WO2018049481A1

WO2018049481A1 - Apparatus for use in falsework and formwork for forming steps and stairs

Info

Publication number: WO2018049481A1
Application number: PCT/AU2017/051008
Authority: WO
Inventors: Tristan TOWNS; Ryan Michael DELLE DONNE
Original assignee: Riserform Pty Ltd
Priority date: 2016-09-15
Filing date: 2017-09-15
Publication date: 2018-03-22

Abstract

An apparatus (10) for use in forming step(s) or stair(s) from concrete or the like has an elongate device (12) of adjustable length. A first part (14), which can be a tube or solid, inserts into a second tubular part (16) of the elongate device providing telescoping to collapse for storage, transport and short length use, and for extension where the elongate device can be extended for use where longer/wider step or stair riser falsework is needed. The outer surface provides a useful flat surface for mounting the stair riser shuttering to. Locking means (18), such as in the form of a pin (20) or threaded fastener (21), engages the two parts (14), (16) together preventing shortening or extension until the lock is released. The pin can pass through aligned holes in each of the two parts. The threaded fastener can provide a similar function or can threadingly engage with the outermost (part 16) and bite against the surface of the inner part (14) to prevent relative movement between the two parts. The outer ends of the elongate device include (brackets 22a), (22b), such as flat plates, for use in mounting the elongate device to a wall or other support, such as timber of metal framing. Each bracket (22a), (22b) can have a plate with apertures therethrough for fasteners to pass through and fix the elongate device to the wall/framing. The elongate device includes or supports riser shuttering (26) for use in supporting the riser face of a step of wet concrete or the like until cured/set. The shuttering can be mounted to shuttering brackets (24) or can be integral to each part ((14),16). Riser shuttering end mounts (25) can be provided, particularly adjacent the end brackets (22a), (22b.)

Description

APPARATUS FOR USE IN FALSEWORK AND FORMWORK FOR FORMING

STEPS AND STAIRS

FIELD OF THE INVENTION

[0001 ] The present invention relates to falsework and/or formwork for forming steps and stairs

[0002] The present invention finds particular application in falsework and formwork for moulds into which concrete or similar settable materials are poured or pumped for forming steps or stairs.

BACKGROUND TO THE INVENTION

[0003] In the context of concrete construction, falsework supports shuttering moulds which contain and support concrete until the concrete is sufficiently cured and self supporting.

[0004] Formwork includes the falsework and shuttering directly containing the wet, uncured concrete. The shuttering is typically made from timber sheets, such as particle board, plywood or oriented strand board (OSB).

[0005] Formwork comes in several types. For traditional timber formwork, timber supports, such as a framework (falsework) support plywood, OSB or moisture-resistant particle board sheets.

[0006] All timber formwork is relatively easy to erect but time-consuming for larger structures, has limited strength, is usually a once only use, and the plywood/board facing has a relatively short lifespan. Timber formwork and falsework are used extensively where the labour costs are lower than the costs for procuring reusable formwork.

[0007] Engineered formwork uses prefabricated modules with a metal frame (usually steel or aluminium) and covered on the application (concrete) side with material having the wanted surface structure (steel, aluminium, timber, etc.). Engineered formwork is used where the structure has repeatable, commonised structures, such as multiple, repeated wall sections. Two advantages of engineered formwork compared to traditional timber formwork are speed of construction (modular systems pin, clip, or screw together quickly) and lower life- cycle costs (barring major force, the frame is almost indestructible, while the covering if made of wood is replaced after one or, at best, a few uses.

[0008] Re-usable plastic formwork uses interlocking and modular systems for relatively simple, concrete structures. The plastic panels are lightweight and very robust. They are especially suited for low-cost, mass housing schemes.

[0009] Steps and flights of stairs are variable in width, elevation, angle, turns from one flight to another, and number of flights. Timber formwork and falsework is commonly used because of the need to create a specific support structure for the project at hand. Typically the timber formwork and falsework for steps and stairs is a once only build, with the timber disassembled and discarded or re- purposed afterwards.

[0010] Engineered (steel and aluminium) falsework and formwork structures for use in forming steps and stairs have been avoided because of the lack of repeatable use for fixed metal formwork/falsework structures and the cost involved with designing and building metal formwork/falsework.

[001 1 ] It is with the aforementioned in mind that the present invention has been developed. [0012] It has been found desirable to provide a falsework or formwork system or device for use in forming steps and stairs that alleviates one or more of the shortcomings of the aforementioned known art.

