WO2009097899A1

WO2009097899A1 - Integral modular formwork

Info

Publication number: WO2009097899A1
Application number: PCT/EP2008/051471
Authority: WO
Inventors: Adolfo Tejedor Entisne; Beatriz Laborda Martos; Juan Carlos Reyes Torollo; David Tomás ELVIRA HERRANZ
Original assignee: Sistemas Industrializados Barcons, S.L.
Priority date: 2008-02-06
Filing date: 2008-02-06
Publication date: 2009-08-13

Abstract

The present invention relates to a high-precision, integrated modular formwork especially designed to increase resistance to the pressures exerted by concrete, comprising panels reinforced by means of additional ribs (10, 10a).

Description

INTEGRAL MODULAR FORMWORK

The present invention relates to a high-precision, integrated modular formwork especially designed to increase resistance to the pressures exerted by concrete.

BACKGROUND OF THE INVENTION

The applicant of the present invention is the holder thereof due to the transfer of patents 9401135 "Improvements in high-precision modular and integral formwork systems for the construction of reinforced concrete structures" and 200202648 "Improvements in the construction systems of reinforced concrete structures or other material by means of a high-precision modular and integral formwork."

The improvements disclosed by the two aforementioned inventions apply to a construction system for fences, walls, structures or complete constructions. Said system assembles an integral or complete construction formwork, disposing the necessary frames, insulations or installations in its interior, for the purpose of pouring special fluid concretes and, upon curing thereof and formwork removal, producing the fence, wall, structure or complete construction, with the exception of finishing touches such as installation of mechanisms, carpentry and bathroom fittings, tiling, paint, etc.

Said improvements basically consist of the use of formwork panels of patterned or normalized sizes, with high-quality finish and minimum tolerances, to produce perfectly regular construction elements without deformities or other defects, and by means of the necessary panel fixing means, in addition to other auxiliary means for assembling or manipulating the formwork and its constituent parts.

For a more complete understanding of the present invention, it is worth mentioning that reinforcements on the rear side of the panels appear in these patents; and also that the join between panels is carried out by means of perimeter flaps implemented therein, provided with orifices for the fitting of self- centering staples, and aided by conical separators with blocking nuts or seals that fix or tighten the formwork panels to the facing panels.

These conical separators establish the distance between the facing panels (concrete thickness), said panels being provided with orifices for their assembly, or semicircular or wedge-shaped notches on the sides or corners thereof designed to generate complete circular orifices upon joining of the panels, whereupon the panel or assembled panel orifices are axially aligned with those of the panels or facing panel assembly for the passage of the conical separators that fix said panels together and establish their separation.

The standard panel used consists of a front panel that forms the wall or floor slab fronts (front and back, or upper and lower part). Specialized panels for specific solutions are also disclosed in the preceding patents. Among these, unmolding panels are worth mentioning, one of the perimeter flaps whereof is tilted rather than disposed perpendicularly to the surface of the panel, diverging or opening as it is projected backwards to facilitate the removal of said panel as the first panel to be removed upon formwork removal.

Other specialized panels, called lid panels herein, are designed for the perimeter sealing of construction openings (windows, doors, etc.). The preceding patents have disposed lower lateral horizontal supports for these, by means of extensible horizontal separating elements that consist of a kind of horizontal screw with two end support strips which can be adapted to the lower part of both facing panels that laterally seal the construction opening in question.

Finally, it is worth mentioning the use, according to the preceding patents, of formwork panel alignment joists, which are secured by means of cantilevers that project therefrom.

Nevertheless, in many cases, particularly when the construction is of a certain height or requires certain wall thickness, deformities and misalignments may occur between the formwork panels, fundamentally in the lower parts thereof, which are subjected to greater pressure due to the weight of the concrete because, for example, it is not possible to fix the lower edges of the front panels to the wall front with conical separators, as these are disposed on the plate or floor slab and not on other panels to generate the passage orifices of the conical separators. In the same manner, although the alignment joists are easily secured to the cantilever, these do not offer the rigidity required in some cases.

A similar problem occurs in the construction of wall continuations on finished floor slabs or in the perimeter of construction openings: conical separators cannot be used to effectively immobilize the panels disposed in the lower part thereof.

DESCRIPTION OF THE INVENTION The formwork of the invention has a greater rigidity than that of other formworks, particularly in those areas most exposed to the pressures exerted by the concrete, with considerable savings and optimum construction finish.

