OA12524A

OA12524A - Formwork for precast concrete panels.

Info

Publication number: OA12524A
Application number: OA1200300111A
Authority: OA
Inventors: Tian Khoo
Original assignee: Ah Kim Khoo; Tian Khoo; Panel Sdn Bhd O Stable
Priority date: 2001-05-11
Filing date: 2002-04-01
Publication date: 2006-05-31
Also published as: EP1385681A1; CA2426566A1; CN1464825A; WO2002092306A1; EA005174B1; MY135260A; JP2004520206A; CN1267260C; ZA200302764B; EA200300494A1

Abstract

A formwork for precast concrete panel comprises of a quadrangle panel with a base and four side panels. The formwork (10) comprises of a base (14), which is provided with an island region (20) and/or a mound region (22), a pair of parallel fixed spaced apart side panels (16) and a pair of parallel moveable side panels (18). The island region (20) and/or mound region (22) is positioned between the parallel moveable paced apart side panels (18) and wherein said parallel moveable spaced apart side panel (18) are removeably secured to the parallel fixed spaced apart side panels (16) in a tight manner in any desired distance from the center of the island (20) and/or mound (22) region.

Description

012524 1

FORMWORK FOR PRE-CAST CONCRETE PANELS

FIELD OF THE INVENTION

The présent invention relates to a forrnwork for pre-cast concrète panels used inthe building industiy. The présent invention mqre particularly relates to an adjustableforrnwork for constructing concrète panels, which are provided with an opening or arecess portion. Most particularly the présent invention relates to a portable and light-weight forrnwork for precast concrète panel.

BACKGROÜNP OF THE INVENTION

In the prior art, there hâve been numerous methods of constructing precastconcrète structures for the purpose of building engineering structures such as houses,office buildings or other concrète structures. Columns and beams are the most commonprecast concrète structures constructed in a factory and later transported to the site.

The site for constructing precast concrète panels are generally located far frontthe construction site and therefore transporting said precast concrète structures is verycostly as it requires heavy transportation. Furthermore, the high cost of transportation isone of the reasons why precast concrète structures hâve not gained much popularity inthe field of building industry.

Normally, each section in a building consiste of different size of structuralpanels, which hâve different widths, heights and thickness. Where precast concrètepanel are used, preparing different moulds for each type of panel in a building can be anexpensive exercise and rime consuming. US patent document 5,219,473 teaches a method of casting a precast beamcomprising of a forrnwork with at least two spatially oriented upper sleeves and twospatially oriented lower sleeves and there between provided a connecting member. Thelength and height of the precast beam is determined by the dimension of the connecting 012524 2 member, which preferablÿ is woqd. There is one drawback of this invention, each time anew beam is to be casted, a new connecting member is required. This method becomesinconvénient as storage space is required to store the connecting members.

The objective of the présent invention is to reduce the above mentioneddrawbacks by providing a portable and light weight formwork, which is easilytransported to the construction site with minimal transportation cost.

Another objective of the présent invention is to provide a longitudinal channelwith sufficient thickness along the edges of the precast concrète panel but reducing thethickness of the central région of the precast concrète panel.

Another objective of the présent invention is that to introduce an universalformwork, wherein the same formwork can be used to cast different size of concrètepanel without adding any additional formwork.

Another objective of the présent invention is to introduce a precast concrètepanel with aesthetic opening for the installation of window and the like

SUMMARY OF THE INVENTION A formwork for precast concrète panel comprises of a quadrangle panel with a baseand four side panels. The formwork comprises of a base which is provided with anisland région and/or a mound région, a pair of parallel fixed spaced apart side panelsand a pair of parallel moveable side panels. The island région and/or mound région is.positioned between the parallel moveable paced apart side panels and wherein saidparallel moveable spaced apart side panel are removeably secured to the parallel fixedspaced apart side panels in a tight manner in any desired distance ffom the center of theisland and/or mound région.

The parallel moveable spaced apart side panel is slideable against the pair of parallelfixed spaced apart side panel. The parallel moveable spaced apart side panels aresecured to the parallel fixed space apart side panels at pre-determined distance from the 012524 ’ 3 cenîer of the mould. The parallel moveable spaced apait side panels are positionable toa predetermined distance apart and wherein the same formwork with an island régionand/or mound région is usable for constructing precast concrète panels of different pre-determined widths.

