US20180298624A1

US20180298624A1 - Assembly of profiles for sustaining, molding and finishing the concrete of slab, beam and column

Info

Publication number: US20180298624A1
Application number: US15/489,686
Authority: US
Inventors: Ilmar LAURINDO
Original assignee: Individual
Current assignee: Individual
Priority date: 2017-04-17
Filing date: 2017-04-17
Publication date: 2018-10-18
Also published as: BR102018006847A2

Abstract

A set of extruded profiles for the construction of slabs, beams and columns, which are assembled in a systematic manner and have the function of covering the slab, column and beam, eliminating the need for any finishing, and has the function of serving as to receive the concrete during construction. The constructive arrangement of the parts forming said set of profiles and allowing their assembly in a systematic manner, guarantees numerous functional advantages, as well as in their use and is comprised of five extrusion profiles, preferably PVC, not limited to this material, comprising a main plate, a filling profile, which will replace the Styrofoam block, and three profile variations for column construction.

Description

This report presents a set of extruded profiles for the construction of slabs, beams and columns, which are assembled in a systematic manner. Such a set of profiles has the function of covering the slab, column and beam, and has the function of serving as a form to receive the concrete during construction. The constructive arrangement of the parts forming the said assembly and allowing its assembly in a systematic manner, guarantees numerous functional advantages, as well as in its use.
The construction of slabs, beams and columns is already of technical knowledge, using blocks of Styrofoam as a fill, to leave the slab lighter and using box and building irons; in this traditional process, after the assembly of the box—as the molds that hold the concrete are called until it solidifies—the Styrofoam blocks are arranged and the lattice beams or concrete beams are assembled, and then the concrete is poured into the box until it will harden and the casing be removed; after removal, the plaster is made to finish. The construction of the slabs in particular is slow and requires intense physical effort of the worker, especially in the assembly of lattice beams and the finishing of the lower part of the slab, knowing that in the latter, the worker must sprinkle cement from the bottom up, which in addition may cause damage to the operator's physical integrity.
In order to increase the practicality and speed in the construction of slabs, some improvements have been developed, focusing on the solution of some specific problem, as shown in document MU8802069-0 that presents a form of brick in thermoplastic to be used in slabs; and document MU9001782-0 which shows an improvement in the construction of lattice girder beams. Also, document BR102012012581-1 that presents a form of construction of slab without finishing, but with proposal totally different from the one that this report refers, mainly because it is the field of the ribbed slabs.
Other patentable priorities which may be cited are the documents BR202015008514-7, which has a constructive profile shape, which presents greater mechanical resistance by distributing the internal stresses to the profile, at the time of concreting and drying the concrete; and CA2097226, which also provides a form of wall construction by means of thermoplastic profiles, which aim to simplify the obtaining of the building, providing finished walls after the pouring of the concrete into the profiles.
Based on the known state of the art, little has been changed in the traditional slab construction process, and some minor improvements have occurred in some processes. Nowadays, little has been altered in the construction of the foundation of a building, mainly of residences and smaller buildings. The process consists of assembling the column case and iron structure, then the concrete is poured; as soon as it hardens the construction of the beams and slab begins. The slab is commonly filled with blocks of Styrofoam between the lattice beams, with the purpose of making the slab lighter, being the trussed beams are what have the function of supporting the slab, and using the cement as a way to connect the slab in the pillars and beams, making them one body. This process is slow, mainly because of the distribution and assembly of the beams on the slab, since it is necessary for the worker to distribute the beams and blocks of Styrofoam uniformly over the whole extension of the slab. There is also the problem of finishing after the withdrawal of the case, since it requires a lot of time and skill of the worker, especially in the finishing stage of the lower part of the slab, which besides having a very high degree of difficulty, may require the worker to work in uncomfortable positions, posing risks to your health and physical integrity in the long and short term.
The interiorities' that more closely approximate the developed object, do not present solution for the construction of slabs as recommended in this document; one can find anteriority that reveal solutions only of walls, because it is a component that should have its weight reduced to the maximum, however, it must have enough mechanical resistance to support the requests that are exposed, providing security for the people. Another problem that involves the construction of slabs is that it needs to thermally and acoustically isolate the lower and upper environments from the slab, which is very difficult to achieve with the use of solid materials such as concrete.
Another problem that may be mentioned is the fact that it is very difficult to insert new hydraulic and electric pipes into walls and slabs produced in concrete, since there is a need to perform the wall breaking along the entire pipe length that If desired, a fact that is aggravated when it comes to the breaking of a slab or floor, as it makes the room or site unusable until the renovation ends.
The fact of filling the profile with concrete generates a variety of problems in the constructed wall, such as the fact that concrete is produced by a mixture of sand, powdered cement and water, and therefore, when drying confined in the profile, it contracts and may cause bubbles and deformations, as it has been poured into a thermoplastic receptacle, and the latter is very easy to deform because it is a flexible material.
In order to solve these problems, this set of form-like facing profiles for slab, beam and column concreting comprises five specific shaped extrusion profiles which provides an assembly in such a way as to result in the elimination of all problems. It comprises an extruded profile preferably in PVC, not limited to this material, comprising the form of a main beam, with supports for the structuring irons and a profile formed of a main beam and grooves for fixing to the concrete, which fit together in pairs, by means of fittings, forming a square hollow column, and around this, the casing will be assembled, and after the pouring and hardening of the concrete, in this column the casing can be removed and the result is a molded and finished column, presenting as lining said profile, eliminating subsequent rework.
It also comprises a plate with grooves on one of the faces which is arranged at the base of the slab, on the case, and this plate provides spaces for the light fill arrangement, for example Styrofoam, and for the iron truss, which forms the beams and lattices, avoiding the use of pre-cast beams in cement, because when the cement is poured on the pre-molded joist, it can cause in a problem of lack of adhesion, since the cement of the joist is already solidified, and due to the contractions during the solidification of the new cement spillage, the lack of adhesion in the surfaces of the shaft can cause future cracks; said assembly further provides for fittings to a further profile that this assembly comprises a filling profile which will replace the Styrofoam block, and with this, we have that the operator needs only to fit the parts coherently, interleaving iron trusses and profiles on said plate, positioning the iron screen on the slab, and pour the concrete, which significantly reduces the time spent in the construction of the slab, and reduces its weight, so that the slab does not need to be very thick, reducing costs, besides the fact of forming hollow chambers that increase the thermal and acoustic insulation and facilitate the opening of channels for passage of new hydraulic and electric pipes, after the slab already is constructed. After removal of the slab from the slab, the lower part will be coated, therefore, only the lower part of the initially arranged plate will be visible, eliminating the need for any finishing at the bottom of the slab.

