WO2000075460A1 - Formwork for building construction - Google Patents

Formwork for building construction Download PDF

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Publication number
WO2000075460A1
WO2000075460A1 PCT/IB2000/000742 IB0000742W WO0075460A1 WO 2000075460 A1 WO2000075460 A1 WO 2000075460A1 IB 0000742 W IB0000742 W IB 0000742W WO 0075460 A1 WO0075460 A1 WO 0075460A1
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WO
WIPO (PCT)
Prior art keywords
formwork
elements
panels
operative
concrete slab
Prior art date
Application number
PCT/IB2000/000742
Other languages
French (fr)
Inventor
Wolfgang Adolf Binder
Original Assignee
Wolfgang Adolf Binder
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Wolfgang Adolf Binder filed Critical Wolfgang Adolf Binder
Priority to AU47739/00A priority Critical patent/AU4773900A/en
Publication of WO2000075460A1 publication Critical patent/WO2000075460A1/en

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Classifications

    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04F—FINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS
    • E04F11/00—Stairways, ramps, or like structures; Balustrades; Handrails
    • E04F11/02—Stairways; Layouts thereof
    • E04F11/022—Stairways; Layouts thereof characterised by the supporting structure
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
    • E04B5/00—Floors; Floor construction with regard to insulation; Connections specially adapted therefor
    • E04B5/16—Load-carrying floor structures wholly or partly cast or similarly formed in situ
    • E04B5/17—Floor structures partly formed in situ
    • E04B5/18—Floor structures partly formed in situ with stiffening ribs or other beam-like formations wholly cast between filling members
    • E04B5/19—Floor structures partly formed in situ with stiffening ribs or other beam-like formations wholly cast between filling members the filling members acting as self-supporting permanent forms
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
    • E04B5/00—Floors; Floor construction with regard to insulation; Connections specially adapted therefor
    • E04B5/16—Load-carrying floor structures wholly or partly cast or similarly formed in situ
    • E04B5/32—Floor structures wholly cast in situ with or without form units or reinforcements
    • E04B5/36—Floor structures wholly cast in situ with or without form units or reinforcements with form units as part of the floor
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04G—SCAFFOLDING; FORMS; SHUTTERING; BUILDING IMPLEMENTS OR AIDS, OR THEIR USE; HANDLING BUILDING MATERIALS ON THE SITE; REPAIRING, BREAKING-UP OR OTHER WORK ON EXISTING BUILDINGS
    • E04G11/00—Forms, shutterings, or falsework for making walls, floors, ceilings, or roofs
    • E04G11/36—Forms, shutterings, or falsework for making walls, floors, ceilings, or roofs for floors, ceilings, or roofs of plane or curved surfaces end formpanels for floor shutterings
    • E04G11/40—Forms, shutterings, or falsework for making walls, floors, ceilings, or roofs for floors, ceilings, or roofs of plane or curved surfaces end formpanels for floor shutterings for coffered or ribbed ceilings
    • E04G11/46—Forms, shutterings, or falsework for making walls, floors, ceilings, or roofs for floors, ceilings, or roofs of plane or curved surfaces end formpanels for floor shutterings for coffered or ribbed ceilings of hat-like or trough-like shape encasing a rib or the section between two ribs or encasing one rib and its adjacent flat floor or ceiling section

