WO2022149005A1

WO2022149005A1 - A column formwork system for concrete structures and a method thereof

Info

Publication number: WO2022149005A1
Application number: PCT/IB2021/051591
Authority: WO
Inventors: Kalepu SURYA VENKATA DURGA PRASAD
Original assignee: Surya Venkata Durga Prasad Kalepu
Priority date: 2021-01-06
Filing date: 2021-02-26
Publication date: 2022-07-14

Abstract

A column formwork system (20) for concrete structures is disclosed. The system includes an external frame (30) including at least three shuttering plates (40, 50, 60) configured to be arranged in a channel type design. The external frame comprises a closing shuttering plate (70) configured to be close ends of the at least three shuttering plates. The shuttering plates includes a first movable plate (80) comprising a first width and a second movable plate (90) comprising a second width, where the first width is greater than the second width. The first movable plate and the second movable plate are movable along a perpendicular direction to each other to achieve a sectional dimensional variability and forms a rectangular or a square formwork. The system includes a screwing and locking arrangement (100, 110) to move and lock the corresponding first movable plate and the second movable plate at a user preferred location on the external frame for column casting.

Description

A COLUMN FORMWORK SYSTEM FOR CONCRETE STRUCTURES AND A

METHOD THEREOF

This International Application claims priority from a Patent application filed in India having Patent Application No. 202141000553, filed on January 06, 2021, and titled “A COLUMN FORMWORK SYSTEM FOR CONCRETE STRUCTURES AND A METHOD THEREOF”.

FIELD OF INVENTION

Embodiments of the present disclosure relate to a mold apparatus and more particularly to a column formwork system for concrete structures and a method thereof. BACKGROUND

The formworks are temporally armed structures composed of elements and accessories with a specially defined shape, form and function to get a rigid structure allowing building a mold over which the concrete is poured which following its solidification must be disassembled and withdraw to leave a molded structure at sight with predesigned shape and characteristics. The panel for formworks is a metallic element used in the building of civil works that acts as basic part of the mold to shape a concrete structure. Its main characteristics is to allow adding joint and adjustment elements at the moment of its disassembly with other panel with similar characteristics.

In now-a-days there are so many products available in the field of construction industry like mostly in the field of formwork for concreting. Presently in market there are many types of formworks/Shuttering’s available for column casting. They are mostly made to give flexibility for any size of column casting using single formwork. However, these formworks take more time for erecting in site, requires high skilled and number of labour. These formworks are very complicated to adjust for any size of column size. Conventionally, the inconvenience with such systems is the impossibility to use the same panels and/or elements with different measurements and functions because they are manufactured with fixed measurements and specific functions, the available systems do not have elements to adjust the panels according to the structure to be molded. Such formworks systems have the technical problem of maladjustment when they secure to smooth spacers through pins or the problem of damaging the structure or difficulty to remove the form when using yokes of threaded spacers.

In this sense, it is clear that this becomes a tedious and unwanted task, since in a construction site it is necessary to have different sizes of panels that must be grouped according to their width measurement, but in some cases, they can create confusions that lead to the construction of pillars or columns of sizes that are not the desired ones, which corresponds to an unnecessary expense. Also, some of formworks includes panels which are made with plurality of holes for adjusting size. However, these holes may create leakage problem while concreting and also may create difficulty during disassembling, concrete structure faces also may not be give smooth surface.

Hence, there is a need for a formwork system for concrete structures to address the aforementioned issue(s).

BRIEF DESCRIPTION

In accordance with an embodiment of the present disclosure, a column formwork system for concrete structures is provided. The system includes an external frame comprising at least three shuttering plates configured to be arranged in a channel type design and jointed in mutual perpendicular direction. The external frame also includes a closing shuttering plate configured to close ends of the at least three shuttering plates. The at least three shuttering plates and the closing shuttering plate are configured to fit at the time of casting. The at least three shutting plates and the closing shuttering plate includes a first movable plate comprising a first width and a second movable plate comprising a second width, where the first width is greater than the second width. The first movable plate and the second movable plate are movable along a perpendicular direction to each other to achieve a sectional dimensional variability. The at least three shutting plates and the closing shuttering plate includes a screwing and locking arrangement configured to move and lock the corresponding first movable plate and the corresponding second movable plate at a user preferred location on the external frame for column casting. The first movable plate and the second movable plate along with the screwing and locking arrangement are adjusted to required column size to form a rectangular or a square formwork. The first movable plate and the second movable plate are arranged inside three shuttering plate channel shape on any two adjacent sides so that movable plates may move perpendicular to each other. The at least three shutting plates and the closing shuttering plate includes a space filler block to fill space which is formed due to movement of two movable plates inside formwork between two movable plates.