The figures presented, by way of example and illustration, together with the description of the profiles and the assembly, will allow a better understanding of the developed object.

FIGS. 1A and 1B show a front cross-sectional view and an isometric view, consecutively, of the profile (100) forming the plate.

FIGS. 2A, 2B and 2C are front profile views (200 and 300) which when assembled form the columns and sides of the slab.

FIGS. 3A, 3B and 3C are isometric views of the

profiles

200 and 300 shown in FIGS. 2A, 2B and 2C.

FIGS. 4A to 4F illustrate the assembly combination logic for column of the profiles (200 and 300).

FIGS. 5A to 5G are some of the possible variations for column construction resulting from the assembly of the profiles (200 and/or 300).

FIGS. 6A and 6B are front and isometric illustrations respectively of the filler profile (400) which, when mounted to the profile (100), forms the filler of the slab. And FIG. 6C shows the cap (410) of the profile (400) which is positioned at the ends of said profile (400).

FIGS. 7A and 7B depict, respectively in side and perspective views, an embodiment of the slab assembly, including the profile (100) forming the slab plate, the profile (200) forming the side of the slab and the slab filler profile (400), as already previously illustrated in isolation.

Based on the figures presented, the profile set, for support, molding and finishing, can be visualized in the concrete slab, beam and column, object of this report. The slab is comprised by the assembly of the profiles (100), which form the main plate, which is the base of said slab. This profile (100), according to FIGS. 1A and 1B comprises a coupling (101) at one end with the insertion opening aligned with the wall of said profile (100) and a hitch (102) at the opposite end to said profile (100), With engaging aperture also opposite the engagement (101); said couplers (101 and 102) provide projections to aid in mounting profile (100 or 200) embedded therein. Each profile (100) provides rods (103) attached at one of their ends to the profile (100), distributed and spaced apart from each other. Said rods (103) may provide shoulders (103′) to assist in fixing the profile (400) which will subsequently about the said profile (100). Said shoulders (103′) may be arranged in all or some of the rods (103). These shoulders (103′) preferably have the “swallowtail” format type.
The columns are formed from the assembly of the profiles (200 and 300). FIGS. 2A, 2B and 2C illustrate said profiles, where after assembled they result in the pre-finished columns. The profile (200) is comprised of a plate (202), which provides claws (204) disposed on one side of said cross member (202) main defining its inner side; The side opposite the jaws (204) is the outer side of the profile (200); said claws (204) are preferably positioned with an inclination, which serve to increase adhesion to the cement after it has been spilled. At one end of the beam (202) there is provided a recess (201), with horizontal engagement and aperture towards the outer side of the profile (200), and at the opposite end a recess (203A) is provided with horizontal engagement and aperture for the Inner side of the profile (200), that is, side opposite the socket (201), according to FIG. 2A; or a recess (203B) with vertical engagement and opening from the inside of the profile (200), according to FIG. 2B. It is also envisaged that the profile (300) which is another variation of the profile set for mounting columns in different ways; the profile (300) includes a crossbar (301) having a central portion in shoulder to the inner part also provides grip (304) in said inner portion, and a recess (302) at one end with coupling upright and open the (303) at the opposite end with horizontal engagement and aperture with inlet from the outer side of the profile (300). FIGS. 3A and 3B show perspective views of the profiles (200 and 300).
The assembly and its variants are shown in FIGS. 4A to 4F, wherein the insert (201) engages the recess (203A) to another profile (200) to form an extension wall as FIG. 4A; the socket (201) engages the socket (203B) to form a corner with another profile (200), according to FIG. 4B; and the insert (201) engages the socket (302) to form a corner with the profile (300), according to FIG. 4C. The plug (303) of the profile (300) engages the recess (203A) to form an extension of the profile wall (200), as FIG. 4D; The socket (303) engages the socket (203B) to form a corner with a profile (200), according to FIG. 4E; and the insert (303) engages the socket (302) to form a corner with another profile (300), according to FIG. 4E.