According to the invention, the formwork comprises the inclusion of panels reinforced by means of additional ribs designed to receive the action of immobilizing elements, in such a manner that deformity of the formwork is prevented in these areas.

These immobilizing elements may be the conical separators themselves, with blocking seals or nuts, in the event that the panel is designed to form the main sides of a wall (front panel), horizontal thrust separation elements in the case of lid panels that laterally seal the perimeter of construction openings (doors, windows, etc.), or upper lid panel intermediate support props in the case of construction openings with large spans.

Additionally, the use of wall or floor slab continuation or overlapping panels, which are disposed on the finished part of a wall or floor slab and support the other panels that will configure the formwork of the wall or floor slab under construction, has also been provided in accordance with the invention.

A means of securing the formwork alignment joists, which improve alignment and in some cases also allow the installation of railings, highly useful in the case of outer wall formworks, has also been provided in accordance with the invention. BRIEF DESCRIPTION OF THE DRAWINGS

For the purpose of complementing this description and to aid towards a better understanding of the characteristics of the invention, a set of drawings has been included as an integral part of said description, in accordance with an example of preferred embodiment thereof, wherein the following figures have been represented in an illustrative and non-limitative manner:

Figure 1 shows a view of a reinforced front panel, according to the invention.

Figure 2 shows a formwork assembly comprised of several front panels, the three lower panels being identical to those represented in figure 1. Figure 3 shows a detail of the assembly represented in figure 2. Figures 4, 5 and 6 show variations of a construction opening formwork, of smaller and larger perimeter, wherein the reinforced lid panels can be observed, in addition to, in figures 5 and 6, intermediate immobilizing elements consisting of vertical support props, according to the invention.

Figure 7 shows a detailed view of the support provided by said vertical support props.

Figures 8 to 11 show, respectively: a finishing panel of the inner connection point between a floor slab and a wall, a detail of said panel, a view of a formwork assembly that includes said panel, and a detail of said assembly. Figure 12 shows a view of a formwork assembly for the continuation of a finished wall upon which a finished floor slab rests, wherein wall continuation or overlapping panels appear.

Figure 13 shows a detail of a wall continuation or overlapping panel. Figures 14 and 15 show additional views of a wall continuation and overlapping panel.

Figure 16 shows a view of a tie with nut, used in the assembly of the wall continuation and overlapping panel.

Figures 17 to 22 show several formwork panel alignment joist assembly possibilities. DESCRIPTION OF A PRACTICAL EMBODIMENT OF THE INVENTION

The formwork of the invention has an integral configuration, i.e. the complete formwork of the construction, or a significant part thereof, is assembled by disposing the installations, insulations and frames therein, for the purpose of subsequently concreting with special fluid concrete and, upon completion of curing thereof and formwork removal, producing the practically finished construction, with the exception of finishing touches such as installation of mechanisms, carpentry and bathroom fittings, tiling, paint, etc.

A regular and high-quality finish, suitable for being exposed, is achieved through the use of high-precision and low-tolerance formwork panels.

The different formwork panels are provided with perimeter flaps (2) with orifices (3) disposed for their joining by means of staples (2b) or other self- centering elements. The panels also have the suitable reinforcements (4) on their rear side to support the pressures exerted by the concrete, in addition to primary semicircular notches (5) on the sides and/or secondary wedge-shaped notches (6) on the corners thereof, designed for the generation of orifices (7a) upon assembly of the panels, said orifices (7a) designed to be aligned with those of the facing panels, which tighten these, cooperating to maintain their interspacing, thereby determining the thickness of the wall under construction. Specialized panels may be used for specific solutions such as, for example, forming of splays, staircases, corners, sealing of door or window openings, etc.

The formwork also comprises, as shown in figures 17-22, panel alignment joists (35), both in outer and inner walls, to ensure the perfect aligned support thereof, supporting the pressures exerted by the concrete.

Precisely for the purpose of better supporting the pressures exerted by the concrete without deformities, the improvements of the invention primarily propose the use of reinforced formwork panels, which can be used in any part exposed to the deformity caused by excessive concrete pressure, and mainly (not exclusively) in the lower parts of walls. These panels have the special feature of implementing additional reinforcement ribs (10, 10a) designed for receiving immobilizing elements, to be detailed later. A first variant of reinforced panel consists of a reinforced front panel (9) to form both sides of the lower parts of walls, shown in figure 1 , in addition to its assembly in figure 2 and detailed assembly in figure 3. Additional lower ribs (10) have been included in said reinforced front panel (9) and, in these, orifices (7) disposed in a slightly setback position with respect to its lower edge. These orifices are designed for the passage of conical separators (8) that act as immobilizing elements upon being tightened by the facing panels in this area.

