WO2012123964A2

WO2012123964A2 - Casting designer walls for building by using moulds

Info

Publication number: WO2012123964A2
Application number: PCT/IN2012/000132
Authority: WO
Inventors: Prakash Prabhakar Pawar
Original assignee: Prakash Prabhakar Pawar
Priority date: 2011-03-06
Filing date: 2012-02-27
Publication date: 2012-09-20
Also published as: WO2012123964A3

Abstract

The present invention related to the constructions of wall more particularly to the technique of civil engineering wherein using a mould inside the formwork for casting designer walls to be used in the construction process without using plastering and thereby eliminating the time and cost of conventional wall making process. The present invention relates to the construction of reinforced concrete building structure, and more particularly, to reinforced concrete construction systems and method of using designer moulds inside the formwork to create various designs and smooth finish of the concrete on the surface of the casted walls, which results in the elimination of plastering or paneling. The use of moulds inside the formwork offers advantages in terms of reduced cost, increased efficiency (in terms of reducing the labor for plastering) and aesthetically appealing.

Description

CASTING DESIGNER WALLS FOR BUILDING BY USING MOULDS FIELD OF INVENTION

The present invention related to the constructions of wall more particularly to the technique of civil engineering wherein using a mould inside the form-working for casting designer walls to be used in the construction process without using plastering and thereby eliminating the time and cost of conventional wall making process. BACKGROUND OF INVENTION

As per existing construction techniques, the walls have been built by various types such as using bricks or blocks or casted concrete which is reinforced by steel and then to plaster these walls for covering the joints of bricks, blocks or the casted concrete or cover these walls with panels of different elements. In all existing processes of constructing walls, which needs plastering or paneling to cover the walls which increases the cost of construction.

Conventionally there was no means to form a design on the exterior part of wall using moulds wherein there is no need to use plastering, it was a tedious and expensive task to make a designer wall after plastering the same. In the existing plastering method, a separate layer is applied to the brick work or concrete walls. After some period of time, due to weather conditions and temperature variation, the plastering tends to separate from the brick work or concrete walls ^' and develops cracks. It is not sustainable and also for plastering the walls, extra cost is incurred. Therefore there exists a need to have a method and means to prepare a mould which can be fitted according to the size and dimension of wall and make it connected in such way that after removal of the mould the wall shows the desired design with fine finishing.

Conventionally, reinforced concrete construction has required plastering or paneling because the surface finish of the wall is not smooth and the joints are visible. To cover all these flaws, it needs plastering or paneling compulsorily, which increases cost. The other known disadvantage of plastering is such that because of temperature variation between the wall and the plaster, cracks are formed on the surface of the wall.

The present invention relates to the construction of reinforced concrete building structure, and more particularly, to reinforced concrete construction systems and method of using designer moulds inside the formwork to create various designs and smooth finish of the concrete on the surface of the casted walls, which results in the elimination of plastering or paneling.

The use of moulds inside the formwork offers advantages in terms of reduced cost, increased efficiency (in terms of reducing the labor for plastering) and aesthetically appealing.

OBJECT OF THE PRESENT INVENTION The object of the present invention is to provide a designer concrete wall for building by using moulds to avoid plastering or paneling. Accordingly, a general object of the invention is to provide an improved method and system of designing the walls by using moulds for various designs and smooth clean finish.

Another object of the invention is to reduce construction cost, reduce skilled/unskilled labor, reduce use of material especially sand and at the same time increase the finish and visual appeal of the design which is not possible manually.

Another object of the invention is to construct and provide stronger and more durable designer walls than the conventional walls.

To completely appreciate these and other objects of the present invention as well as the invention itself, all of which will become apparent to those skilled in the art, the following detailed description of the invention and the claims should be read in conjunction with the accompanying drawings.

DESCRIPTION OF THE DRAWINGS

Figure 1 is a schematic picture of Mould Panel to be fitted on the formwork for final finishing without using plaster Figure 2 is a schematic picture of reinforced concrete construction systems and method of using designer moulds inside the formwork to create various designs. Figure 3 is a schematic picture of a designer wall after mould has been removed and further the wall surface has been dried. DETAILED DESCRIPTION OF THE INVENTION

The present invention related to the constructions of wall more particularly to the technique of civil engineering wherein using a mould inside the form -working for casting designer walls to be used in the construction process without using plastering and thereby eliminating the time and cost of conventional wall making process.

