slab floor/foundation is to be built.

The formwork will be located within the confines of a peripheral formwork or boxing (not shown but hereinafter referred to as "boxing" for convenience) which confines the concrete when poured over the formwork and will thereby define the peripheral edge of the floor/foundation slab.

Over the top of the formwork is laid reinforcing mesh (not shown). Reinforcing rods are typically also located between the peripheral extent of the formwork and the boxing. Reinforcing rods can also be located as may be necessary between pods in the formwork especially if pods are spaced from one another by one of more connector elements as hereinafter described. Following this concrete is laid over the formwork, reinforcing mesh and reinforcing rods to create a floor/foundation slab.

The pod 10 according to a preferred embodiment will dimensionally be about 600mm x 600mm and of a height of about 220mm. As shown in Figures 1, 2, 3 and 6 the pod 10 can be described a stool-like being essentially a hollow body 13 which has a plurality of legs 14 (preferably four in number) downwardly extending from an upper wall 15. As shown the upper wall 15 is overall of slightly convex shape.

Between adjacent legs 14 there is an arch-shaped open space 16 which is defined by the pair of adjacent legs 14 and that part of the upper wall 15 that extends between the legs 14.

An outwardly projecting shaped rim 17 extends up each leg 14 of the pair of legs and across the part of the upper wall 15 between the legs 14. The rim is thus also substantially arch-shaped and has an outwardly facing surface. The upper part 18 of the rim 17 has attachment means (described below) whereby the rim 17 of one pod can be coupled face to face with the rim 17 of another pod so as to couple the pods together e.g. see Figure 11.

Preferably the rim attachment means is formed by a pair of attachment points 19 and 20. The attachment point 19 is essentially a male part formed by a projection 19a which is substantially "T" shaped in cross section. The other attachment point 20 is essentially a female part formed by a groove 20a of a "T" shaped cross section which is complimentary to the cross section of the T shaped male part 19a. In the preferred form the female groove 20a has a pin 22 which slides into a slot 21 formed in the male part 19a when the male 19a and female 20a parts are coupled together.

It will be seen from Figure 11, for example, that pods 10 can be joined together by relative movement between the pods 10 causing the rim 17 of one pod 10 to slide face to face over the rim 17 of the other pod 10 so that the male parts 19a of the respective rims 17 slide into the female groove parts 20a. In the preferred form of the invention the slot 21 has an enlarged part 24 about mid way along the length of the slot 21. The pin 22 of the female groove 20a is of a cross sectional dimension which is slightly greater than width of the slot 21 whereby the pin 22 needs to be forced along the slot 21 so that it becomes captured in the enlarged part 24 in a snap lock type coupling.

Consequently the coupling of two pods 10 is a positive coupling such that once coupled together the two pods will generally not separate. Figure 11 provides an illustration of how four pods 10 can be coupled together by the interlocking of the attachment points 19 and 20. It should be noted that this coupling can be achieved where clips are provided, on any side, in any direction.

The pod 10 according to the present invention has a means of supporting reinforcing mesh away from the upper wall 15. In the preferred form of the invention the support means 25 is integrally moulded as part of the pod 10 though in a less preferred form of the invention the support means could include a separate element that can be combined with the pod 10 in say a snap lock fitting. In such an arrangement the snap locked element could be configured to retain the mesh in contact with the pod 10 rather than simply have the mesh rest on the support means In the preferred form the support 25 is a circular wall 26 of a height sufficient to locate the mesh at a desired distance above the upper wall 15. In the preferred form bracing members 27 integrally moulded in the pod and wall 26 extend somewhat diametrically within the confines of the wall 26.

Radiating out from the circular wall 26 are strengthening valleys 28. Each valley extends across the upper wall 15 and down a leg 14. These valleys 28 provide strengthening/stiffening to both the upper wall 15 and the legs 14. As can be seen in the drawings the valleys 28 can also have a plurality of lateral bracing walls 30 though generally these will be in that part of the valley which is in the upper wall 15.

The upper wall 15 also has upwardly raised sections 31 which extend between the valleys 28 adjacent the support 25 and extend down the legs 14. There is thus a raised section 31 between each pair of valleys 28 and associated legs 14.