A second variant of reinforced panel consists of a reinforced lid panel (9) for formwork perimeter sealing of construction openings, for example doors, as shown in figures 4 and 5, provided with additional lower ribs (10) and/or additional intermediate ribs (10a).

The immobilization means associated for the case wherein two facing vertical reinforced lid panels (9a) seal the construction opening laterally, consists of fixed horizontal separation elements (12), which may also be extended adaptably such as those disclosed in patent 200202648, and are not represented in this example of the invention. These fixed (12) or extensible horizontal separation elements are provided with end anchors that consist, for example, of horizontal gusseted bars (14) that thrust against the additional ribs

(10), which are provided with end tongues that hook onto the sides of the lid panels (9a).

As shown in figures 5 and 6, for the case wherein the reinforced lid panels (9a) seal the upper perimeter of a construction opening with a large span, intermediate immobilizing elements consisting of vertical support props

(16) with a support base (17) and upper distribution profile (18) have been provided.

In the case of window openings, as shown in figures 6 and 7, the base

(17) of the support prop (16) rests upon the additional intermediate ribs (10a) of the reinforced lid panel (9a) that seals the opening. In the case of door openings, as shown in figure 5, the base (17) rests upon the ground by means of a pedestal (19), having provided the juxtaposed use (see figure 5) of several fixed or extensible horizontal separators (12) such as that represented in figure 4, among which the pedestals (19) are inserted to allow them to rest upon the ground. Said pedestals (19) have the adequate shape and size to receive the end anchors of the separators.

According to the invention, centering and/or fixing stubs (20), designed to be inserted into orifices (21 ) disposed in the base (17) of the support props (16), are implemented in both the reinforced lid panels (9a) and pedestals (19). The stubs can be observed in the detail of figure 7, in this case stemming from a reinforced lid panel (9a).

As shown in figures 8-11 , a third reinforced panel variant has also been included in the present invention, consisting of a finishing panel (9b) disposed at the connection point between a floor slab and a wall. This finishing panel (9a) has a straight dihedral shape with rear reinforcements (14), one of the sides

(23) of which forms the part corresponding to the floor slab and the other side

(24) forms the upper part of the wall, wherein some of the upper or lower perimeter flaps, in this case the latter (2a), are convergently tilted as it is projected backwards for joining thereof to the divergently tilted flap of an unmolding panel (25) or wedge panel, as shown in figures 10 and 11.

This finishing panel (9b) may incorporate, at least, one additional rear reinforcement rib (10b) with an orifice (7b) perpendicularly directed towards the side (24) that forms the part corresponding to the wall. This orifice or orifices (7b) are designed for the passage of other conical separators (8) fixed by means of a blocking seal (8a) designed for, on the one hand, the interspaced fixing and securing of the finishing panel (9b) to the rest of the formwork and, on the other (see figure 12), the generation of openings (26) on the wall (28), upon concreting and removal of the conical separators (8), for the purpose of subsequently fixing other wall continuation or overlapping panels (27) by their ends, designed to support the wall formwork of the continuation on a floor slab (29) that rests upon the finished wall (28).

Figure 12 also shows the manner wherein the reinforced lower front panels (9) that comprise the formwork of the wall under construction fly over the exterior of the floor slab (29), thereby resting upon the wall continuation or overlapping panels (27), in the event of continuing a finished wall (28) upon which a finished floor slab (29) rests. The wall continuation or overlapping panels (27) are perfectly fixed to the finished wall (28) by means of ties (30) that pass through the openings (28) generated in the walls (28) by the conical separators (8) and by panel (27) windows (31 ) that face said openings (26). Several views of the panel (27) are shown in figures 14 and 15.

These ties (30), as shown in figure 16, are provided with an end strip (32) which is larger in size than that of the windows (31 ) and, at the opposite end thereof, a thread to receive a tightening nut (33) through the interior of the finished wall (28). Additionally, the wall continuation panels (27) are provided with an adjustment strip (34) along the inner part or contact side thereof to aid in the horizontal and vertical position adjustment of the panel with respect to the finished wall (28).