In accordance with another embodiment of the present disclosure, a method to operate the column formwork for concrete structures is provided. The method includes providing an external frame comprising at least three shuttering plates configured to be arranged in a channel type design and closing the at least three shuttering plates using a closing shuttering plate. The method also includes adjusting a first movable plate and a second movable plate fitted to the at least three shuttering plates arranged before erecting formwork for column casting. The method further includes locking the first movable plate and the second movable plate at a user preferred location on the external frame using a screwing and locking arrangement. The method further includes placing a space filler block in a predefined arrangement such that a space left due to movement of the first movable plate and the second movable plate is covered. The method further includes erecting the at least three shuttering plates arranged around column reinforcement and a remaining side is closed by the closing shuttering plate for casting.

To further clarify the advantages and features of the present disclosure, a more particular description of the disclosure will follow by reference to specific embodiments thereof, which are illustrated in the appended figures. It is to be appreciated that these figures depict only typical embodiments of the disclosure and are therefore not to be considered limiting in scope. The disclosure will be described and explained with additional specificity and detail with the appended figures.

BRIEF DESCRIPTION OF THE DRAWINGS

The disclosure will be described and explained with additional specificity and detail with the accompanying figures in which: FIG. 1 is a schematic representation of a prior art formwork system;

FIG. 2 is a schematic representation of a column formwork system for concrete structures in accordance with an embodiment of the present disclosure;

FIG. 3 is a schematic representation of isometric view of one embodiment of the column formwork of FIG. 2 in accordance with an embodiment of the present disclosure; and

FIG. 4 is a flow chart representing the steps involved in a method to operate the column formwork for concrete structures in accordance with an embodiment of the present disclosure.

Further, those skilled in the art will appreciate that elements in the figures are illustrated for simplicity and may not have necessarily been drawn to scale. Furthermore, in terms of the construction of the device, one or more components of the device may have been represented in the figures by conventional symbols, and the figures may show only those specific details that are pertinent to understanding the embodiments of the present disclosure so as not to obscure the figures with details that will be readily apparent to those skilled in the art having the benefit of the description herein.

DETAILED DESCRIPTION

For the purpose of promoting an understanding of the principles of the disclosure, reference will now be made to the embodiment illustrated in the figures and specific language will be used to describe them. It will nevertheless be understood that no limitation of the scope of the disclosure is thereby intended. Such alterations and further modifications in the illustrated system, and such further applications of the principles of the disclosure as would normally occur to those skilled in the art are to be construed as being within the scope of the present disclosure.

The terms "comprises", "comprising", or any other variations thereof, are intended to cover a non-exclusive inclusion, such that a process or method that comprises a list of steps does not include only those steps but may include other steps not expressly listed or inherent to such a process or method. Similarly, one or more devices or sub-systems or elements or structures or components preceded by "comprises... a" does not, without more constraints, preclude the existence of other devices, sub-systems, elements, structures, components, additional devices, additional sub-systems, additional elements, additional structures or additional components. Appearances of the phrase "in an embodiment", "in another embodiment" and similar language throughout this specification may, but not necessarily do, all refer to the same embodiment.

Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by those skilled in the art to which this disclosure belongs. The system, methods, and examples provided herein are only illustrative and not intended to be limiting.

In the following specification and the claims, reference will be made to a number of terms, which shall be defined to have the following meanings. The singular forms “a”, “an”, and “the” include plural references unless the context clearly dictates otherwise.

