WO2011101768A2

WO2011101768A2 - Modular non-retrievable formwork with locking inserts

Info

Publication number: WO2011101768A2
Application number: PCT/IB2011/050486
Authority: WO
Inventors: Romeo Tonello
Original assignee: Rexpol Srl
Priority date: 2010-02-18
Filing date: 2011-02-04
Publication date: 2011-08-25
Also published as: ITPD20100046A1; WO2011101768A3; IT1398661B1

Abstract

The invention is a non - retrievable formwork comprising two facing and parallel modular panels (P), a spacer (D) for joining said panels and a pair of inserts (S) for connecting said spacer, wherein at least one of said inserts (S) is incorporated in each one of said panels, each one of said inserts in turn comprising at least one seat (Al) for removably inserting a lateral edge of said spacer. Said seat of said inserts comprises two housings: a first housing (S2) in proximity to the surface of the panel directed towards the facing panel and a second housing (S3) that is more recessed in the thickness of said panel. The coupling between the panels guarantees excellent resistance thanks to the special "V" shape of the projections and seats.

Description

MODULAR NON-RETRIEVABLE FORMWORK WITH LOCKING

INSERTS

DESCRIPTION

The present invention concerns non-retrievable modular formworks, and in particular it concerns a new modular non-retrievable formwork with facing panels, union spacers and connection inserts for said spacers.

Non-retrievable formworks are known that are used for making walls or partitions generally made of concrete.

Non-retrievable formworks covering the entire height are known, comprising two facing walls made of a foam material, with vertical reinforcing bars buried inside the walls and cross reinforcing bars that hold the walls together, in order to counteract the thrust exerted on the walls during the concrete casting operation.

Said formworks are laid when already assembled, which involves considerable storage, transport and handling problems.

Modular non-retrievable formworks are also known, wherein each module comprises a pair of facing panels with modular dimensions, and wherein said panels are joined to each other by means of spacers fixed between the panels during production.

Modular non-retrievable formworks are also known, wherein each module comprises a pair of facing panels with modular dimensions, with spacers that can be positioned directly in the building site.

The panels used in said known modular non-retrievable formworks are generally made of an insulating material, typically a foam material.

The European patent 0 803 016 discloses a modular building element that can be superimposed to and coupled with similar elements and consists of two insulating panels that are arranged so as to face and be parallel to each other, each provided with lower and upper edges and with interconnection devices for superimposing and connecting similar elements. Said interconnection devices are provided on said upper and lower edges of the panels and comprise at least two rows of projections and recesses, alternate and arranged so as to be staggered on said upper and lower edges, and a raised sealing element, or wall, arranged in an intermediate position between said rows of projections and recesses.

In each pair of said facing panels the panels are joined by means of a spacer or rigid connection arm suited to be slidingly inserted in grooves made in connection inserts positioned in the panels, wherein said arm can be provided in variable widths in order to obtain construction elements having different overall thicknesses.

One of the drawbacks posed by said elements lies in that in order to make said elements it is necessary to assemble two of said panels and one or more connection arms whose width is suitable for making the wall in the desired thickness.

Therefore, in order to make, for example, two walls having different thickness, it is necessary to use different connection arms having suitable dimensions.

Furthermore, in order to constrain the panels of superimposed elements it is necessary to arrange said spacer arms so that they are staggered with respect to the panels, that is, so that each arm is engaged in the inserts of two of said superimposed panels.

In order to overcome the above mentioned drawbacks, a new type of modular non-retrievable formwork with facing panels has been designed and carried out which is provided with union spacers and connection inserts for said spacers. The main object of the present invention is to provide a formwork that is made up of separate parts that are assembled during the construction process.

Another object of the present invention is to ensure that the separate parts can be stored, transported and handled more comfortably while at the same time occupying less space.

Another object of the present invention is to ensure complete flexibility of use, as spacers having all the same width are used and this makes it possible to assemble formworks in at least two different thicknesses, by simply varying the position of said spacers in said inserts.

It is also possible to assemble a formwork by using two panels having different thickness, for example using for the outer wall a panel that is larger than the inner one.

In this way it is possible to make insulating walls having overall thickness and stratification characteristics that are suitable for the design conditions. Thus it is possible to use non-retrievable formworks to make walls that comply with special conditions, for example with building construction rules in seismic areas and energy saving rules.

It is another object of the present invention to ensure that superimposed formworks can be effectively joined by coupling the inserts and/or spacers of corresponding superimposed panels to each other, with no need to stagger the spacers.

It is another object of the present invention to prevent concrete from flowing out of the space between two superimposed panels during the concrete casting operation.

These and other direct and complementary objects are achieved by the new modular non-retrievable formwork with facing panels, provided with union spacers and connection inserts for said spacers.