The valleys 28 and raised sections 31 combined provide substantial strengthening/stiffening to the overall structure of the pod 10 and this results in a robust pod which is able to withstand forces applied thereto when walked on during a concrete laying process. However, as shown in Figure 2 additional strengthening can be provided by, for example, honeycomb arrays of walls within the hollow body of the pod.

In addition to the raised sections 31 of the pod 10 providing strengthening/stiffening of the pod 10 they also increase the external bulk of the pod and thereby reduce the amount of concrete that needs to be poured over the formwork when creating the slab.

According to a preferred form of the pod 10 a laterally extending land or flange 33 is provided at the lower or foot end of each of the legs 14 (see e.g. Figures 1, 2 and 3).

This can provide further strengthening to the foot end of the legs 14. It also provides a broader pressure area at the foot of the legs 14 which can be advantageous as it reduces the likelihood of puncturing of the membrane on which the pods are located.

Figure 12 of the drawings shows how pods can be stacked together for the purposes of storage, transportation and on site handling.

In a further preferred form of the invention coupling means are provided whereby pods can be coupled together at the bottom of the legs 14. This, for example, permits the formation of a block B of four pods e.g. as shown in Figure 11. Because of the hollow nature of the pods 10 a plurality of such blocks B of pods 10 can be stacked one upon the other i.e. nestle together (see Figure 11). This provides a number of advantages such as stable stacks of pods can be formed for storage and transport purposes. Also at a building site stacks of blocks of pods can be strategically positioned over the foundation/slab area and a worker then only has to lift individual blocks B off the stack and couple them to blocks B already placed on the membrane close by the stack. This obviates the need for the worker to physically fit the four pods together "on site" and also results in the worker being able to work more efficiently.

One preferred means for coupling the foot ends of the legs is shown in Figures 1 to 3. As can be seen in Figures 1 to 3 each land 33 has a female coupling element 34 a male coupling element 35. The land 33 between these has a pair of male 35 and female 34 coupling elements. These coupling elements 34 and 35 are configured and orientated so that when pods 10 are bought together the coupling elements 34 and 35 of adjacent lands 33 will combine in say an interference fit or more preferably a snap lock fit. The coupling elements 34 and 35 engage and lock together at the same time that the attachment point 19 and 20 come into engagement and lock together during the relative movement between the pods when the rim 17 of one pod slides face to face with the rim 17 of the other pod.

When a formwork of pods 10 is formed there will be arch-like open spaces 16 at the periphery of the formwork. These need to be closed off to prevent concrete from flowing into the interior of the formwork. Thus a cover element 11 is provided to close off the open space 16.

As shown in Figures 4, 5 and 6 the cover element 11 comprises a panel 36 with a projecting peripheral wall 37. At the upper end of the panel 36 there are a pair of attachment points 39 and 40 which interact with the attachment points 19 and 20 of the pod 10Thus when the cover element 11 is slid down over the rim 17 of the pod the attachment points 39 and 40 engage with attachment points 20 and 19 respectively to snap lock the cover element 11 in place. When in place the peripheral wall 37 of the cover element 11 is located over the rim 17 (see e.g. Figure 6).

Figure 5 shows that attachment point 39 is a headed stud which can engage in the slot 21 of the attachment point 19 of the rim 17. The attachment point 40 is similar to attachment point 20 and engages in the groove 20a of the pod 10.

The cover element 11 also includes at its lower end a flange 41 which projects in the opposite direction to the peripheral wall 37. This flange 41 has two pairs of upwardly projecting spigots 42 the function of which will hereinafter become apparent.

Figures 7 and 8 show connector elements 12. These can be used (as shown in Figures 9 and 10) to locate effectively extend the position of the arch-like open space 16 and close it with the cover element 11 at a distance from the pod 10. This may be desirable, for example, to provide an extension of the pod 10 so as to reduce the amount of concrete used to form the slab/foundation e.g. near the boxing when there is insufficient space for a full pod 10 to be positioned.