Embodiments of the present disclosure relate to a column formwork system for concrete structures. The system includes an external frame comprising at least three shuttering plates configured to be arranged in a channel type design and jointed in mutual perpendicular direction. The external frame also includes a closing shuttering plate configured to close ends of the at least three shuttering plates. The at least three shuttering plates and the closing shuttering plate are configured to fit at the time of casting. The at least three shutting plates and the closing shuttering plate includes a first movable plate comprising a first width and a second movable plate comprising a second width, where the first width is greater than the second width. The first movable plate and the second movable plate are movable along a perpendicular direction to each other to achieve a sectional dimensional variability. The at least three shutting plates and the closing shuttering plate includes a screwing and locking arrangement configured to move and lock the corresponding first movable plate and the corresponding second movable plate at a user preferred location on the external frame for column casting. The first movable plate and the second movable plate along with the screwing and locking arrangement are adjusted to required column size to form a rectangular or a square formwork. FIG. 1 is a schematic representation of a prior art formwork system (10) for comparison with the present invention. According to the prior art, a plurality of panels (4) in which a flange (2) in which a bolt hole (1) is formed is vertically protruded around an edge of a flat plate (3) of a predetermined shape are connected to each other to form a frame, and the connected panels (4) flanges (2) abutting in a horizontal plane are coupled by a bolt (5) and a nut (6), the panel 4 is bent at an angle to the joint portion is a shape having the same angle of the bent and on both flanges (2). The corner joint material (7) in which the bolt hole (1) is formed is inserted between the panel (4) and is coupled to the bolt (5) and the nut (6). The pillar formwork is formed by the combination of a plurality of panels (4) and a plurality of angled joints (7), and the connection of each member is characterized by consisting of a bolt (5) and a nut (6). Each panel (4) is composed of a flat plate (3) having a predetermined shape such as a rectangular shape, and a flange (2) projecting perpendicularly to the surface of the flat plate (3) and connected and fastened to the flange (2).

However, in order to construct the column, it is necessary to manufacture the column form according to the size of the column by referring to the design diagram. The construction of the column form is often performed directly by the operator in the field. The use of prefabricated column formwork according to the design may lead to an increase in manufacturing cost. In particular, since the reinforcement structure having rigidity against the lateral pressure transferred from concrete is insufficient, basic safety of the column form cannot be secured.

FIG. 2 is a schematic representation of a column formwork system (20) for concrete structures in accordance with an embodiment of the present disclosure. The system (20) includes an external frame (30) including at least three shuttering plates (40, 50, 60). The at least three plates are configured to be arranged in a channel type design. The external frame (30) also includes a closing shuttering plate (70) which is configured to be coupled to the at least three shuttering plates (40, 50, 60). As used herein, shuttering in concrete construction is used as a mold for a structure in which fresh concrete is poured only to harden subsequently. It supports and holds the liquid concrete till the time it solidifies and takes shape. In one embodiment, the external frame (30) may be composed of a material including steel, any rust proof metals, glass reinforced plastic, fabric, wood, plywood, Aluminum or iron. In a specific embodiment, the external frame (30) may include dimensions including a height in the range of 150-250 cm, width in the range of 50-100 cm and thickness in the range of 50-100 cm.

The at least three shuttering plates (40, 50, 60) and the closing shuttering plate (70) are configured to form a rectangular or a square formwork. The formwork (20) serves as mold for concrete structural components unless such mold is provided by the soil, other structural components, or the like. The rectangular or square formwork molds the placed fresh concrete, which in this stage normally is viscous, to the shape specified in the drawing for column construction. The concrete is a fluid that offers the opportunity to economically create structures of almost any geometry - concrete may be poured into a mold of almost any shape. This fluidity is seldom used, with concrete instead being poured into rigid molds to create high material use structures with large carbon footprints. The column formwork includes low cost fabric sheets, where flexible formwork takes advantage of the fluidity of concrete to create highly optimized, architecturally interesting, building forms. Significant material savings may be achieved. The optimized section provides ultimate limit state capacity while reducing embodied carbon, thus improving the life cycle performance of the entire structure.