FIGS. 5A to 5G are some of the possible variations for column construction as a result of assembling the profiles (200 and/or 300) according to the engagement of the above described recesses, rectangular beams can be formed in FIGS. 5A, 5F and 5G, In cross-section in FIG. 5B, in “T” in FIG. 5C, square in FIG. 5D, in “L” in FIG. 5E, as well as several other possibilities of combinations, being “T” shaped, “U”, with different combinations of profiles (200 and/or 300) resulting in numerous other possible variations not restricted to these figures presented by way of illustration.
The profile (400) comprises filling a main beam (402), which may have continuous straight shape, circular, or may preferably have notches (403) or fillets; (404) has perpendicular and spaced extensions (404) along the crosspiece (402) coincident with the spacing of the rods (103) of the profile (100), and said extensions (404) have female fittings (401), (405) perpendicular to the main cross-member (402) and positioned between said main cross-member (402) and the female catch grooves (401), and said profile (400) further provides for claws (406) disposed on its main beam (402), which serve to increase adhesion to the cement after it has been poured. In order to keep the filling space (400) hollow, shown in the figures, this assembly has closed end and can be closed in a single body profile (400), or providing a lid (410), which is shown in 6C, with cross-section supported to engage the end of said filling space (400), preventing the concrete, when poured, fill the empty spaces inside of the filling space (400) and thereby forming hollow chambers inside the filling space (400), increasing the thermal and acoustic insulation and facilitating the opening of channels for the passage of new hydraulic and electric pipes, after the slab is already constructed, since the channels remain hollow inside the slab.
For the purpose of understanding and presenting an embodiment of the object presented here, the process of assembling this new constructive layout of slab and columns is described. For the construction of a column, profiles (200) and/or profiles (300) are used; By way of illustration, it will be described herein mounting a square simple column using two profiles (200) and two profiles (300), as shown in FIG. 5D: first mounts the insert (201) a profile (200) in a fitting (301) of a profile (300) sequentially, one on top of the other, to form a square column as shown in FIG. 5D, and then it builds the casing around this column is positioned irons construction the supports (202) of the profile (200) and pour the concrete. After the concrete has set, the wood is removed from the casing and the result is a column finished in thermoplastic or other material, but preferably PVC.
The construction of the slab, according to FIGS. 6 and 7, takes place after the construction of the columns, then the slab casing is constructed on the columns and temporary stakes are provided under the slab casing. After constructed casing, the plate is neatly distributed 100) horizontally to the slab, and repeats the process, joining the insert (101) of a plate (100) in the groove (102) of the consecutive plate (100) until the entire slab has been covered. The framing trusses (T) are then disposed on the extensions (103), preferably on the two first ones, and fastened with the clip; then the filler profiles (400) are distributed, by attaching the filler flanges (401) of the filling profile (400) into the rods (103) of the plate (100), hence the importance of the shoulders (103′) to assist in that fastening. In the illustrated case, where the filler profile has caps (410), then the ends of the filler profiles (400) with the said cap (410) must be capped to prevent the yet liquid concrete from filling the empty space of the filling profile (400) so that it continues hollow after pouring of the concrete. To form the sides, it connects to the insert (203B) of the profile (200), the insert (101) of the plate (100), and repeats the procedure until the entire side of the slab has been circumvented. The concrete is then sprayed and waited for the concrete to dry for subsequent removal of the crate, which, when removed, reveals a finished slab on its underside, ruling out the need for subsequent finishing. The material of this finish may be in thermoplastic or other similar material, or in the similar group of materials, preferably PVC.
Other embodiments for this system may exit, using the profiles described herein with profiles combinations (200 and 300) random and varied to form different shapes of columns, setting that has at least one fitting, but which result in a configuration that provides mechanical strength and also results in the construction of slabs, columns and the like. Those embodiments are also characteristic of this system.
By doing this and using this sequence, we can build low cost slabs, beams and columns, in a short period of time without compromising the mechanical strength of the structure, and without the need for final finishing after construction.