SUMMARY OF THE INVENTION

[0013] With the aforementioned in mind, an aspect of the present invention provides an apparatus for use in formwork for forming steps or stairs, the apparatus including an elongate device of adjustable length having at least two parts adjustable relative to one another for use in forming at least one step riser formwork of the steps or stairs, and a locking means to lock the at least two parts at a desired length adjustment of the device.

[0014] The elongate device may include at least one mounting portion for mounting the device to a wall or to support work or falsework, such as timber framing or a scaffold like support structure. .

[0015] Preferably, the at least one mounting portion may be provided at one end of the elongate device or at each of two opposed ends thereof. For example, a fixed or removable plate may be provided at one or both opposed ends of the elongate device. The plate or plates may include attachment means to

removably attach the device to a wall or opposed walls, to framework/falsework or to stringers of stairs/steps (e.g. steel or timber stringers).

[0016] The elongate device may be connected to one or more other of said elongate device to extend the length thereof to accommodate steps/stirs wider than one elongate member.

[0017] A mounting portion, such as at an end of the elongate device for attachment of the elongate device to a wall or framework, may be detachable. The mounting portion may attach by a retaining means to the end of the elongate device. The retaining means may include one or more fasteners, clips or pins etc. For example, an end of a portion of the elongate device may attach to an end plate portion for use in attaching the elongate device to a wall or other framework. It will be appreciated that the mounting portion may be chosen form a selection of different types of mounting portion to suit the orientation and type of surface by which the end of the elongate device is to be supported. For example, the mounting portion may include a plate perpendicular to the longitudinal extent of the elongate device, or may include a plate in a plane coaxial with the longitudinal extent of the elongate device

[0018] It will be appreciated the apparatus may include a mounting means attachable to a wall or support framework, such as falsework framing, and the device removably connects to the mounting means. Thus, the mounting means may be pre-mounted to a wall or framing and the elongate device attached thereafter to the predetermined position.

[0019] The elongate device provides falsework or formwork for the riser of one or more steps e.g. of a flight of stairs to be created from poured manually delivered (e.g. shovelled, bucketed or wheelbarrowed) or pumped concrete or other settable/curable slurry type structural material.

[0020] The elongate device may include attached shuttering for supporting the face of at least one riser of the steps or stairs of concrete or the like whilst curing/setting sufficiently to be self supporting. For example, each of the at least two parts may include a riser surface or adjustable length.

[0021 ] Alternatively, the elongate device may include at least one support for attachment of the shuttering. For example, the shuttering may be at least one board (e.g. plywood, particle board, OSB etc.) screwed, adhered or otherwise fastened to the elongate device. [0022] Preferably the locking means may include at least one fastener for restraining relative separating or closing motions of the two parts of elongate device.

[0023] The locking means may include at least one pin inserted into aligned apertures in the at least two parts. Alternatively or in addition, the locking means may include one or more latches or bolts for preventing unwanted separating or closing motions of the at least two parts of the elongate device.

[0024] The elongate device may be telescopic. For example, one of the two parts may slidingly fit within or over the other of the two parts.

[0025] For an elongate device that includes, for example, three said parts, the centre one of the three parts slidingly partially telescope into each of the other two parts. Alternatively, one end part may telescope into the centre part, and the centre part may telescope into the third part.

[0026] The ability to adjust the overall length of the elongate device allows the apparatus to be used for forming a variety of widths of steps or stair. Being reusable, the apparatus also reduces the need to measure and cut timber for each step/stair falsework/formwork.

[0027] Preferably the apparatus include metal components, such as preferably the elongate device being formed of or including steel or aluminium parts. Alternatively, the elongate device may be formed of or include carbon fibre. For a balance of relative lightness, durability and strength, aluminium is preferred.

[0028] The elongate device may include at least one mounting bracket to receive board shuttering to support the riser face for at least one step or stair. [0029] The apparatus may include at least one tread step. The at least one tread step may be integral or preferably removable. For example, the at least one tread step may be removable and may mount to at least one tread step mount on the elongate device.