Furthermore, the at least three shuttering plates and the closing shuttering plate includes a first movable plate (80) having a first width and a second movable plate (90) having a second width. The first width is greater than the second width. In one embodiment, the first movable plate (80) and the second movable plate (80) are coupled inside the external frame (30). More specifically, the inner side of channel type design includes first movable plate which is a movable long plate and the second movable plate which is a movable short plate, where the movable long plate and the movable short plate are perpendicular to each other. The first movable plate and the second movable plate are arranged inside three shuttering plate channel shape on any two adjacent sides so that movable plates may move perpendicular to each other. Moreover, the first movable plate (80) and the second movable plate (90) are movable along a perpendicular direction to each other to achieve a sectional dimensional variability. In detail, the movable long plate and the movable short plate moves in the perpendicular direction to form different sizes of formwork for column casting. The at least three shuttering plates and the closing shuttering plate further includes a screwing and locking arrangement (100, 110) which is configured to move and lock the corresponding first movable plate (80) and the corresponding second movable plate (90) at a user preferred location on the external frame for column casting. In a specific embodiment, the screwing and locking arrangement includes a set of locking plates (100) and a set of screws and bolts (110). The locking plate and screw systems offer certain advantages over other plates such that it becomes unnecessary for the plate to intimately contact the underlying bone in all areas. As the screws are tightened, they lock to the plate, thus stabilizing the segments without the need to compress the bone to the plate. This makes it impossible for the screw insertion to alter the reduction. The locking plate and screw systems have been shown to provide more stable fixation.

FIG. 3 is a schematic representation of isometric view of one embodiment of the column formwork (20) of FIG. 2 in accordance with an embodiment of the present disclosure. The formwork (20) includes the external frame (30) comprising the at least three shuttering plates (40, 50, 60). The at least three shuttering plates may include a plurality of holes (120) arranged along height and width of the channel type design. The plurality of holes is configured to accommodate the screwing and locking arrangement. In one embodiment, the plurality of holes may also be configured to allow adding joint and adjustment elements at the moment of its disassembly with other panel with similar characteristics. Such holes also permit the longitudinal adjustment of the formwork at the moment of the assemble.

The internal side of the external frame (30) includes a first movable plate (80) comprising a first width and a second movable plate (90) comprising a second width. The first movable plate and the second movable plate are movable along a perpendicular direction using a screwing and locking arrangement (100, 110). In one embodiment, the screwing and locking arrangement may include a set of locking plates and a set of screws and bolts. In such an embodiment, the set of locking plates may include a plurality of perforations (130) and a set of screw arrangement (140) to adjust the size in a horizontal direction to increase the width of the column.

More specifically, two types of arrangements are there for size adjustment. First is nut and bolt arrangement (100) and second is perforated rivet with pins to movable plates (110). In another embodiment, only nut and bolt system at center and at four corners to movable plates are provided to make any size of formwork, even up to 1 m as per column size). In operation of size adjustment, before adjusting formwork to required size for column casting, remove all pins from four corners (110) to move movable plates. Then using nut and bolt arrangement (100) move the movable plate by adjusting nut to req formwork inside size as per column size. After adjustment of movable plate as per requirement, the pins are required to be fix in respective holes which are formed on rivet along longitudinal direction. The same process may apply to another movable plate for adjustment.

Additionally, the formwork (20) includes a space filler block (150) which is configured to fill a space left between the first movable plate and the second movable plate created during movement due to geometrical configuration. In such an embodiment, the space filler block may include a plurality of sizes used as per column size. The space filler block is provided for the separation of the metallic panels face to face to a required distance with which the thickness of the concrete wall to be molded. The space filler block may be adjusted in a side of the formwork which may speed up the operation and guarantying the uniformity of the structure, since these when are installed or removed are not deformed. The spacer is always protected during the fusing of the concrete from the screws of the screwing and locking arrangement nut to maintain the width of the wall. .

In operation, before erecting formwork (20) for column casting, the movable plates (80, 90) fitted to “C” shaped shuttering have to be adjusted by using screw arrangement and locking system (100, 110) as per column size and then the required space filler is needed to be placed in proper arrangement such that the whole space left due to movement of movable plates is covered. After that the adjusted “C” Shaped Shuttering (40, 50, 60) is required to be erected around column reinforcement and then the remaining side is closed by closing shuttering plate (70) for casting.

FIG. 4 is a flow chart representing the steps involved in a method (200) to operate the column formwork for concrete structures in accordance with an embodiment of the present disclosure. The method (200) includes providing an external frame comprising at least three shuttering plates configured to be arranged in a channel type design and a closing shuttering plate configured to be coupled to the at least three shuttering plates in step 210. In one embodiment, the external frame may be composed of a material including steel any rust proof metals, glass reinforced plastic, fabric, wood, plywood, Aluminum or iron. In a specific embodiment, the external frame including the at least three shuttering plates may include a plurality of holes arranged along height and width of the channel type design. The plurality of holes may be configured to accommodate the screwing and locking arrangement.