Claims

1. ASSEMBLY OF PROFILES FOR SUSTAINING, MOLDING AND FINISHING THE CONCRETE OF SLAB, BEAM AND COLUMN used in the lining of the slab, column and beam, acting as a mold to receive the concrete during the construction and with constructive arrangement of the parts that allows its assembly in a systematic way and with numerous geometric shapes, characterized by the profile (100), which form the main plate, which is the base of said slab comprising an engagement (101) at one end, with a fitting aperture aligned with the wall of said profile (100) and an engagement (102), at the end opposite said profile (100), with engaging aperture also opposite the engagement (101) and each profile (100) provides rods (103) attached at one of their ends to the profile (100), distributed and spaced apart from each other; And a profile (200) comprised by a beam (202), wherein it provides for claws (204) disposed on one of the faces of said main beam (202), defining its inner side and the side opposite the claws (204) being the outer side of the profile (200) and at one end of the crosspiece (202) there is provided a recess (201), with horizontal engagement and opening towards the outer side of the profile (200), and at the opposite end a recess is provided (203A) with horizontal engagement and aperture to the inner side of the profile (200); and a profile (300) formed by a crosspiece (301), with a central protruding inner portion, including claws (304), in said inner part, as well as a recess (302) at one end with vertical engagement and opening (300), and engagement (303) at the opposite end with horizontal engagement and aperture with inlet from the outer side of the profile (300); and the filling profile (400) comprising a main crosspiece (402) with projections (404) perpendicular to the crosspiece (402) spaced along the crosspiece (402) coincident with the spacing of the rods (103) of the profile (100), and said extensions have female fittings (401) at their end so as to be engaged in said rods (103), and provides a secondary crosspiece (405) perpendicular to the main crosspiece (402) and positioned between said main crosspiece (402) and female fittings (404), and said profile (400) further provides claws (406) disposed on its main beam (402)

2. ASSEMBLY OF PROFILES FOR SUSTAINING, MOLDING AND FINISHING THE CONCRETE SLAB, BEAM AND COLUMN, according to claim 1, characterized by said engagement (101 and 102) providing shoulders.