Definitions

  • THIS I NVENTION relates to formwork for building construction.
  • the invention relates particularly to formwork elements for forming a formwork for concrete slabs to be cast in situ, and to a method of casting concrete slabs, in situ, with the aid of such formwork elements.
  • the most commonly used formwork for concrete slabs to be cast in situ comprises an arrangement of metal panels that are supported by a suitable supporting structure in a required elevated configuration above a support surface.
  • a suitable supporting structure in a required elevated configuration above a support surface.
  • metal panels used for formwork generally are relatively difficult to handle and to support, while the inherent inflexibility of the panels, being formed of metal, renders it extremely difficult to accommodate situations that require panels to fit in locations where standard panels cannot fit.
  • This inflexibility of metal panels also permits little flexibility in respect of the configuration of the operative bottom faces of cast slabs and often requires these faces to be covered, typically by suspended ceilings, or the like. It is thus an object of this invention to provide formwork elements for forming formwork for casting concrete slabs in situ, in respect of which the above disadvantages associated with the use of metal panels for forming formwork is at least ameliorated.
  • formwork elements for forming a formwork for a concrete slab to be cast in situ, which formwork elements comprise
  • substantially rectangular panels formed of either one of polystyrene and polyurethane, that define two oppositely directed major faces, two side faces and two end faces;
  • the panels define an elongate groove in each side face thereof along the length thereof and the spacer elements define complementary formations locatable in the grooves of adjacently positioned panels, to provide for their operative configuration in which they form a formwork for a concrete slab.
  • the spacer elements may be profiled to define a substantially continuous operative bottom face with the operative bottom faces of adjacently positioned panels when disposed in their operative configuration in which they form a formwork for a concrete slab.
  • the side faces of the panels in their operative configuration in which they form a formwork for a concrete slab, may taper towards one another from the operative top face side thereof towards the operative bottom face side thereof, providing, in use, for the panels and the spacer elements to be locked into a concrete slab cast thereon by the concrete filling the spaces defined between the opposing side walls of the panels and above the operative top faces of the spacer elements.
  • An alternative embodiment of the invention provides for the side faces of the panels, in their operative configuration in which they form a formwork for a concrete slab, to taper towards one another from the operative bottom face side thereof towards the operative top face side thereof and for the spacer elements to define complementary tapering faces on their operative sides, the abutment of the complementary tapering faces of the side walls of the panels and of the spacer elements, in their operative configuration in which they form a formwork for a concrete slab, providing for the secure location of the spacer elements between their respectively adjacently positioned panels.
  • each panel may comprise a base member defining a hollow cellular structure and a lid member locatable on the base member.
  • the base member and the lid member may define complementary locating formations that engage one another by the location of the lid member on the base member, for securing the location of the lid member on the base member.
  • the spacer elements may be formed of either one of polystyrene and polyurethane.
  • the formwork elements also can be formed of other similar materials having similar physical qualities and the scope of the invention must be interpreted as such.
  • the panels may have reinforcing elements located therein for providing the panels with their required strength qualities.
  • the reinforcing elements may include reinforcing bars, rods, and the like, of metal, a polycarbonate material, or any other material having required strength qualities.
  • the elongate spacer elements may define transversely extending spaced projections along the length thereof on the operative top face side thereof, the projections providing support formations for reinforcing members to be located within the spaces between the side walls of adjacently positioned panels above the spacer elements, in the operative configuration of the panels and the spacer elements in which they form a formwork.
  • the operative length of the panels and of the spacer elements may be such that they can span the entire space between two support walls on which opposite ends of a concrete slab is to be supported.
  • the formwork elements of the invention also may include locating elements for securely locating panels in an end-to-end relationship with respect to one another in an operative configuration in which they form formwork for a concrete slab.
  • the locating elements may be equivalently configured to the spacer elements and the end faces of the panels may be equivalently configured to the side faces thereof, for cooperating with the locating elements.
  • the formwork elements may include also elongate reinforcing elements that are locatable between the panels and the spacer elements in a configuration in which they enhance the structural strength of the formwork formed of the panels and the spacer elements for supporting the load of concrete to be cast thereon. Particularly for panels having grooves defined in the operative side faces thereof, the reinforcing elements may be formed to be located within these grooves.
  • a method of casting, in situ, a concrete slab which includes the steps of
  • a formwork of formwork elements in accordance with the invention, by supporting, at a required elevated level above a support surface with the aid of a suitable supporting structure, the panels of the formwork elements and the spacer elements of the formwork elements in an adjacently positioned operative configuration in which the spacer elements hold the panels in a spaced configuration and the operative top faces of the spacer elements are disposed beneath the operative top faces of the panels;
  • the method of the invention may include also removing the supporting structure for the formwork elements after the concrete has set and cured sufficiently.
  • the method of the invention may include applying a finishing layer to a substantially continuous operative bottom face defined by the panels and the spacer elements, to provide said face with a required ceiling finish.
  • the method of the invention may include separating the panels and the spacer elements from the concrete slab formed.
  • the invention extends also to substantially rectangular panels that can form part of formwork elements, in accordance with the invention, and to spacer elements that can form part of formwork elements, in accordance with the invention.
  • Figure 1 shows an exploded three-dimensional view of a polystyrene panel forming part of formwork elements for forming a formwork for a concrete slab to be cast in situ, in accordance with the invention
  • Figure 2 illustrates in cross-sectional end view a first mode of use of panels, as shown in Figure 1 ;
  • Figure 3 illustrates in cross-sectional side view an extension of the first mode of use of panels as shown in Figure 1 ;
  • Figure 4 illustrates in cross-sectional end view a second mode of use of panels, as shown in Figure 1 ;
  • Figure 5 illustrates in cross-sectional side view a special application of the panels, as shown in Figure 1 .
  • one of a set of formwork elements for forming a formwork for a concrete slab to be cast in situ comprises a substantially rectangular polystyrene panel, designated generally by the reference numeral 10.
  • the panel 10 comprises a base part 1 2, that defines an open cellular structure as shown, and a lid 14 that fits securely on the base part 1 2, thus providing for the panel 10 to be hollow.
  • the base part 1 2 and the lid 1 4 particularly define complementary formations 1 6 which cooperate with one another for the secure location of the lid 14 on the base part 1 2 and also to provide horizontal shear resistance between the parts during casting of concrete, as described hereafter.