The new formwork comprises, in its main parts, at least two modular panels suited to be arranged so that they face and are substantially parallel to each other, at least one union spacer for said panels and at least one pair of inserts for inserting said spacers, said inserts being incorporated within the thickness of said panels.

Each insert comprises a seat for the insertion of the fitting edge of a spacer, said seat of at least one insert of each pair comprising at least two housings, in particular a first housing in proximity to the surface of the panel and a second housing that is more recessed in the thickness of said panel.

Said housings are preferably aligned, in particular they are arranged so as to be aligned along the normal to the surface of the panel.

Said spacers therefore comprise lateral edges suited to be fitted in one of said housings, said edges being for example T-shaped.

According to the invention, said T-shaped edges may comprise one or more seats or projections suited to match projections or seats created in said inserts, suited to prevent said spacers from accidentally coming off said inserts in the longitudinal direction.

Thanks to said double housing, it is possible to assemble the same spacer in three different ways, thus making formworks in three different overall thicknesses using the same spacer.

According to the first assembly mode, said spacer is inserted with both the lateral fitting edges inserted each in the first housing of both inserts of the two facing panels, thus obtaining a formwork with maximum overall thickness.

According to a second assembly mode, said spacer is inserted with a lateral fitting edge inserted in the first housing and the opposite lateral edge inserted in the second more recessed housing, thus obtaining a formwork with an overall thickness reduced by a distance equal to the distance between the two housings.

According to a third assembly mode, said spacer is inserted with both the lateral fitting edges inserted each in the second housing of both inserts of the two facing panels, thus obtaining a formwork with minimum overall thickness reduced by twice the distance between the two housings with respect to the maximum thickness.

For example, assuming that the distance between said housing is equal to 2,5 cm, it is possible to obtain, for example, a formwork where the concrete thickness is maximum 20 cm, according to the first assembly mode, a formwork with concrete thickness of 17,5 cm, according to the second assembly mode, or a formwork with a minimum concrete thickness of 15 cm, according to the third assembly mode.

The length of each one of said inserts is preferably such as to substantially correspond to the entire height of said panels and each insert comprises, on its upper and lower terminals, coupling elements that serve for connection with inserts incorporated in the underlying or overlying panels.

In particular, said coupling elements comprise hooks or projections suited to match corresponding hooks or projections or seats of the corresponding terminal of the insert of the overlying or underlying panel.

Said coupling elements prevent the superimposed elements from separating by translating with respect to each other along the vertical direction, due to the thrusting action of the concrete during the casting and successive hardening step.

Each one of said spacers has a substantially flat shape, with T-shaped lateral edges for fitting in said inserts, and upper and/or lower edge provided with one or more seats for inserting the longitudinal reinforcing bars to be positioned between the panels before casting the concrete.

According to the preferred solution, each one of said spacers also comprises, on its upper and lower terminals, coupling elements for connection with overlying or underlying spacers.

In particular, said coupling elements comprise hooks or projections suited to match corresponding hooks or projections or seats of the corresponding terminal of the overlying or underlying spacer.

According to the invention, said panels are made of a foam material, said inserts being buried in the thickness of said panels at modular distances. One of the advantages of the present invention lies in that each formwork can be produced in separate parts and assembled later on, thus accelerating operations and considerably reducing costs.

The new formwork can be assembled previously or preferably directly at the building site, thus facilitating storage, transport and handling of the various component parts.

Furthermore, it is possible to assemble said formworks by combining spacers, external and internal panels according to the design, for example using thicker internal or external panels in order to maximize heat insulation.

For example, it is possible to use 7, 10, 12,5, 15, 17,5, 20 cm thick panels and spacers in different thicknesses, combined in various ways, in the same formwork.

Each one of said panels also comprises, on its upper and/or lower edges, elements for connection with overlying or underlying panels.

According to the preferred embodiment of the invention, said connection elements comprise at least one or preferably at least two parallel rows of alternating projections and recesses having substantially the same size, said rows being arranged on the upper and lower edges of each panel, in the longitudinal direction, and wherein said projections and recesses of one edge are arranged so as to be inverted with respect to the projections and recesses of the opposite edge of an adjacent panel, so that the recess of a row on one edge faces the projection of the opposite edge.

Said rows of projections/recesses of the same edge are staggered, that is, each projection of a row is opposite a recess in the other row and vice versa. In the preferred embodiment of the invention, said projections and recesses are V-shaped, with vertex directed towards the outside of the panel and sides directed towards the parallel row.

Said projections and recesses shaped in this way offer not only the advantage that it is possible to effectively assemble two superimposed panels, but also that it is possible to prevent the concrete from flowing out through the space between two superimposed panels during the casting operation.

The characteristics of the invention will be highlighted in greater detail in the following description, with reference to the drawings attached as non- limiting examples.