The connector element 12 is substantially a "U" or arch shaped body 43 with a central rib form 44 for strengthening and to make handling of the connector element 12 easier. To one side of the rib 44 there is a rim 17' similar to the rim 17 of the pod . This has attachment points 19' and 20' which are of the same form as attachment points 19 and 20 of the pod 10. To the other side of the rib 44 there is a projecting wall 37' which has an internal flange 45. The flange 45 has attachment points 39' and 40' which are similar to attachment points 39 and 40 of the cover element 11.

In the preferred form the connector element 12 has a foot 33' at each of the lower ends of the rim 17' and rib 44.

Thus, as shown in Figures 9 and 10 , a plurality of connector elements 12 can be combined together by the inter-fitting of the attachment points 19'/20' and 39'/40' to form an elongate extension element 12'. The ends of the extension element 12' can attach to respectively a cover element 11 and a pod 10. It will be appreciated that the number of connector elements 12 will depend on the distance required between the cover element 11 and the pod 10.

The skilled person will appreciate that one or more connector elements 12 can be fitted between and join adjacent pods 10 if there is a need to space pods apart.

The connector element 12, cover element 11 and the manner in which they fit with the pod 10 provides an effective and versatile means of creating formwork for a concrete slab/foundation. Because the connector elements 12 fit onto rather than into the pod and lock onto the pod assembly of the formwork is quick and easy. Also because the connector elements 12 fit onto the pod and have the upstanding ribs 44 more airspace is taken up by a connector element 12 (or extension element 12') with the result that the use of concrete can be minimised.

Figure 10 also illustrates a reinforcing support 47 which can be coupled to the cover element 11 and extend from the cover element 11 toward the boxing within which the formwork F is located.

The support 47 (which preferably is made from plastics material) comprises an elongate member 48 which has a plurality of indents 49 of a size that can accommodate reinforcing rod(s) (not shown). At one end of the elongate member 48 is a flange 50 which can engage against the surface of the panel 36. At the foot of the flange 50 are a pair of female coupling features 51 which can press or snap lock fit onto the spigots 42 of the cover element 11. The reinforcing support 47 can thereby be anchored to the cover element 11.

The elongate member 48 as shown in Figure 10 is of a length than accommodates three indents 49. However, to suit different distances between the cover element 11 and the boxing different lengths of support 47 will be provided. Consequently a shorter support 47 may have one or two indents 49.

The reinforcing support 47 can thus be used to support lengths of reinforcing rod that will typically be located in the area between the edge of the formwork created by the pods 10 and the surrounding boxing. Because the support 47 is coupled to the cover element 11 it will provide a stable support for the reinforcing. It will be appreciated by the skilled person that the support 47 can in many instances be simply coupled to a cover element 11 that is coupled directly to the pod 10 rather than via an extension element 12' formed by one or a plurality of connector elements The present invention has been described and illustrated by way of a specific embodiment. It is not the intention of the Applicant to restrict or in any way limit the scope of the invention to such an embodiment. Modifications and changes within the inventive concept will be apparent to the skilled person.

An example of a modified form of the pod is shown in Figure 13. In this embodiment the pod 10' has a stepped down substantially flat surfaced upper wall 15'. According to the preferred embodiment the step down makes the pod 10' about 60mm lower in height but otherwise the pod 10' is of the same configuration as pod 10. It can therefore be connected to adjacent pods via the rims 17 and connector points 19 and 20. It will, however, be observed in Figure 13 that the rims 17 project above the level of the flat wall surface 15' and thereby form upwardly projecting flanged arches With most domestic concrete floors provision needs to be made for a tiled shower (concrete needs to step down 50mm - 60mm in this area) and protruding piping for sewer and waste plumbing needs to be accommodated. The stepping down and forming of the flat surface 15' makes it easier to cut a hole in the upper wall 15' for a pipe to protrude there through. A pipe protrusion flange component 52 (shown in Figure 14) comprises a flange 53 with an opening 54 so that the flange 53 be slid down over the protruding pipe and optionally the flange can then taped down to the pod. This ensures that no concrete can spill through an oversize hole cut in the pod '.

In the preferred form the hole 54 is sized so that it fits with an interference fit with the pipe and has radiating slits 55 to give flex.

Figure 15 shows a different form of the flange component 52' where a box like structure 56 is formed by a peripheral wall 57. This flange component 52' is also designed to slide over the plumbing pipe that protrudes through the pod 10' and form a box (in a preferred form 300mm x 300mm x 80mm) in the finished concrete.