  • the lid 14 applied to the base part 1 2 the resulting panel defines two oppositely directed major faces 1 8, two side faces 20 and two end faces 22.
  • the opposite side faces 20 each have an elongate groove 24 defined therein along the length thereof.
  • the dimensions of the panel 10 are greatly variable and it is envisaged in particular that the operative width of the panel 10 can be in the order of 500mm, whereas the length can be determined by the application of the panel, which is referred to in more detail hereafter. It is envisaged in the above regard also that the length dimension of the panel 10 may be a multiple of the width dimension, thereby rendering panels modular and enhancing their versatility in use, as is also described in more detail hereafter.
  • panels 10 are provided in combination with spacer elements 26 to form a formwork for a concrete slab to be cast in situ.
  • the spacer elements each define a T-shaped cross-sectional profile as is illustrated clearly in Figure 2 of the drawings and, as such, define projecting formations 28 that extend along opposite sides thereof.
  • the projecting formations 28 define a complementary profile to that of the grooves 24 of the panels 10, providing for the secure location of spacer elements 26 between adjacently positioned panels 10, as shown.
  • the spacer elements 26 also are formed of polystyrene, the panels 10 and spacer elements 26 thus providing light weight formwork elements that can be easily handled and manipulated for forming a formwork for a concrete slab to be cast in situ, as described hereafter.
  • the panels 10 and spacer elements 26 can be provided in lengths which permit them to span the support walls and have opposite ends supported on the support walls.
  • a series of panels 10 will thus be located in a transverse configuration along the length of the support walls with adjacent panels having spacer elements 26 located between them, thus forming a formwork substantially as illustrated in Figure 2.
  • This formwork will be associated with a conventional support structure including support poles (see Figure 3) , thus providing for the necessary support for the formwork elements to serve as a formwork for a concrete slab to be cast.
  • the physical qualities including the material density, the configuration and the dimensions of the panels 10 and of the spacer elements 26 particularly are such that in their operative configuration as shown, in which they are supported to form a formwork for a concrete slab, the strength qualities thereof are such that they can support the concrete for the concrete slab to be cast thereon.
  • the panels 10 may have reinforcing bars 30 located therein.
  • reinforcing bars 32 may be located between the spacer elements 26 and the panels 10 within the grooves 24.
  • the physical qualities such as the material density, the configuration and the dimensions of the panels and the spacer elements can be easily varied to accommodate load requirements, polystyrene as such having suitable qualities that will permit its use for load bearing formwork elements for a formwork as envisaged .
  • polyurethane that has similar physical qualities to those of polystyrene, also can be used for forming panels 10 and spacer elements 26, as can other materials that are lightweight and that have similar qualities to that of polystyrene.
  • the spacer elements 26 may define a series of spaced projections 32 that project transversely to the longitudinal axis thereof, permitting reinforcing rods 34 to be supported thereon in a configuration in which these rods will become at least partially embedded in concrete cast on the formwork.
  • concrete 36 can be cast on the formwork to the required thickness of the concrete slab to be formed .
  • This concrete clearly will fill the spaces between the side walls of adjacently positioned panels above the operative top faces of the spacer elements to form concrete ribs, the dimensions of the ribs and the thickness of the concrete 36 above the operative top faces of the panels 10 being such that the concrete slab formed will comply with predetermined load bearing requirements.
  • the opposite side faces of the panels 10 taper towards one another from the operative top face side thereof to the operative bottom face side thereof and by setting and curing of the concrete 36 on the formwork, the panels 10 and spacer elements 26 will be locked into position with respect to the concrete slab formed, thus forming a structural part of the concrete slab formed.
  • the operative bottom faces thereof can define a substantially continuous surface that can conveniently serve as a ceiling surface, this surface either being substantially planar as shown in the region 38, or being profiled as shown in the region 40.
  • This ceiling surface can have a finishing layer 42 of any required material applied thereto to provide the slab with a required ceiling finish and for panels having projections 43 projecting therefrom, the projections may determine the minimum thickness of the layer 42 for providing a flush surface.
  • the formwork will be relatively light weight, the cost of support thereof also will be less than the cost of supporting conventional metal formwork. Still further, the volume of concrete utilised for forming the slab can be optimised and essentially minimised, particularly insofar as the formwork elements will form a part of the concrete slab formed . As such, the overall method of casting a concrete slab with the aid of formwork elements as envisaged can be carried out very cost effectively, particularly when compared with conventional methods, and insofar as the panels 10 and spacer element 26 will form a part of the slab formed, the heat insulating qualities of the slab can save on future heating or cooling costs.
  • elements 26 also can form a secondary waterproofing barrier where the slab formed serves as roofing .
  • FIG. 3 of the drawings an alternative configuration formwork supported by a support structure incorporating support poles 41 is shown, the formwork illustrating two panels 10 utilised perpendicularly with respect to one another.
  • one end face of the panel 1 0.1 also has a groove, equivalent to the groove 24 as shown in Figure 1 , formed therein.
  • a spacer element 26 therefore can be used between the two panels 1 0 for their location with respect to one another and it will be appreciated in this regard that particularly by dimensioning panels in a manner in which modular use is facilitated, many different configuration formworks can be provided that will accommodate the method of casting, in situ, a concrete slab as herein envisaged.
  • panels could be supported in an end-to-end configuration and also in a configuration in which the concrete ribs formed are disposed transversely with respect to one another, particularly to accommodate physical requirements of slabs to be formed .
  • Figure 4 shows an alternative mode of use of panels 10 for forming a formwork, the panels 10 in this configuration formwork being inverted so that the side walls thereof taper towards one another from the operative bottom face side of the panels to the operative top side thereof.
  • spacer elements 50 defining complementary tapering side faces can be provided for location between adjacent panels 10, following which the method of forming a concrete slab as above defined can be carried out as before.
  • the panels 10 and the spacer elements 50 can be removed from the concrete structure, this being permitted by the taper of the panels.
  • a bond breaker in the form of a water-based oil may be applied to the elements before the concrete is cast, or a polythene sheeting liner (not shown) may be applied for the same purpose on the formwork elements, before positioning the required slab reinforcing .
  • a sloping concrete slab 60 can be formed, essentially in accordance with the method described above and with the aid of polystyrene formwork elements, the operative top concrete layer 62 of the concrete slab permitting polystyrene tread formations to be applied thereto to form the tread of a staircase.
  • the method of forming a concrete slab as herein envisaged thus accommodates the construction of a staircase.
  • the polystyrene tread formations can be conveniently covered with any suitable covering material 66 in order to finish the staircase and it will again be understood in this regard that many different configuration staircases can be constructed by utilising this method, as well as other structures that require a concrete slab.