The parallel moveable spaced apart side panel includes a longitudinal ledge suchthat the therein-casted panel would indude a longitudinal channel corresponding to thelongitudinal ledge. At least one of the pair of parallel fixed spaced apart side panelsincludes at least one aperture to receive at least one reinforcement member. .Theperipheral side of the island région includes a patterned edge. The peripheral side of themound région includes a patterned surface. The mound région optionally includes amould of any desired impressions. A subsidiaiy formwork is assembled thereon to the formwork in which thesubsidiary formwork comprises of a pair of longitudinal spaced apart panels across thepair of parallel fixed spaced apart side panels. The inner sides of the longitudinal spacedapart panel form the sides of a mould and the upper surface of the concrète in theformwork forms the base of the mould, said mould is designed to receive concrète suchthat on setting, a projecting edge is formed. The subsidiaiy formwork is positionable atany point along the parallel fixed spaced apart side panels. The distancé apart betweeneach member of the said of longitudinal spaced apart panel is variable such that thecasted longitudinal ledge is of variable pre-determined width. A longitudinal channel isaccommodated within the subsidiary formwork such that the therein, casted projectingedge (30) includes a longitudinal channel.

BRIEF DESCRIPTION OF THE FIGURES

Figure 1 is a perspective view of the présent embodiment of the invention.

Figure 2 is a perspective view of a parallel sideable spaced apart side panel.

Figure 3 is a plan view and, side and front cross sectional view of the completed precastconcrète panel.

Figuré 4A - 4G shows the sequence of forming a base in cross sectional views. 012524 4

Figure 5 shows various designs of precast concrète panels panel formed by a varioustype of moulds.

Figure 6 shows various types of precast concrète panels with different widths formed byusing the same mould.

Figure 6A shows precast concrète panels with and without the subsidiary ‘T’ and ‘L’joints formed using the same mould.

Figure 7 shows a perspective view of the subsidiary formwork shown in Figure 1.

Figure 8 shows a cross sectional view of the formwork with a subsidiary ‘T’ jointformwork.

Figure 9 shows a cross sectional view of the formwork with a subsidiary ‘L’ jointformwork.

Figure 10 shows a perspective view of the ‘L’ shaped subsidiary formwork of theprésent embodiment.

Figure 11 shows a perspective view of the formwork provided with a ‘L* shapedsubsidiary formwork.

Figure 12 shows a cross sectional view of the securing raeans of the parallel fixed spaceapart side panels to the base.

Figure 13 shows a perspective view of the formwork shown in Figure 1 withoutproviding any subsidiary formwork.

Figure 14 shows a side view of the securing means of the parallel slideable spaced apartside panels as shown in Figure 10.

Figure 15 shows a cross sectional view of the formwork shown in Figure 13.

DETAILED DESCRIPTION OF THE INVENTION

The présent invention comprises of a main formwork (10) and optionally asubsidiary formwork (12). The main formwork (10) comprises of a preferablyquadrangular shaped base (14), a pair of parallel fixed spaced apart side panels(hereinafter referred to as fixed panels) (16) and a pair of parallel slideable spaced apartside panels (hereinafter referred to as slideabe panels) (18). The base (14) is fùrtherprovided with an island région (20) and/or a mound région (22) preferably between theslideable panels (18), (Figure l). 012524 5

The said fixed panels (16) are longitudinal structures. One side of the said panels(16A) borders the upper part of the thereafter, casted concrète panel and the other sideborders the lower part of the thereafter casted concrète panel (16B). The fixed panel(16) includes guides (15) along the length of the panel to receive the slideable panel(18). The said panel (16A) is provided with at Ieast one aperture (24). The aperture (24)is provided to receive reinforcement bars.

The said slideable panels.(18) are also longitudinal structures and.arepositionalbe perpendicular to the fixed panels (16) along the same plane. At least oneside of the each of the slideable panels (18) is provided with an longitudinal ledge (26),(Figure 2). When the panels (16,18) are secured to the base (14) and concrète is pouredthereîn, the longitudinal edge of the casted panel will include a longitudinal channel(34) corresponding to the said longitudinal ledge (26) when the concrète has set andthen the parallel side panels (16,18) are removed from the base (14), (Figure 3).

An island région (20) is defined wherein after casting, the precast concrète panelis provided with an opening. Said opening can be an opening for ventilation or can befor the putpose of installing a window or a door frame or the like. A mound région (22)is defined wherein after casting, the thickness of the precast concrète panel where themound région is provided is smaller compared to the thickness of the other sections ofthe precast concrète panel. This configuration of the panel enable the structural strengthof the panel to be maintained but the weight of the panel is substantially reducedwithout sacrificing the structural strength.

Gypsum famé (50) is placed on a fiat working platform (17) to form therectangular enclosure, (Figures 4A & 4B). Borders (52) are placed along the peripheraledge of the gypsum frame (50), (Figure 4C). Said borders (52) are made of gypsum orany other appropriate settable material. It will be appreciated that a depressed portion iscreated in the centre portion of the gypsum frame (50). Either fiberglass or plasticsmaterial is introduced into the enclosed portion and the borders (52) and left to set.(Figure 4D). After the fiberglass material has set, a fiberglass mould is formed. It will 012524 6 be appreciated that a métal trame (19), which is laminated with fiberglass material isprovided to the fiberglass mould before the gypsum frame (50) and the borders (52) areremoved, (Figures 4E & 4F). The purpose of the said métal frame is to support thefiberglass mould when the said gypsum frame (50) and the borders (52) are removed,(Figure 4G).