Figure 1 shows a schematic plan view of a panel (P), where it is possible to observe the rows of connection elements (K) between superimposed panels

(P) and the inserts (S) for inserting the spacers between facing panels (P).

Figures la and lb show a detailed three-dimensional view of the V-shaped projections (Kl) and recesses (K2).

Figures 2 and 2a-c show views of an insert (S).

Figures 3 and 3a-c show views of a spacer (D).

Figures 4a-c show plan views of three connection modes of a spacer (D) between two inserts (S) incorporated in facing panels (P).

Figures 5a-b respectively show a view and a detail of the assembly of two superimposed spacers (D).

Figures 6a-b respectively show a view and a detail of the assembly of two superimposed inserts (S).

The new formwork comprises two modular facing and substantially parallel panels (P), at least one spacer (D) for joining said facing panels (P) and at least one pair of inserts (S) for the insertion of each spacer (D), as shown in Figure 4.

Each one of said inserts (S) is incorporated within the thickness of a panel (P) at a modular distance from the adjacent insert (S), as shown in Figure 1, and comprises a longitudinal seat (SI) for the insertion of the fitting edge of a spacer (D), wherein said seat (SI) has an opening (Sl l) on the surface (PI) of the panel (P) facing the opposite panel.

Said seat (SI) of said insert (S) comprises at least two housings (S2, S3) for the insertion of the fitting edge (Dl) of said spacer (D).

Said housings (S2, S3) are preferably and substantially aligned along the normal to said surface (PI) of said panel (P).

The first one of said housings (S2) is near said surface (PI) of the panel (P) facing the opposite panel, while the second housing (S3) is more recessed within the thickness of said panel (P).

In the embodiment of the invention shown in the figures, said seat (SI) is defined by a substantially box-shaped profile (S12), while said two housings (S2, S3) are defined by partitions (SI 3) that are within said box-shaped profile (SI 2). Said insert also comprises one or more wings (SI 4) suited to be fitted and locked in the panel (P).

The length of each one of said inserts (S) is such as to substantially correspond to the entire height of said panels (P) and comprises, on the upper (S4) and lower (S5) terminals, one or more hooks or coupling projections (S6, S7) for connection to corresponding hooks or projections (S7, S6) of the opposite terminal of inserts (S) incorporated in the overlying or underlying panels.

Each one of said spacers (D) has a substantially flat shape, with T-shaped lateral edges (Dl) suited to be fitted in said housings (S2, S3) of said inserts (S), and upper and/or lower edge (D2, D3) provided with one or more seats (D4) for inserting the longitudinal reinforcing bars to be positioned between the panels before casting the concrete.

Each one of said spacers (D) comprises, on the upper and lower terminals (Dl l, D12) of said T-shaped fitting edges (Dl), hooks or projections (D13, D14) suited to match corresponding hooks or projections (D14, D13) of the opposite terminal of the overlying or underlying spacer.

As shown in Figures 4a-c, it is possible to assemble the same spacer (D) between two inserts (S) incorporated in two facing panels (P) in three different ways, thus producing formworks in three different overall thicknesses.

According to the first assembly mode, shown in Figure 4a, said spacer (D) is inserted with each one of the two fitting edges (Dl) in the first housing (S2) of both inserts (S).

According to the second assembly mode, shown in Figure 4b, said spacer (D) is inserted with one fitting edge (Dla) in the first housing (S2) and with the opposite edge (Dlb) in the second housing (S3) of the opposite insert (S).

According to the third assembly mode, shown in Figure 4c, said spacer (D) is inserted with both fitting edges (Dl) in the second housing (S4) of both inserts (S).

According to the invention, said T-shaped fitting edges (Dl) of each spacer may comprise one or more seats or projections (D15) matching seats (S8) or projections created on said box- shaped body (SI 2) of said inserts (S), suited to prevent said spacers (D) from accidentally coming off said inserts (S) in the longitudinal direction.

Each one of said panels (P) also comprises, on the upper and/or lower edges (P2, P3), elements (K) for connection to overlying and underlying panels (P), said connection elements (K) comprising two parallel longitudinal rows (Ka, Kb) of alternating projections (Kl) and recesses (K2) having substantially the same dimensions, wherein said projections (Kl) and recesses (K2) of an edge (P2, P3) are arranged so as to be inverted with respect to the projections (Kl) and recesses (K2) of the opposite edge (P3, P2) of an adjacent panel, so that each recess (K2) in an edge (P2, P3) faces the projection (Kl) of the opposite edge (P3, P2) and vice versa.

Said rows (Ka, Kb) of projections/recesses of the same edge are staggered, that is, each projection (Kl) of a row (Ka) is opposite a recess (K2) in the other row (Kb) and vice versa.