Abstract

The invention relates to formwork for concrete slabs to be cast in situ. The formwork comprises formwork elements including polystyrene panels (10) and polystyrene spacer elements (26) that can be supported by a suitable support structure at a required elevated level above a support surface in a configuration in which they define a formwork for a concrete slab. The panels (10) and the spacer elements (26) are configured so that they engage one another when forming a formwork in a configuration in which their inherent strength qualities and their mode of inter-engagement permit the support of the load of concrete cast thereon when forming a slab. The formwork elements also are configured so that they can form an integrated part of a slab formed, when their operative bottom faces can provide a ceiling finish.

Description

FORMWORK FOR BUILDING CONSTRUCTION
THIS I NVENTION relates to formwork for building construction.
The invention relates particularly to formwork elements for forming a formwork for concrete slabs to be cast in situ, and to a method of casting concrete slabs, in situ, with the aid of such formwork elements.
The most commonly used formwork for concrete slabs to be cast in situ comprises an arrangement of metal panels that are supported by a suitable supporting structure in a required elevated configuration above a support surface. Insofar as the configuration of the metal panels used for such formwork and their mode of support are already well known and do not form a part of the present invention, the above are not described in any further detail herein.
It is also known that metal panels used for formwork generally are relatively difficult to handle and to support, while the inherent inflexibility of the panels, being formed of metal, renders it extremely difficult to accommodate situations that require panels to fit in locations where standard panels cannot fit. This inflexibility of metal panels also permits little flexibility in respect of the configuration of the operative bottom faces of cast slabs and often requires these faces to be covered, typically by suspended ceilings, or the like. It is thus an object of this invention to provide formwork elements for forming formwork for casting concrete slabs in situ, in respect of which the above disadvantages associated with the use of metal panels for forming formwork is at least ameliorated.
According to a first aspect of the invention there is provided formwork elements for forming a formwork for a concrete slab to be cast in situ, which formwork elements comprise
substantially rectangular panels, formed of either one of polystyrene and polyurethane, that define two oppositely directed major faces, two side faces and two end faces; and
elongate spacer elements that are positionable with respect to the panels in an operative configuration in which the panels are held in a spaced relationship with respect to one another and in which the operative top faces of the spacer elements are disposed operatively beneath the operative top faces of the panels, and in which operative configuration the panels and the spacer elements can be supported above a support surface to form a formwork for a concrete slab, the physical qualities, the configuration and the dimensions of the panels and the spacer elements being such that in their operative configuration in which they are supported to form a formwork for a concrete slab, the strength qualities thereof are such that they can support the concrete for a concrete slab to be cast thereon.
According to one particular embodiment of the invention, the panels define an elongate groove in each side face thereof along the length thereof and the spacer elements define complementary formations locatable in the grooves of adjacently positioned panels, to provide for their operative configuration in which they form a formwork for a concrete slab. Also, the spacer elements may be profiled to define a substantially continuous operative bottom face with the operative bottom faces of adjacently positioned panels when disposed in their operative configuration in which they form a formwork for a concrete slab.
Still further according to this embodiment of the invention, the side faces of the panels, in their operative configuration in which they form a formwork for a concrete slab, may taper towards one another from the operative top face side thereof towards the operative bottom face side thereof, providing, in use, for the panels and the spacer elements to be locked into a concrete slab cast thereon by the concrete filling the spaces defined between the opposing side walls of the panels and above the operative top faces of the spacer elements.
An alternative embodiment of the invention provides for the side faces of the panels, in their operative configuration in which they form a formwork for a concrete slab, to taper towards one another from the operative bottom face side thereof towards the operative top face side thereof and for the spacer elements to define complementary tapering faces on their operative sides, the abutment of the complementary tapering faces of the side walls of the panels and of the spacer elements, in their operative configuration in which they form a formwork for a concrete slab, providing for the secure location of the spacer elements between their respectively adjacently positioned panels.
For both the above embodiments of formwork elements, the panels may comprise hollow bodies. As such, each panel may comprise a base member defining a hollow cellular structure and a lid member locatable on the base member. The base member and the lid member may define complementary locating formations that engage one another by the location of the lid member on the base member, for securing the location of the lid member on the base member.
Also for both the above embodiments of formwork elements, the spacer elements may be formed of either one of polystyrene and polyurethane. For purposes of this invention, the formwork elements also can be formed of other similar materials having similar physical qualities and the scope of the invention must be interpreted as such.
Still further, for both the above embodiments of the formwork elements, the panels may have reinforcing elements located therein for providing the panels with their required strength qualities. The reinforcing elements may include reinforcing bars, rods, and the like, of metal, a polycarbonate material, or any other material having required strength qualities.
The elongate spacer elements may define transversely extending spaced projections along the length thereof on the operative top face side thereof, the projections providing support formations for reinforcing members to be located within the spaces between the side walls of adjacently positioned panels above the spacer elements, in the operative configuration of the panels and the spacer elements in which they form a formwork.
The operative length of the panels and of the spacer elements may be such that they can span the entire space between two support walls on which opposite ends of a concrete slab is to be supported.
For formwork in which the panels and spacer elements will not span the entire space between two support walls on which opposite ends of a concrete slab is to be supported, the formwork elements of the invention also may include locating elements for securely locating panels in an end-to-end relationship with respect to one another in an operative configuration in which they form formwork for a concrete slab. The locating elements may be equivalently configured to the spacer elements and the end faces of the panels may be equivalently configured to the side faces thereof, for cooperating with the locating elements. The formwork elements may include also elongate reinforcing elements that are locatable between the panels and the spacer elements in a configuration in which they enhance the structural strength of the formwork formed of the panels and the spacer elements for supporting the load of concrete to be cast thereon. Particularly for panels having grooves defined in the operative side faces thereof, the reinforcing elements may be formed to be located within these grooves.