An imprint of a purposed window frame design is formed of gypsum materialand is placed in the center of the enclosed portion constructed as mentioned above andthereafrer fiberglass or plastics material is introduced. It will be appreciated that a métalframe, which is laminated with fiberglass material is provided to the fiberglass mouldbefore the gypsum frame and the borders are removed. The purpose of the said métalframe is to support the fiberglass mould when the said gypsum frame and the bordersare removed.

It will be appreciated that a mould maker will be able to casf suitable mould forother desired design, (Figures 5,6 & 6A).

In this embodiment the base (14) is formed as a single piece manually. It will beappreciated that for a large project, where large scaîe of identical mould is required,then the process of manufacturing said moulds can be done by utilizing the plasticsmoulding method.

The subsidiary formwork (12) comprises of a pair of longitudinal parallel sidepanels (28). Said subsidiary formwork is provided on the casted main formwork for thepurpose of providing an adjoining projecting structure such as a T-joint or a L-joint toreceive other precast concrète panels. Said subsidiary formwork (12) is positionàble atany point along the parallel fixed side panels (16). The subsidiary formwork (12) isprovided on the main formwork either when the concrète poured in the main formworkhas fully set or parüy set. A longitudinal ledge (30) is accommodated within the pair ofparallel side panels (28), wherein when the subsidiary formwork is casted and concrètematerial had set, the casted projecting structure would include a longitudinal channel(32) corresponding to the longitudinal ledge (30), (Figures 7 & 8). When a projecting °12524 7 structure is to be positioned at the terminal edge of the panel, the slideable panel (18) onthe outside can be replaced by a panel (13), which is integrated with the slideable panel(18), (Figures 9 to 11).

The working mechanism of the présent invention and other features notdescribèd earlier will be described now. Firstly, the said base (14) is placed on asupporting structure (36), which is essentially a rigid planar surface, (Figures 8 & 9).The supporting structure is placed in a totaily horizontal plane. Each of the fixed panels(16) is placed on a rebated portion (38) on the base (14), (Figure 12). The width of thesaid rebated portion (38) is équivalait to the width of the fixed panels (16). A restrictingmeans (40) is provided on the supporting structure (36) to secure the fixed panels (16)on the base (14) and also to secure the base (14) on the supporting structure (36). Saidrestricting means (40) is preferably a métal bar which is welded to the supportingstructure (36), (Figure 1). The said base (14) is placed on the supporting structure (36)in such a manner that, each terminal edge of the upper part and the Iower part of thebase (14) is provided with at least one restricting means (40). A gap is aliocatedbetween the edge of the base and the restricting means (40) to receive a wedged spacermeans (42). Said wedged spacer means (42) is provided to ensure that the fixed panels(16) is secured on the rebated portion (38) of the hase (14) and the base (14) is securedto the supporting structure (36).

Once the width of the precast concrète panel has been determined, the slideablepanels (18) are slideably positioned apart frora the central portion of the base (14) andbetween the fixed panel (16). When said determined width is confirmed, the saidslideable panels (18) are locked in its présent position. The means of locking theslideable panels (18) in its position is done by providing an adjustable arm (44) whereinone end of the adjustable arm (44) is placed against the slideable panels (18) whfle theother end extends and placed in a bracket (46), (Figure 13). To secure the other end ofthe adjustable arm (44) in the bracket (46), a spacer (48) is introduced into the gapbetween the said end of the adjustable arm (44) and the bracket (46), (Figure 14).Furthermore, the terminal edge of the slideable panels (18) is configured to matingly fitthe contour on the fixed panels (16) in order to provide a rigid structure. This method 0Î2524 8 ensures that the slideable panels (18) remains in an upright position when the concrète ispoured into the formwork (10). This configuration enables easy and convenientdismantling of the side panels from the base (14).

When the said side panels (16,18) are securely mounted to the base (14),concrète is poured into the formwork. After the concrète has set, the parallel âde panels(16,18) are removed and the casted concrète panel is stored while waiting to betransported to the construction site.

When concrète is poured in the formwork; it can be either poured by fullycovering the island région (20) on the base (14) or by just covering the sides of theisland région (20). When the concrète is poured in the formwork and is flushed with theheight of the fixed panels (16), a recess is created on the thereafter casted precastconcrète panel corresponding to the mound région in the mould. Whereas, when theconcrète is poured in the formwork and is flushed with the upper side edges of theisland région (20), an opening is created.