[0030] The at least one tread step mount may be provided by at least one slot or channel provided on the elongate device

[0031 ] The at least one tread step for attachment to the tread step mount may include a corresponding mounting means, such as a plate that slots into the at least one slot or channel, and preferably is mechanically fixed. The at least one tread step may be attached to the elongate device by one or more pins or threaded fasteners, such as one or more bolts. Alternatively, or in addition, the at least one tread step may be mounted to the elongate device by the end of the elongate device having a screw thread or latch arrangement.

[0032] It will be appreciated the at least one tread step helps to avoid tradesmen or other persons on-site from walking on and damaging/spoiling the wet concrete on the treads of the stairs/steps whilst the concrete is curing/setting. It will be appreciated that the at least one tread step provides a valuable safety feature in giving a defined and safe place to walk on and avoid the wet concrete and any potentially slippery/narrow edge to formwork and shuttering for the riser.

[0033] The apparatus may include at least one upright support for a handrail. The at least one handrail support may be attached by a bracket to the elongate device.

[0034] A further aspect of the present invention provides formwork or falsework including an apparatus herein described and defined. [0035] Another aspect of the present invention provides formwork or falsework modular system incorporating an apparatus as herein described and defined.

BRIEF DESCRIPTION OF THE DRAWINGS

[0036] One or more embodiments of the present invention will hereinafter be described with reference to the accompanying figures, in which:

[0037] Figure 1 shows an apparatus according to an embodiment f the present invention.

[0038] Figure 2 shows a number of apparatuses embodying the present invention and each mounted at one end to a wall.

[0039] Figure 3 shows in even greater detail some of the apparatuses of the present invention showing the locking means and shuttering in place.

[0040] Figure 4 shows a reverse view of an elongate device of an apparatus according to an embodiment of the present invention showing riser shuttering mounts.

[0041 ] Figure 5 shows a tread step mount portion on the elongate device of an apparatus according to an embodiment of the present invention

[0042] Figure 6 shows a tread step mounted to the elongate device of an apparatus according to an embodiment of the present invention.

[0043] Figures 7 and 8 show a handrail support mounted to the elongate device of an apparatus according to an embodiment of the present invention. DESCRIPTION OF PREFERRED EMBODIMENT(S)

[0044] Figures 1 to 8 show embodiments of the present invention.

[0045] An apparatus 10 for use in forming at least one step or stair from concrete or the like includes an elongate device 12 of adjustable length (see arrows labelled 17.

[0046] A first part 14 inserts into a second part 16 of the elongate device. This provides a telescoping function allowing collapse for storage, transport and short length use, and extension where the elongate device can be extended for use where longer/wider step or stair riser falsework is needed. The elongate device first and second parts (and any further such parts) can be provided by tube sections, such as square tubes as shown in the figures. The outer surface of a square tube section provides a useful flat surface for mounting the stair riser shuttering to.

[0047] Locking means 18 in the form of a pin 20 or threaded fastener 21 engages the two parts 14, 16 together to prevent shortening or extension until the lock is released. The pin can pass through aligned holes in each of the two parts. The threaded fastener can provide a similar function or may threadingly engage with the outermost part 16 and bite against the surface of the inner part 14 to prevent relative movement between the two parts.

[0048] It will be appreciated that more than two such parts 14 and 16 may be employed. The elongate device may be formed of three or more engaging parts to collapse smaller than using two parts. Locking means can be provided wherever two adjacent parts interleave/telescope together.

[0049] Alternatively, the elongate device may be modular with additional lengths added to one or both ends thereof to vary the length of the elongate device. Connection can be by way of bolting, screw fastening or clip fit together. [0050] The outer ends of the elongate device include brackets 22a, 22b, such as flat plates, for use in mounting the elongate device to a wall or other support, such as timber of metal framing. Each bracket 22a, 22b may include a plate with apertures therethrough for fasteners to pass through and fix the elongate device to the wall/framing.

[0051 ] The elongate device includes or supports riser shuttering 26 for use in supporting the riser face of a step of wet concrete (or the like) until cured/set. As shown, the shuttering can be mounted to shuttering brackets 24 or can be integral to each part 14,16. Riser shuttering end mounts 25 can be provided, particularly adjacent the end brackets 22a, 22b.

[0052] The elongate device can include a removable or fixed tread step 28 (preferably removable to aid smoothing of the concrete tread and then attached). The tread step can include a tread step mounting portion 30 which engages with a tread step retainer 32 on the elongate device. For example, the tread step retainer 32 may include a tread step retainer portion 34 in the form of a channel or slot formed by at least one plate spaced from the elongate device parts 14 and 16.