According to a second aspect of the invention, there is provided a method of casting, in situ, a concrete slab, which includes the steps of
forming a formwork of formwork elements, in accordance with the invention, by supporting, at a required elevated level above a support surface with the aid of a suitable supporting structure, the panels of the formwork elements and the spacer elements of the formwork elements in an adjacently positioned operative configuration in which the spacer elements hold the panels in a spaced configuration and the operative top faces of the spacer elements are disposed beneath the operative top faces of the panels;
positioning required reinforcing for the concrete slab to be cast on the formwork;
casting concrete on the formwork to the required thickness of the concrete slab to be formed; and
allowing the concrete to set and cure.
The method of the invention may include also removing the supporting structure for the formwork elements after the concrete has set and cured sufficiently.
Particularly for formwork elements having panels with side faces that taper towards one another from the operative top face side thereof to the operative bottom face side thereof, in which the elements upon setting and curing of the concrete are integrated with the concrete, the method of the invention may include applying a finishing layer to a substantially continuous operative bottom face defined by the panels and the spacer elements, to provide said face with a required ceiling finish.
Particularly for formwork elements having panels with side faces that taper towards one another from the operative bottom face side thereof to the operative top face side thereof, after the removal of the supporting structure for the formwork, the method of the invention may include separating the panels and the spacer elements from the concrete slab formed.
The invention extends also to substantially rectangular panels that can form part of formwork elements, in accordance with the invention, and to spacer elements that can form part of formwork elements, in accordance with the invention.
Further features of the formwork elements, in accordance with the first aspect of the invention, and of the method of casting, in situ, a concrete slab, in accordance with the second aspect of the invention, including the benefits associated with the use of the formwork elements and the method, are described hereafter, by way of example, with reference to the accompanying diagrammatic drawings. In the drawings:
Figure 1 shows an exploded three-dimensional view of a polystyrene panel forming part of formwork elements for forming a formwork for a concrete slab to be cast in situ, in accordance with the invention;
Figure 2 illustrates in cross-sectional end view a first mode of use of panels, as shown in Figure 1 ;
Figure 3 illustrates in cross-sectional side view an extension of the first mode of use of panels as shown in Figure 1 ; Figure 4 illustrates in cross-sectional end view a second mode of use of panels, as shown in Figure 1 ; and
Figure 5 illustrates in cross-sectional side view a special application of the panels, as shown in Figure 1 .
Referring initially to Figure 1 of the drawings, one of a set of formwork elements for forming a formwork for a concrete slab to be cast in situ, in accordance with the invention, comprises a substantially rectangular polystyrene panel, designated generally by the reference numeral 10. The panel 10 comprises a base part 1 2, that defines an open cellular structure as shown, and a lid 14 that fits securely on the base part 1 2, thus providing for the panel 10 to be hollow. The base part 1 2 and the lid 1 4 particularly define complementary formations 1 6 which cooperate with one another for the secure location of the lid 14 on the base part 1 2 and also to provide horizontal shear resistance between the parts during casting of concrete, as described hereafter. With the lid 14 applied to the base part 1 2, the resulting panel defines two oppositely directed major faces 1 8, two side faces 20 and two end faces 22. The opposite side faces 20 each have an elongate groove 24 defined therein along the length thereof.
The dimensions of the panel 10 are greatly variable and it is envisaged in particular that the operative width of the panel 10 can be in the order of 500mm, whereas the length can be determined by the application of the panel, which is referred to in more detail hereafter. It is envisaged in the above regard also that the length dimension of the panel 10 may be a multiple of the width dimension, thereby rendering panels modular and enhancing their versatility in use, as is also described in more detail hereafter.
Referring also to Figure 2 of the drawings, panels 10 are provided in combination with spacer elements 26 to form a formwork for a concrete slab to be cast in situ. The spacer elements each define a T-shaped cross-sectional profile as is illustrated clearly in Figure 2 of the drawings and, as such, define projecting formations 28 that extend along opposite sides thereof. The projecting formations 28 define a complementary profile to that of the grooves 24 of the panels 10, providing for the secure location of spacer elements 26 between adjacently positioned panels 10, as shown. The spacer elements 26 also are formed of polystyrene, the panels 10 and spacer elements 26 thus providing light weight formwork elements that can be easily handled and manipulated for forming a formwork for a concrete slab to be cast in situ, as described hereafter.
In their simplest mode of use, for casting a concrete slab that must extend across two spaced support walls, the panels 10 and spacer elements 26 can be provided in lengths which permit them to span the support walls and have opposite ends supported on the support walls. A series of panels 10 will thus be located in a transverse configuration along the length of the support walls with adjacent panels having spacer elements 26 located between them, thus forming a formwork substantially as illustrated in Figure 2. This formwork will be associated with a conventional support structure including support poles (see Figure 3) , thus providing for the necessary support for the formwork elements to serve as a formwork for a concrete slab to be cast.
The physical qualities including the material density, the configuration and the dimensions of the panels 10 and of the spacer elements 26 particularly are such that in their operative configuration as shown, in which they are supported to form a formwork for a concrete slab, the strength qualities thereof are such that they can support the concrete for the concrete slab to be cast thereon. It is envisaged in this regard that the panels 10 may have reinforcing bars 30 located therein. It is envisaged also that reinforcing bars 32 may be located between the spacer elements 26 and the panels 10 within the grooves 24. It will be appreciated in this regard that the physical qualities such as the material density, the configuration and the dimensions of the panels and the spacer elements can be easily varied to accommodate load requirements, polystyrene as such having suitable qualities that will permit its use for load bearing formwork elements for a formwork as envisaged . It must be appreciated that polyurethane, that has similar physical qualities to those of polystyrene, also can be used for forming panels 10 and spacer elements 26, as can other materials that are lightweight and that have similar qualities to that of polystyrene.