This creates a void for plumbers to place S traps and additional drainage fittings etc. needed with a shower or bath.

The pod or pods 10' can be put in place in the formwork where a recess is needed for a tile shower with the flange top arches 53 supporting the reinforcing mesh.

Therefore, the invention in its broader aspects is not limited to the specific details, representative means of manufacture and method, and illustrative examples shown and described in this specification. Accordingly departures may be made from such details without departing from the spirit or scope of the Applicant’s general inventive concept.

Claims (24)

WHAT WE CLAIM IS: 1.-

1. A modular element for use in the creation of a formwork for making concrete floor or foundation slabs, the modular element being a substantially stool-like structure formed by an upper wall with a plurality of support legs downwardly extending from the upper wall and defining a plurality of open spaces, the modular element being characterised by support means associated with the upper wall whereby reinforcing can be supported so that it is located away from the surface of the upper wall.

2. A modular element as claimed in claim 1 wherein a reinforcing or stiffening valley is formed in the support leg.

3. A modular element as claimed in claim 2 wherein part of the reinforcing or stiffening valley extends into the upper wall.

4. A modular element as claimed in claim 1, 2 or 3 wherein the upper wall includes a plurality of upwardly raised areas configured to provide strengthening/stiffening of the upper wall.

5. A modular element as claimed in claim 3 wherein the upper wall includes an upwardly raised area, configured to provide strengthening/stiffening of the upper wall, located between each of the adjacent parts of the reinforcing/stiffening valleys extending into the upper wall.

6. A modular element as claimed in any one of claims 1 to 5 in combination with at least one cover element coupled to the modular element to close off a said open space.

7. A modular element as claimed in any one of claims 1 to 5 in combination with at least one connector element coupled to the modular element to extend an open space beyond the periphery of the modular element.

8. A modular element as claimed in claim 7 in combination with a cover element coupled to the connector element to close off the extended open space.

9. A modular element as claimed in any one of claims 1 to 5 in combination with a plurality of connector elements coupled together to form an elongate connector.

10. A modular element as claimed in claim 9 wherein the elongate connector is coupled at one end to the modular element and coupled at an opposite end to a cover element.

11. A modular element as claimed in any one of claims 7, 9 and 10 coupled to another modular element by a connector element or an elongate connector whereby open spaces of the modular elements are coupled together.

12. A modular element as claimed in any one of the preceding claims wherein the modular element is moulded from a plastics material.

13. A modular element as claimed in any one of the preceding claims wherein the support means is a circular wall extending upwardly from an outer surface of the upper wall.

14. A modular element as claimed in claim 13 wherein the circular wall is located substantially centrally in the upper wall.

15. A modular element as claimed in any one of the preceding claims wherein a laterally extending land or flange is provided at the lowermost extremity of each leg.

16. A modular element as claimed in any one of claims 7 to 10 and 11 wherein the connector element is a substantially arch-shaped body.

17. A modular element as claimed in any one of the preceding claims of a hollow form whereby a plurality of modular elements can be stacked together.

18. A modular element as claimed in any one of the preceding claims further including connection means whereby modular elements located adjacent one another can be connected together.

19. A modular element as claimed in claim 18 wherein connection means are located at or adjacent a foot end of the support legs.

20. A modular element as claimed in claim 18 or 19 wherein connection means are located with an outwardly facing rim associated with each pair of adjacent support legs and a part of the upper wall located between each pair of adjacent support legs.

21. A modular element as claimed in claim 19 or 20 wherein the cover element(s) and the connector element(s) as claimed herein also include connection means adapted to interconnect with the connection means of the modular element.

22. A plurality of modular elements as claimed in any one of claims 18 to 20 connected together by the connection means to form a block of modular units.

23. A plurality of modular elements, cover elements and connector elements as claimed in any one of the preceding claims coupled together to form a formwork for creating a concrete floor or foundation slab.

24. A modular element substantially as herein described with reference to the accompanying drawings. POLYMER SYSTEMS INTERNATIONAL LIMITED By its Attorney Don Hopkins IP Support Services