The invention has also provided fixing the formwork panel alignment joists (35) more solidly, as shown in figures 17-20. For this purpose, orifices (36) designed for the passage of fixing stem rods (37) have been implemented in said joists (35), conveniently secured to the outer part of the panels and projecting perpendicularly therefrom. These stem rods (37) are provided with means for tightening thereof against the joists (35). According to figures 17-18, the stem rods (37), in an embodiment of the invention, are provided with a flange (38) on one of their ends that is fixed onto other flanges (38a) implemented in the reinforced front panels (9), in addition to an opposing end thread designed for the coupling and tightening of a nut (33) that constitutes the means for tightening thereof against the joist (35). The flanges (38a) may also be implemented in the standard front panels described in the preceding patents, to which the stem rods (37) could therefore be fixed. In any case, this embodiment is preferably used in the alignment of the formwork panels corresponding to outer walls.

In the case of inner walls, such as facings or inner divisions, the preceding embodiment would not be convenient, due to the fact that, if the objective is to join several standard or reinforced front panels (9) positioned opposite each other in order to, for example, introduce them through the openings provided in the formwork for door or window openings, the stem rods (37) of said panels must be removed. For this reason, the invention has provided a variant shown in figures 21-22, wherein the stem rods (37) are threaded into threaded sockets (43), fixed without projecting therefrom among fixing ribs (60) implemented in the standard front panels or in the reinforced front panels (9), as shown in figures 21 and 22.

Said sockets (43) cannot be welded directly onto the fixing ribs (60), due to which they are coupled without possibility of rotation to bushings (42), which are welded to the ribs (60). The stem rods (42) are provided with an end thread (41) for coupling to the socket (43) and an opposing end threading adapter (44) with a broadening for tightening thereof against the joist (35).

Finally, the aforementioned joists (35), particularly when disposed in such a manner as to align formwork panels corresponding to outer walls, shall be capable of supporting railings to ensure the safe assembly of the roofs and upper parts of the walls. For this purpose, as shown in figures 19 and 20, vertical tubular bodies (39) have been fixed to some of the joists (35) in order to connect the handrails, not represented, having provided the optional fastening thereof by means of pins or similar, not represented, that enter orifices (40) disposed on said tubular bodies (39).

Claims

1. Integral modular formwork comprising panels that form a mold formed by parallel panels joined together by separators (8) that pass through the orifices usually defined by lateral and/or corner notches on said panels, the formwork of which may contain the frames, installations and insulations and into which concrete is poured to produce, upon curing thereof and formwork removal, a complete construction; and wherein said panels incorporate reinforcements in their rear side, in addition to perimeter flaps (2) with orifices for the assembly of adjacent panels; comprising, among others, a standard front panel to form the front of walls or floor slabs, an unmolding panel (25), one of the perimeter flaps of which is divergently tilted as it is projected backwards to facilitate its removal as first formwork removal panel; and also having provided other lid panels that seal the perimeter of the construction openings; and outer panel alignment joists (35); characterized in that it complementarily comprises panels reinforced by means of additional ribs designed for receiving the action of immobilizing elements, in order to prevent deformities resulting from the pressure exerted by the concrete.

2. Integral modular formwork according to claim 1 , characterized in that it comprises a first reinforced panel consisting of a reinforced front panel (9) to form the lower parts of walls, provided with additional lower ribs (10), wherein orifices (7) are implemented, slightly set back with respect to the lower edge of the panel, and through which the immobilizing elements consisting of conical separators (8) with blocking seals or nuts pass.

3. Integral modular formwork according to claim 1 , characterized in that it comprises a second reinforced panel consisting of a reinforced lid panel (9a) provided with additional lower ribs (10) and/or additional intermediate ribs (10a).

4. Integral modular formwork according to claim 3, characterized in that it comprises immobilizing elements consisting of fixed or extensible horizontal separators (12) provided with end anchors with which to rest upon the additional lower ribs (10) of two opposing vertical reinforced lid panels (9a) that laterally seal a construction opening.

5. Integral modular formwork according to claim 4, characterized in that the end anchors of the horizontal separators consist of horizontal gusseted bars

(14) that thrust against the additional lower ribs (10), and which are provided with end tongues (15) that hook onto the sides of the reinforced lid panels (9a).