In order to cast a concrete slab utilising formwork elements as described, following the construction of the formwork and the effective support thereof by a support structure, reinforcing for the concrete slab to be cast can be positioned on the formwork. In this regard, the spacer elements 26 may define a series of spaced projections 32 that project transversely to the longitudinal axis thereof, permitting reinforcing rods 34 to be supported thereon in a configuration in which these rods will become at least partially embedded in concrete cast on the formwork.
Following the positioning of the formwork elements as described and the positioning of the required reinforcing for the concrete slab to be cast, concrete 36 can be cast on the formwork to the required thickness of the concrete slab to be formed . This concrete clearly will fill the spaces between the side walls of adjacently positioned panels above the operative top faces of the spacer elements to form concrete ribs, the dimensions of the ribs and the thickness of the concrete 36 above the operative top faces of the panels 10 being such that the concrete slab formed will comply with predetermined load bearing requirements.
As is illustrated clearly in Figure 2 of the drawings, the opposite side faces of the panels 10 taper towards one another from the operative top face side thereof to the operative bottom face side thereof and by setting and curing of the concrete 36 on the formwork, the panels 10 and spacer elements 26 will be locked into position with respect to the concrete slab formed, thus forming a structural part of the concrete slab formed. It will be appreciated in the above regard that in the operative configuration of the panels 10 and reinforcing elements 26, the operative bottom faces thereof can define a substantially continuous surface that can conveniently serve as a ceiling surface, this surface either being substantially planar as shown in the region 38, or being profiled as shown in the region 40. This ceiling surface can have a finishing layer 42 of any required material applied thereto to provide the slab with a required ceiling finish and for panels having projections 43 projecting therefrom, the projections may determine the minimum thickness of the layer 42 for providing a flush surface.
It will be understood that by using polystyrene formwork elements as proposed for forming a formwork for a concrete slab, on the basis that the formwork elements are relatively light weight, the actual construction of the formwork can be easily dealt with. Furthermore, modifications can be easily effected on the polystyrene formwork elements in order to accommodate special requirements, whereas the mode of inter- engagement of the panels 10 and the spacer elements 26 is such that a substantially concrete slurry proof seal is provided between them, or even a waterproof seal where required for special applications. This mode of inter-engagement also can optimise the load distribution of concrete loads acting on the panels and the spacer elements during casting of concrete.
Because the formwork will be relatively light weight, the cost of support thereof also will be less than the cost of supporting conventional metal formwork. Still further, the volume of concrete utilised for forming the slab can be optimised and essentially minimised, particularly insofar as the formwork elements will form a part of the concrete slab formed . As such, the overall method of casting a concrete slab with the aid of formwork elements as envisaged can be carried out very cost effectively, particularly when compared with conventional methods, and insofar as the panels 10 and spacer element 26 will form a part of the slab formed, the heat insulating qualities of the slab can save on future heating or cooling costs. The panels 10 and spacer - 1 1 -
elements 26 also can form a secondary waterproofing barrier where the slab formed serves as roofing .
Referring also to Figure 3 of the drawings, an alternative configuration formwork supported by a support structure incorporating support poles 41 is shown, the formwork illustrating two panels 10 utilised perpendicularly with respect to one another. For this purpose one end face of the panel 1 0.1 also has a groove, equivalent to the groove 24 as shown in Figure 1 , formed therein. A spacer element 26 therefore can be used between the two panels 1 0 for their location with respect to one another and it will be appreciated in this regard that particularly by dimensioning panels in a manner in which modular use is facilitated, many different configuration formworks can be provided that will accommodate the method of casting, in situ, a concrete slab as herein envisaged. For example, panels could be supported in an end-to-end configuration and also in a configuration in which the concrete ribs formed are disposed transversely with respect to one another, particularly to accommodate physical requirements of slabs to be formed .
Figure 4 shows an alternative mode of use of panels 10 for forming a formwork, the panels 10 in this configuration formwork being inverted so that the side walls thereof taper towards one another from the operative bottom face side of the panels to the operative top side thereof. With panels 1 0 used in this configuration, spacer elements 50 defining complementary tapering side faces can be provided for location between adjacent panels 10, following which the method of forming a concrete slab as above defined can be carried out as before. Following sufficient setting and curing of a concrete slab formed and the removal of the support structure of the formwork, the panels 10 and the spacer elements 50 can be removed from the concrete structure, this being permitted by the taper of the panels. In this mode of use of the panels 10, they will not form a part of the concrete slab formed and repeated use of the formwork elements is thus enabled. In order to prevent adhesion between the formwork elements and the concrete, a bond breaker in the form of a water-based oil may be applied to the elements before the concrete is cast, or a polythene sheeting liner (not shown) may be applied for the same purpose on the formwork elements, before positioning the required slab reinforcing .
Instead of using spacer elements 50 for the above mode of use of the panel 10, timber planks supported beneath the spaced side edges of the panels 10 can be used. Also, instead of using panels 10 as shown, panels that are specially adapted for this mode of use also may be provided.
Referring to Figure 5 of the drawings, it is envisaged also that a sloping concrete slab 60 can be formed, essentially in accordance with the method described above and with the aid of polystyrene formwork elements, the operative top concrete layer 62 of the concrete slab permitting polystyrene tread formations to be applied thereto to form the tread of a staircase. The method of forming a concrete slab as herein envisaged thus accommodates the construction of a staircase. The polystyrene tread formations can be conveniently covered with any suitable covering material 66 in order to finish the staircase and it will again be understood in this regard that many different configuration staircases can be constructed by utilising this method, as well as other structures that require a concrete slab.
It will be understood that the configurations of the polystyrene formwork elements are greatly variable while still incorporating the principles of the invention as herein described and the invention extends also to all such alternative configurations formwork elements which still incorporate these principles. The invention extends also to all different configuration individual formwork elements which in combination can form a formwork for a concrete slab as herein envisaged and described.