[0053] The tread step 28 can include a tread plate 28a to provide a defined tread zone for users. Preferably, the tread step provides an upper tread surface flush with the upper surface of the elongate device parts 14 and 16 so as to create a flat surface to aid application of a smooth or textured finishing of the concrete (or the like ) tread upper surface.

[0054] A hand rail may be mounted to one side/end of the elongate device. The handrail can be mounted an upright 36 attached e.g. via a bracket 38 adjacent an end of the elongate device. [0055] Each elongate device used in creating formwork for a series of steps in a flight of stairs may include a handrail upright attached thereto, of the upright may be attached to every other one.

[0056] The handrail is particularly beneficial when the outboard end of the elongate device is not attached to a wall or other substantial upright support or framework, and ensures that users have a safety support.

[0057] It will be appreciated that the present invention provides adjustable, reusable falsework/formwork for use in creating steps or stairs from concrete or the like, and which avoids the need to remake timber falsework/formwork for stair/step risers, reduces storage space, can be of relatively lightweight material, such as aluminium and can provide mounting for treads and handrails for trades people.

10 Apparatus 24 Riser shuttering mount

12 Elongate device 25 Riser shuttering mount adjacent

14 Elongate device first part 26 Shuttering

16 Elongate device second part 28 Tread step

17 Two way arrows showing 28a Tread plate of tread step

18 Locking means 30 Tread Step mount portion

20 Locking means (pin) 32 Tread step retainer

21 Locking means (threaded) 34 Tread step retaining portion

22a End mount (first part) 36 Handrail upright

22b End mount (second part) 38 Handrail upright bracket

Claims

CLAIMS:

1 . An apparatus for use in formwork for forming steps or stairs, the apparatus including an elongate device of adjustable length having at least two parts adjustable relative to one another for use in forming at least one step riser formwork of the steps or stairs, and a locking means to lock the at least two parts at a desired length adjustment of the device.

2. The apparatus of claim 1 , wherein the elongate device includes at least one mounting portion for mounting the device to a wall or to supporting formwork or falsework.

3. The apparatus of claim 2, the at least one mounting portion is provided at one end of the elongate device or at each of two opposed ends thereof.

4. The apparatus of claim 2 or 3, the at least one mounting portion including a fixed or removable plate provided at one or both respective opposed ends of the elongate device.

5. The apparatus of any one of the preceding claims, wherein the elongate device includes at least one support for attachment of shuttering for supporting a face of at least one riser of the steps or stairs of concrete or the like whilst curing/setting sufficiently to be self supporting.

6. The apparatus of any one of the preceding claims, the elongate device including shuttering.

7. The apparatus of claim 6, the shuttering being at least one board fastened to the elongate device.

8. The apparatus of any one of the preceding claims, wherein the locking means includes at least one fastener for restraining relative separating or closing motions of the two parts of elongate device.

9. The apparatus of claim 8, the locking means including at least one pin inserted into aligned apertures in the at least two parts.

10. The apparatus of claim 8, the locking means including one or more latches or bolts for preventing unwanted separating or closing motions of the at least two parts of the elongate device.

1 1 . The apparatus of any one of the preceding claims, wherein the elongate device is telescopic.

12. The apparatus of claim 1 1 , wherein one of the two parts of the elongate device slidingly fits within or over the other of the two parts of the elongate device.

13. The apparatus of claim 1 1 , wherein, for the elongate device including three said parts, a centre one of the three parts slidingly partially telescopes into each of the other two parts or one end part may telescope into the centre part and the centre part may telescope into a third part.

14. The apparatus of any one of the preceding claims, wherein the elongate device is formed of or includes steel or aluminium or is formed of or includes carbon fibre.

15. The apparatus of any one of the preceding claims, wherein the elongate device includes at least one attached or removable tread step.

16. The apparatus of claim 15, wherein the removable tread step mounts mount to at least one tread step mount provided on the elongate device.

17. The apparatus of claim 16, the at least one tread step mount provided by at least one slot or channel provided on the elongate device.

18. The apparatus of any one of the preceding claims, including at least one upright support for a handrail.

19. The apparatus of claim 18, the at least one handrail support attached by a bracket to the elongate device.

20. Formwork or falsework including an apparatus according to any one of the preceding claims.

21 . A formwork or falsework modular system incorporating an apparatus according to any one of the preceding claims.