3. ASSEMBLY OF PROFILES FOR SUSTAINING, MOLDING AND FINISHING THE CONCRETE SLAB, BEAM AND COLUMN, according to claim 1, characterized in that the rods (103) provide projections (103′) to assist in securing the female fittings (401) of the profile (400).

4. ASSEMBLY OF PROFILES FOR SUSTAINING, MOLDING AND FINISHING THE CONCRETE SLAB, BEAM AND COLUMN, according to claim 1, characterized in that the shoulders (103′) can be arranged on all or some of the rods (103).

5. ASSEMBLY OF PROFILES FOR SUSTAINING, MOLDING AND FINISHING THE CONCRETE SLAB, BEAM AND COLUMN, according to claim 1, characterized in that the shoulders (103′) have the “swallowtail” shape.

6. ASSEMBLY OF PROFILES FOR SUSTAINING, MOLDING AND FINISHING THE CONCRETE SLAB, BEAM AND COLUMN, according to claim 1, characterized by claws (204) or (304) or (406) to be positioned inclined.

7. ASSEMBLY OF PROFILES FOR SUSTAINING, MOLDING AND FINISHING THE CONCRETE SLAB, BEAM AND COLUMN, according to claim 1, characterized by the fitting (203A) being replaced by a fitting (203B) with a vertical engagement and an inside opening in the profile (200).

8. ASSEMBLY OF PROFILES FOR SUSTAINING, MOLDING AND FINISHING THE CONCRETE SLAB, BEAM AND COLUMN, according to claim 1, characterized by the female fittings (401) having inner shoulders.

9. ASSEMBLY OF PROFILES FOR SUSTAINING, MOLDING AND FINISHING THE CONCRETE SLAB, BEAM AND COLUMN, according to claim 1, characterized by the inner shoulders are of the swallowtail type.

10. ASSEMBLY OF PROFILES FOR SUSTAINING, MOLDING AND FINISHING THE CONCRETE SLAB, BEAM AND COLUMN, according to claim 1, characterized by the end of the profile (400) being closed.

11. ASSEMBLY OF PROFILES FOR SUSTAINING, MOLDING AND FINISHING THE CONCRETE SLAB, BEAM AND COLUMN, according to claim 1, characterized by the end of the profile (400) being closed by a cap (410), with a compatible cross section to be fitted at the end of the profile (400).

12. ASSEMBLY OF PROFILES FOR SUSTAINING, MOLDING AND FINISHING THE CONCRETE SLAB, BEAM AND COLUMN, according to claim 1, characterized by the profile (400) being shaped with chamfers (403) or fillets.

13. ASSEMBLY OF PROFILES FOR SUSTAINING, MOLDING AND FINISHING THE CONCRETE SLAB, BEAM AND COLUMN, according to claim 1, characterized by the fitting (201) being compatible to engage the fitting (203A) of another profile (200); And the fitting (201) is compatible to engage the fitting (203B) to form a corner with another profile (200); And the fitting (201) is compatible to engage the fitting (302) so as to form a corner with the profile (300); And the fitting (303) of the profile 300 is compatible to engage the fitting (203A) to form a wall extension with the profile (200), and the fitting (303) is compatible to engage the fitting (203B), so as to form a corner with a profile (200), and the fitting (303) is compatible to engage the fitting (302) so as to form a corner with another fitting (300); And the fitting (203B) of the profile (200) is compatible so as to engage the fitting (101) of the plate (100) forming the side of the slab.