In the présent embodiment, the island région (20) and the mound région (22) aredesigned as a flat planar surface, but said island région (20) and mound région (22) canbe designed in any other geometrical shaped structure or can be provided with designwherein upon casting, it resembles an impression of an object such as a vase, an animaland the like, (not illustrated).

In the présent embodiment, the island région (20) and/or the mound région (22)is positioned on the base (14) in such a manner that, said island région (20) and/ormound région (22) is centrally located between the slideable spaced apart side panel(18) or between both the fixed and slideable panels (16,18). Said island région (20)and/or mound région .(22) can be positioned anywhere between the two pairs of parallelside panels (16,18) with or without additional adjustment or modifications. 012524 9

In the présent embodiment, the fixed panels (16) is secured to the base byproviding a restraining member (38) and a wedged spacer timber (42), but said fixedpanels (16) can be either secured to the base by providing a tongued member of thefixed panel (16) and a grooved member on the rebated portion of the base or by anyother means known in the art, (not illustrated).

In the présent embodiment, the completed precast concrète panel includes aprojectmg portion such as a ‘T joint or a ‘L’ joint for the puipose of providing anadjoining projecting structure to receive other precast concrète panels. However, saidprecast concrète panel can also be constructed without the projecting structures, (Figure15). Therefore, to secure precast concrète panels to each other, a separate ‘T’, ‘L’,crossed or even a rectangular shaped columns can be erected on site.

Claims

012524 10 CLAIMS

1. A formwork for precast concrète panel comprising of a quadrangle panel with abase and four side panels characterized in that the formwork (10) comprises of abase (14) which is provided with an island région (20) and/or a mound région(22), a pair of parallel fixed spaced apart side panels (16) and a pair of parallelmoveable side panels (18), wherein said island région (20) and/or mound région(22) is positioned between the parallel moveable paced apart side panels (18)and wherein said parallel moveable spaced apart side panel (18) are removeablysecured to the parallel fixed spaced apart side panels (16) in a tight manner inany desired distance from the center of the island (20) and/or mound (22) région.
2. A formwork as claimed in Claim 1 wherein the parallel moveable spaced apartside panel (18) is slideable against the pair of parallel fixed spaced apart sidepanel (16).
3. A formwork as claimed in Claim l wherein the parallel moveable spaced apartside panels (18) are secured to the parallel fixed spaced apart (16) side panels atpre-determined discrète distance from the center of the mould.
4. A formworic as claimed in Claim 1 wherein the parallel moveable spaced apartside panels (18) are positionable to a predetermined distance apart and whereinthe same formwork (10) with an island région (20) and/or mound région (22) isusable for constiucting precast concrète panels of different pre-determinedwidths.
5. A formwork as claimed in Claim 1, wherein at least one of the pair of theparallel moveable spaced apart side panel (18) includes a longitudinal ledge (26)such that the therein-casted panel would include a longitudinal channel (34)corresponding to the longitudinal ledge (26). 012524 11
6. A formwork as claimed in Claim 1 wherein at least one of the pair of parallèfixed spaced apart side panels (16) includes at least one aperture (24) to receiveat least one reinforcement member.
7. A formwork as claîmed in Claim 1 wherein the peripheral side of the islandrégion (20) includes a pattemed edge.
8. A formwork as claîmed in Claim 1 wherein the peripheral side of the moundrégion (22) includes a pattemed surface.
9. A formwork as claîmed in Claim 1 wherein the mound région (22) optionallyincludes a mould of any desired impressions.
10. A formwork as claîmed in Claim 1, wherein a subsidiary formwork (12) isassembled thereon to the formwork (10) in which the subsidiary formworkcomprises of a pair of longitudinal spaced apart panels (28) across the pair ofparallel fixed spaced apart side panels (16) wherein the inner sides of thelongitudinal spaced apart panel (28) form the sides of a mould and the uppersurface of the concrète in the formwork (10) forms the base of the mould, saidmould is designed to receive concrète such that on setting, a projecting edge (30)is formed.
11. A formwork as claîmed in Claim 10, wherein the subsidiary formwork (12) ispositionable at any point along the parallel fixed spaced apart side panels (16).
12. A formwork as claimed in Claim 10, wherein in the subsidiary formwork (12),the distance apart between each member of the set of longitudinal spaced apartpanel (28) is variable such that the casted longitudinal ledge (30) is of variablepre-determined width. 012524 12
13. A formwork as claimed in Claim 10, wherein a longitudinal channel (32) isaccommodated within the subàdiaiy formwork (12) such that the therein, castedprojecting ledge (30) inchides a longitudinal channel (32).