As per existing construction techniques, the walls are build by various types such as using bricks or blocks or casted concrete which is reinforced by steel and then further plastering these walls for covering the joints of br-icks, blocks or the casted concrete or covering these walls with panels of different elements. In all existing processes of constructing walls, there is need for plastering or paneling to cover the walls which is why the cost of construction increases. As shown in appended figure the present invention provides a method to construct the designer walls for buildings which does not need plastering or any paneling. Yet the walls can be visually appealing and at the same time cost is reduced. As shown in figure 1 , there is fabrication of an appropriate mould depending upon the size of the wall. These moulds can be made from PVC or rubber or any other suitable material. One side of these moulds will be embossed with the pattern which will later be impressed onto the concrete as shown in Figure 2. They can be in various sizes or shapes and designs however; these moulds will be made in standard sizes according to the wall sizes. Similar type of moulds are used in making pre casted cement tiles or paving blocks but the key difference of these moulds and the present inventive moulds is that said mould does not have the side walls to hold the concrete whereas in the cement tiles and paving block moulds have the side walls to hold the concrete and make the tiles in perfect size as shown in Figure 3. Therefore using said unique moulds, panel is prepared. For example: for a 10 ft long and 10 ft high wall, formwork of the same dimension is required, and to this panel, for fixing said moulds. These moulds can be fixed to the panel (like we fix tiles to the wall) by using nut bolts/clips/vacuum or fixed in slots or any other method. After preparing this panel, it will be fixed from outside and depending upon the need the inside of this wall to be plain then there will be fixation of the plain panel from inside and keeping the distance between these two panels according to the wall thickness. Before this as per the design, steel for reinforcing the concrete is laid and further there is pouring of the concrete inside this prepared form work shuttering or paneling with the help of vibrators and when concrete gets settled, shuttering is been opened carefully. Thus, because of the moulds, which were fitted to the panels, the outside of the wall will come out with the design and it doesn't need the plastering. These designs can be tessellated according to the aesthetic factors.

In the existing plastering method, a separate layer is applied to the brick work or concrete walls. After some period of time, due to weather conditions and temperature variation, the plastering tends to separate from the brick work or In the existing plastering method, a separate layer is applied to the brick work or concrete walls. After some period of time, due to weather conditions and temperature variation, the plastering tends to separate from the brick work or concrete walls and develops cracks. It is not sustainable and also for plastering the walls, extra cost is incurred.

Whereas in our process, we don't need plastering hence no cracks, no maintenance and that is why the life of these RCC walls increases and cost reduces in terms of one time construction cost and lifetime maintenance cost. In our system, we are using the moulds. These moulds can be used several times. Due to this, the cost will be divided and will be reduced. Using these moulds, we can create thousands of designs for any side of the wall which is not possible in plastering by hands. Accuracy will also be maintained in this method. Although specific embodiments have been illustrated and described, it will be obvious to those skilled in the art that various modifications may be made without departing from what is intended to be limited solely by the appended claims.

Claims

A process for casting a designer wall for building, using a mould comprising step of preparing the panel and fixing said mould to the panel by using nut bolts / clips / vacuum or fixed in slots or any other method, further to preparing this panel, internally and/or externally.

A process for casting a designer wall for building using a mould as claimed in claim 1 , wherein fix the plain panel from inside and keep the distance between these two panels according to the wall thickness.

A process for casting a designer wall for building using a mould as claimed in claim 1 , wherein the fixing the textured mould in order to obtain the textured aesthetics of the wall surface.

A process for casting a designer wall for building using a mould as claimed in claim 1 , wherein the steel for reinforcing the concrete is laid and pouring the concrete inside this prepared formwork followed by shuttering or paneling with the help of vibrators and subsequently the concrete settles and, further the shutter is been opened thereby the outside or inside or both side of the wall will come out with the design and it does not need the plastering.