Claims

1 . Formwork elements for forming a formwork for a concrete slab to be cast in situ, which formwork elements comprise
substantially rectangular panels, formed of either one of polystyrene and polyurethane, that define two oppositely directed major faces, two side faces and two end faces; and
elongate spacer elements that are positionable with respect to the panels in an operative configuration in which the panels are held in a spaced relationship with respect to one another and in which the operative top faces of the spacer elements are disposed operatively beneath the operative top faces of the panels, and in which operative configuration the panels and the spacer elements can be supported above a support surface to form a formwork, for a concrete slab, the physical qualities, the configuration and the dimensions of the panels and the spacer elements being such that in their operative configuration in which they are supported to form a formwork for a concrete slab, the strength qualities thereof are such that they can support the concrete for a concrete slab to be cast thereon.
2. Formwork elements as claimed in Claim 1 , in which the panels define an elongate groove in each side face thereof along the length thereof and the spacer elements define complementary formations locatable in the grooves of adjacently positioned panels, to provide for their operative configuration in which they form a formwork for a concrete slab.
3. Formwork elements as claimed in Claim 1 or Claim 2, in which the spacer elements are profiled to define a substantially continuous operative bottom face with the operative bottom faces of adjacently positioned panels when disposed in their operative configuration in which they form a formwork for a concrete slab.
. Formwork elements as claimed in any one of the preceding claims, in which the side faces of the panels in their operative configuration in which they define a formwork for a concrete slab, taper towards one another from the operative top side thereof towards the operative bottom face side thereof, providing for the panels and the spacer elements to be locked into a concrete slab cast thereon by the concrete filling the spaces defined between the opposing side walls of the panels and above the operative top faces of the spacer elements.
5. Formwork elements as claimed in Claim 1 , in which the side faces of the panels, in their operative configuration in which they form a formwork for a concrete slab, taper towards one another from the operative bottom face side thereof towards the operative top face side thereof and in which the spacer elements define complementary tapering faces on their operative sides, the abutment of the complementary tapering faces of the side walls of the panels and of the spacer elements, in their operative configuration in which they form a formwork for a concrete slab, providing for the secure location of the spacer elements between their respectively adjacently positioned panels.
6. Framework elements as claimed in any one of the preceding claims, in which the panels comprise hollow bodies.
7. Framework elements as claimed in Claim 6, in which each panel comprises a base member defining a hollow cellular structure and a lid member locatable on the base member.
8. Framework elements as claimed in Claim 7, in which the base member and the lid member define complementary locating formations that engage one another by the location of the lid member on the base member, for securing the location of the lid member on the base member.
. Framework elements as claimed in any one of the preceding claims, in which the spacer elements are formed of either one of polystyrene and polyurethane.
10. Framework elements as claimed in any one of the preceding claims, in which the panels have reinforcing elements located therein for providing the panels with their required strength qualities.
1 1 . Framework elements as claimed in any one of the preceding claims, in which the elongate spacer elements define transversely extending spaced projections along the length thereof on the operative top face side thereof, the projections providing support formations for reinforcing members to be located within the spaces between the side walls of adjacently positioned panels above the spacer elements, in the operative configuration of the panels and the spacer elements in which they form a formwork.
1 2. Formwork elements as claimed in any one of the preceding claims, in which the operative lengths of the panels and of the spacer elements are such that they can span the entire space between support walls on which opposite ends of a concrete slab is to be supported.
13. Formwork elements as claimed in any one of Claims 1 to 1 1 , which includes locating elements for securely locating panels in an end-to-end relationship with respect to one another in an operative configuration in which they form formwork for a concrete slab.
14. Formwork elements as claimed in Claim 1 3, in which the locating elements are equivalently configured to the spacer elements and the end faces of the panels are equivalently configured to the side faces thereof, for cooperating with the locating elements.
5. Formwork elements as claimed in any one of the preceding claims, which includes elongate reinforcing elements that are locatable between the panels and the spacer elements in a configuration in which they enhance the structural strength of the formwork formed of the panels and the spacer elements for supporting the load of concrete to be cast thereon.
6. Formwork elements as claimed in Claim 1 5, insofar as this claim is dependent on Claim 2, in which the reinforcing elements are formed to be located within the grooves defined in the operative side faces of the panels.
7. A method of casting, in situ, a concrete slab, which includes the steps of
forming a formwork of formwork elements, as claimed in any one of Claims 1 to
1 6, by supporting, at a required elevated level above a support surface with the aid of a suitable supporting structure, the panels of the formwork elements and the spacer elements of the formwork elements in an adjacently positioned operative configuration in which the spacer elements hold the panels in a spaced configuration and the operative top faces of the spacer elements are disposed beneath the operative top faces of the panels;
positioning required reinforcing for the concrete slab to be cast on the formwork;
casting concrete on the formwork to the required thickness of the concrete slab to be formed; and
allowing the concrete to set and cure.
8. A method as claimed in Claim 1 7, which includes removing the supporting structure for the formwork elements after the concrete has set and cured sufficiently.
1 9. A method as claimed in Claim 1 7 or Claim 1 8 and in which the formwork formed includes panels as claimed in Claim 4 and the formwork elements upon setting and curing of the concrete are integrated with the concrete, which includes applying a finishing layer to a substantially continuous operative bottom face defined by the panels and the spacer elements, to provide said face with a required ceiling finish.
20. A method as claimed in Claim 1 7 or Claim 1 8 and in which the formwork formed includes panels as claimed in Claim 5, which includes, after the removal of the supporting structure for the formwork, separating the panels and the spacer elements from the concrete slab formed.
21 . A substantially rectangular panel that can form part of formwork elements for forming a formwork for a concrete slab to be cast in situ, as claimed in any one of Claims 1 to 1 6.
22. A spacer element that can form part of formwork elements for forming a formwork for a concrete slab to be cast in situ, as claimed in any one of Claims 1 to 1 6.
23. Formwork elements for forming a formwork for a concrete slab to be cast in situ, substantially as described in the specification with reference to and as illustrated in the accompanying drawings.
24. A method of casting, in situ, a concrete slab, substantially as described in the specification with reference to and as illustrated in the accompanying drawings.
25. A panel for formwork for casting a concrete slab in situ, substantially as described in the specification with reference to and as illustrated in the accompanying drawings.
6. A spacer element for formwork for casting a concrete slab in situ, substantially as described in the specification with reference to and as illustrated in the accompanying drawings.
PCT/IB2000/000742 1999-06-07 2000-06-02 Formwork for building construction WO2000075460A1 (en)

Priority Applications (1)

Application Number Priority Date Filing Date Title
AU47739/00A AU4773900A (en) 1999-06-07 2000-06-02 Formwork for building construction

Applications Claiming Priority (8)

Application Number Priority Date Filing Date Title
ZA993803 1999-06-07
ZA99/3803 1999-06-07
ZA994761 1999-07-26
ZA99/4761 1999-07-26
ZA995186 1999-08-16
ZA99/5186 1999-08-16
ZA99/7552 1999-12-09
ZA997552 1999-12-09

Publications (1)

Publication Number Publication Date
WO2000075460A1 true WO2000075460A1 (en) 2000-12-14

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AU (1) AU4773900A (en)
WO (1) WO2000075460A1 (en)