In the preferred embodiment of the invention, said projections (Kl) and recesses (K2) are V-shaped, with vertex (K3) directed towards the outside of the panel and sides (K4) directed towards the parallel row.

According to the invention, the ends (K41) of said sides (K4) of the projections (Kl) and recesses (K2) of a row (Ka) are near the ends (K41) of the sides (K4) of the projections (Kl) and recesses (K2) of the parallel row

(Kb).

Therefore, with reference to the above description and the attached drawings, the following claims are expressed.

Claims

L Non-retrievable formwork, comprising at least two modular panels (P) suited to be arranged so as to face and be parallel to each other, at least one spacer (D) for joining said facing panels (P) and at least one pair of inserts (S) for connecting said spacer (D), each one of said inserts (S) being incorporated in one of said panels (P) and in turn comprising at least one seat (SI) suited to house a lateral edge (Dl) of said spacer (D), characterized in that said seat (SI) of at least one of said inserts (S) comprises at least two housings (S2, S3), wherein a first housing (S2) is near the surface (PI) of the panel (P) directed towards the facing panel (P) and a second housing (S3) is more recessed within the thickness of said panel (P).

2. Non-retrievable formwork according to claim 1, characterized in that said housings (S2, S3) of each one of said inserts (S) are substantially aligned.

3_* Non-retrievable formwork according to claim 2, characterized in that each one of said inserts (S) is incorporated within the thickness of the panel (P) so that said housings (S2, S3) are substantially aligned along the normal to the surface (PI) of the panel (P).

* Non-retrievable formwork according to the preceding claims, characterized in that each one of said inserts (S) is incorporated within the thickness of the panel in the direction of the height of the panel (P), and its length is such as to substantially correspond to the entire height of said panel.

5. Non-retrievable formwork according to the preceding claims, characterized in that each one of said spacers (D) can be inserted with each one of its lateral fitting edges (Dl) in said first housing (S2) or in said second housing (S3) of an insert (S).

6. Non-retrievable formwork according to the preceding claims, characterized in that said T-shaped fitting edges (Dl) of each spacer (D) comprise one or more projections (Dl l) or seats matching seats (S8) or projections created on said inserts (S), suited to prevent said spacers (D) from accidentally coming off said inserts (S) in the longitudinal direction.

7. Non-retrievable formwork according to the preceding claims, characterized in that each one of said inserts (S) comprises, on the upper and lower terminals (S4, S5), at least one coupling element (S6, S7) for connection to corresponding inserts (S) incorporated in the overlying or underlying panels (P9).

8_* Non-retrievable formwork according to claim 7, characterized in that said coupling element (S6, S7) comprises at least one hook or projection suited to be fitted in a corresponding hook or projection of the opposite terminal of an overlying or underlying insert (S).

9_* Non-retrievable formwork according to the preceding claims, characterized in that each one of said spacers (D) comprises, on the upper and lower terminals (Dl l, D12) of said fitting edges (Dl), at least one coupling element (D13, D14) for connection to corresponding overlying or underlying spacers (D).

10. Non-retrievable formwork according to claim 9, characterized in that said coupling element (D13, D14) comprises at least one hook or projection suited to be fitted in a corresponding hook or projection of the opposite terminal of the fitting edge (Dl) of an overlying or underlying spacer (D).

11. Non-retrievable formwork according to the preceding claims, characterized in that said panels (P) are made of a foam material, said inserts (S) being buried in the thickness of said panels at modular distances.

12. Non-retrievable formwork according to the preceding claims, characterized in that each one of said panels (P) comprises, on the upper (P2) and/or lower edges (P3), elements (K) for connection to overlying or underlying panels (P).

13. Non-retrievable formwork according to claim 12, characterized in that said connection elements (K) comprise one or more longitudinal parallel rows (Ka, Kb) of alternating projections (Kl) and recesses (K2) having substantially the same dimensions, said rows (Ka, Kb) of projections/recesses of the same edge being staggered so that each projection (Kl) of a row (Ka) is opposite a recess (K2) of the other row (Kb) and vice versa, and wherein said projections (Kl) and recesses (K2) of an edge (P2, P3) are arranged so as to be inverted with respect to the projections (Kl) and recesses (K2) of the opposite edge (P3, P2) of an adjacent panel, so that each recess (K2) in an edge (P2, P3) faces the projection (Kl) of the opposite edge (P3, P2) and vice versa.

14. Non-retrievable formwork according to claims 12, 13, characterized in that said projections (Kl) and recesses (K2) are V-shaped, with vertex (K3) directed towards the outside of the panel and sides (K4) directed towards a parallel row, so that the ends (K41) of said sides (K4) of the projections (Kl) and recesses (K2) of a row (Ka) are near the ends (K41) of the sides (K4) of the projections (Kl) and recesses (K2) of the parallel row (Kb).