6. Integral modular formwork according to claim 3, characterized in that it comprises immobilizing elements consisting of vertical support props (16) with an upper distribution profile (18) upon which rests a horizontal reinforced lid panel (9a) that seals the upper part of a construction opening with a large span.

7. Integral modular formwork according to claim 6, characterized in that, in window construction openings, the support prop (16) rests upon the additional intermediate ribs (10a) of the reinforced lid panel (9a) that seals the lower part of the window construction opening.

8. Integral modular formwork according to claim 6, characterized in that the juxtaposed use of several fixed or extensible horizontal separators (12) has been provided in door construction openings, inserting support pedestals (19) for the support props (16) among the end anchors thereof, and having the adequate shape and size to receive said anchors.

9. Integral modular formwork according to claims 7 and 8, characterized in that stubs (20) have been provided in the lid panels (9a) that seal the lower perimeter of window constructions and openings in the pedestals (19), which stubs are designed to be inserted through the orifices (21 ) of bases (17) provided in the support props (16), with centering and fixing functions.

10. Integral modular formwork according to claim 1 , characterized in that it comprises a third reinforced panel consisting of a finishing panel (9b) disposed at the connection point between a floor slab and a wall; said finishing panel (9b) having a straight dihedral shape with rear reinforcements (14), one of the sides

(23) of which forms the part corresponding to the floor slab while the other side

(24) forms the part corresponding to the wall; some of the upper or lower end perimeter flaps (2a) being convergently tilted as it is projected backwards for joining thereof to the divergently tilted flap of an unmolding panel (25).

11. Integral modular formwork according to claim 10, characterized in that the finishing panel (9b) incorporates, at least, one additional rear rib (10b) with an orifice (7b) perpendicularly directed towards the side (24) that forms the part corresponding to the wall, and designed for the passage of a reinforcement conical separator (8), and which generates openings (26) in the finished wall (28) for the purpose of subsequently fixing other wall continuation or overlapping panels (27) by the outer part thereof, designed to support the formwork of the continuation of a finished wall (28), upon which a finished floor slab (29) rests.

12. Integral modular formwork according to claim 11 , characterized in that the wall continuation or overlapping panels (27) have windows (31 ) designed to face the openings (26) generated in the finished wall (28) for the passage of fixing ties (30).

13. Integral modular formwork according to claim 12, characterized in that the ties (30) comprise a stem rod designed to traverse the windows (31 ) and openings (26), having an end strip (32) which is larger in size than that of the windows (31) and, at the opposite end thereof, a thread to receive a tightening nut (33) through the interior of the finished wall (28).

14. Integral modular formwork according to claim 11 , characterized in that the wall continuation or overlapping panels (27) have an adjustment strip (34) along the side thereof to aid in the horizontal and vertical position adjustment of the wall continuation or overlapping panels (27) when the wall (28) is finished.

15. Integral modular formwork according to claim 1 , characterized in that the outer panel alignment joists (35) have orifices (36) designed for the passage of stem rods (37) fixed to the outer part of the panels and projecting perpendicularly therefrom, provided with means for tightening thereof against the joists (35).

16. Integral modular formwork according to claims 1 and 15, characterized in that each stem rod (37) has a flange (38) on one of its ends designed to be fixed onto other flanges (38a) implemented in the standard front panels and/or reinforced front panels (9), in addition to an opposing end thread designed for the coupling of a nut (33) that constitutes the means for tightening thereof against the joist (35).

17. Integral modular formwork according to claims 1 and 15, characterized in that each stem rod (37) includes an end thread (41 ) designed to be threaded into threaded sockets (43) fixed to some fixing ribs (60) provided in the standard front panels and/or reinforced front panels (9), and an opposing end threading adapter (44) with a broadening (45) that constitutes the means of tightening thereof against the joist (35).

18. Integral modular formwork according to claims 1 and 17, characterized in that the sockets (43) are fixed to the fixing ribs (60) without projecting from the panels, by means of bushings (42) welded to said ribs and to which these are coupled without possibility of rotation.

19. Integral modular formwork according to claim 1 , characterized in that tubular bodies (39) for the connection of handrails are disposed on the outer panel alignment joists (35).

20. Integral modular formwork according to claim 19, characterized in that orifices (40) are disposed on said tubular bodies (39) for fastening of the handrails by means of pins or similar.