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FR2850688A1 (en) * 2003-01-31 2004-08-06 Knauf Snc Structural floor unit connecting component, has base presenting form falling under section of structural floor unit and tooth presented on both sides, where tooth penetrates into full zones of adjacent structural floor unit
CN1293274C (en) * 2003-11-02 2007-01-03 邱则有 Concrete filled light mould member
CN1296585C (en) * 2003-11-02 2007-01-24 邱则有 Concrete filled light member
CN1296586C (en) * 2003-11-02 2007-01-24 邱则有 Concrete filled light mould member
CN1296582C (en) * 2003-10-01 2007-01-24 邱则有 Shuttering member
CN1296584C (en) * 2003-11-02 2007-01-24 邱则有 Concrete filled light mould member
CN1297720C (en) * 2003-10-21 2007-01-31 邱则有 Hollow component
CN1304710C (en) * 2003-11-02 2007-03-14 邱则有 Concrete filled light mould member
ES2274660A1 (en) * 2004-01-26 2007-05-16 Carlos Manuel Gonzalez Oppenheim Unidirectional forging system for hollow blocks combined with joists or beams for in-situ forging, involves forging hollow blocks from plates made of expanded polystyrene, and cutting hollow blocks for perfect alignment with each other
CN1325736C (en) * 2003-11-02 2007-07-11 邱则有 Concrete filled light mould member
CN1325737C (en) * 2003-11-02 2007-07-11 邱则有 Concrete filled light mould member
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CN100336996C (en) * 2003-11-02 2007-09-12 邱则有 Concrete filled light mould member
CN100342100C (en) * 2003-10-21 2007-10-10 邱则有 Hollow form component
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CN100354486C (en) * 2003-10-21 2007-12-12 邱则有 Thin wall pipe for concrete filling
CN100354488C (en) * 2003-10-30 2007-12-12 邱则有 Permanent shuttering member
CN100354489C (en) * 2003-10-30 2007-12-12 邱则有 Permanent shuttering member
CN100362185C (en) * 2002-04-30 2008-01-16 邱则有 Reinforced concrete building floor with solid load-carrying structure
CN100362188C (en) * 2003-10-21 2008-01-16 邱则有 Hollow form structural parts
CN100363571C (en) * 2002-04-30 2008-01-23 邱则有 Solid load-carrying shuttering used for reinforced concrete
CN100365221C (en) * 2002-04-30 2008-01-30 邱则有 Solid load-carrying shuttering used for reinforced concrete
CN100365219C (en) * 2003-11-02 2008-01-30 邱则有 Concrete filled light mould member
CN100365225C (en) * 2002-04-30 2008-01-30 邱则有 Stereo force bearing formwork for reinforced concrete
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CN100439625C (en) * 2003-10-01 2008-12-03 邱则有 Cast-in-situ hollow floor with shuttering member
CN100439618C (en) * 2002-04-30 2008-12-03 邱则有 Reinforced concrete building floor with solid load carrying structure
CN100439619C (en) * 2002-04-30 2008-12-03 邱则有 Reinforced concrete building floor with solid load-carrying structure
CN101158233B (en) * 2003-10-21 2010-06-02 邱则有 Cavity mould component
FR2942252A1 (en) * 2009-02-13 2010-08-20 Deltisol Floor block for concrete forming of concrete slab of concrete floor of building, has cleavable and breakable elements re-arranged on core to form transversal and longitudinal correctors to limit thermal bridges
CN101230732B (en) * 2004-05-25 2011-09-07 湖南邱则有专利战略策划有限公司 Bowl-shaped formwork component
CN101158201B (en) * 2003-10-21 2013-05-01 湖南邱则有专利战略策划有限公司 Cavity mould component

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FR784645A (en) * 1935-01-25 1935-07-22 Le Beton Ponce Ribbed reinforced concrete floor system
FR1368700A (en) * 1962-09-13 1964-07-31 lightweight formwork element for the construction of reinforced concrete rib ceilings
GB1545246A (en) * 1975-07-15 1979-05-02 Scheichenbauer M Thermoplastics resin extrudates for composite concrete floors
DE3318431A1 (en) * 1983-05-20 1984-11-22 Bernhard 7613 Hausach Künstle Ceiling element
EP0494061A1 (en) * 1991-01-03 1992-07-08 José Antonio Sainz de la Maza del Castillo A method and elements for assembling a non-recoverable formwork
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CN100402771C (en) * 2002-04-30 2008-07-16 邱则有 Reinforced concrete building floor with solid load-carrying structure
CN100362184C (en) * 2002-04-30 2008-01-16 邱则有 Reinforced concrete three-dimensional bearing structure floor
CN100408776C (en) * 2002-04-30 2008-08-06 邱则有 Reinforced concrete three-dimensional bearing structure floor
CN100386492C (en) * 2002-04-30 2008-05-07 邱则有 Steel reinforced concrete stereo force bearing structure floor slab
CN100402772C (en) * 2002-04-30 2008-07-16 邱则有 Building floor of reinforced concrete stereo force bearing structure
CN100402770C (en) * 2002-04-30 2008-07-16 邱则有 Reinforced concrete building floor with solid load-carrying structure
CN100365224C (en) * 2002-04-30 2008-01-30 邱则有 Stereo froce bearing form work for reinforced concrete
CN100439618C (en) * 2002-04-30 2008-12-03 邱则有 Reinforced concrete building floor with solid load carrying structure
CN100439619C (en) * 2002-04-30 2008-12-03 邱则有 Reinforced concrete building floor with solid load-carrying structure
CN100402769C (en) * 2002-04-30 2008-07-16 邱则有 Building floor of reinforced concrete stereo force bearing structure
CN100365223C (en) * 2002-04-30 2008-01-30 邱则有 Solid load-carrying shuttering used for reinforced concrete
CN100362185C (en) * 2002-04-30 2008-01-16 邱则有 Reinforced concrete building floor with solid load-carrying structure
CN100365225C (en) * 2002-04-30 2008-01-30 邱则有 Stereo force bearing formwork for reinforced concrete
CN100365221C (en) * 2002-04-30 2008-01-30 邱则有 Solid load-carrying shuttering used for reinforced concrete
CN100363571C (en) * 2002-04-30 2008-01-23 邱则有 Solid load-carrying shuttering used for reinforced concrete
FR2850688A1 (en) * 2003-01-31 2004-08-06 Knauf Snc Structural floor unit connecting component, has base presenting form falling under section of structural floor unit and tooth presented on both sides, where tooth penetrates into full zones of adjacent structural floor unit
CN100400767C (en) * 2003-03-04 2008-07-09 邱则有 Cast-in-situ concrete building floor
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