The method (200) also includes adjusting a first movable plate and a second movable plate fitted to the at least three shuttering plates arranged before erecting formwork for column casting in step 220. The method (200) further includes locking the first movable plate and the second movable plate at a user preferred location on the external frame using a screwing and locking arrangement in step 230. In one embodiment, the screwing and locking arrangement may include a set of locking plates and a set of screws and bolts. In such an embodiment, the set of locking plates may include a plurality of perforations and a set of screw arrangement to adjust the size. In a specific embodiment, the first movable plate and the second movable plate are coupled inside the external frame. More specifically, two types of arrangements are there for size adjustment. First is nut and bolt arrangement (100) and second is perforated rivet with pins to movable plates (110). In another embodiment, only nut and bolt system at center and at four corners to movable plates are provided to make any size of formwork, even up to 1mm as per column size). In operation of size adjustment, before adjusting formwork to required size for column casting, remove all pins from four corners (110) to move movable plates. Then using nut and bolt arrangement (100) move the movable plate by adjusting nut to req formwork inside size as per column size. After adjustment of movable plate as per requirement, the pins are required to be fix in respective holes which are formed on rivet along longitudinal direction. The same process may apply to another movable plate for adjustment.

The method (200) further includes placing a space filler block in a predefined arrangement such that a space left due to movement of the first movable plate and the second movable plate is covered in step 240. In one embodiment, the space filler block may include a plurality of sizes used as per column size. The space filler block is provided for the separation of the metallic panels face to face to a required distance with which the thickness of the concrete wall to be molded. The method (200) further includes erecting the at least three shuttering plates arranged around column reinforcement and a remaining side is closed by the closing shuttering plate for casting in step 250.

Various embodiments of the column formwork for concrete structures as described above enable size flexibility of the formwork, with single formwork may form any size of column so that the formwork suppliers will get benefit of maintain less formwork for any size of column. Due to very less fittings for erection of this type of formworks, the requirement of labour and erection time may maintain to very good and efficient level. These formworks may give good profits in construction field because of less labour consumption, time saving and use of less formwork for any size of column. This type of formwork takes very less time for erecting around reinforcement for column casting as compare to any another present available formwork in construction field right know. The flexible formwork uses lightweight, high strength sheets of fabric to take advantage of the fluidity of concrete and create highly optimized, architecturally interesting, building forms. Using flexible formwork, it is possible to cast optimized structures that use significantly less concrete than an equivalent strength prismatic section, thereby offering the potential for significant embodied energy savings in new concrete structures. The space filler block guaranties a uniform width of the wall segments and allows graduating the formworks for the molding of irregular structures. Besides this, the formwork solves the problem of protuberances during molding process. The formwork has movable plates with screwing and locking arrangement for the alignment that make the assemble easy to use and provide uniformity in the structures. The formwork contributes to speed out the operations in the concrete molding process in civil work building, providing better finishing and reducing the number of pieces and accessories required for the project execution in which intervene the adjustable movable plates with predefined sizes. It will be understood by those skilled in the art that the foregoing general description and the following detailed description are exemplary and explanatory of the disclosure and are not intended to be restrictive thereof.

While specific language has been used to describe the disclosure, any limitations arising on account of the same are not intended. As would be apparent to a person skilled in the art, various working modifications may be made to the method in order to implement the inventive concept as taught herein.

The figures and the foregoing description give examples of embodiments. Those skilled in the art will appreciate that one or more of the described elements may well be combined into a single functional element. Alternatively, certain elements may be split into multiple functional elements. Elements from one embodiment may be added to another embodiment. For example, the order of processes described herein may be changed and are not limited to the manner described herein. Moreover, the actions of any flow diagram need not be implemented in the order shown; nor do all of the acts need to be necessarily performed. Also, those acts that are not dependent on other acts may be performed in parallel with the other acts. The scope of embodiments is by no means limited by these specific examples.

Claims

WE CLAIM:

1. A column formwork system (20) for one or more concrete structures comprising: an external frame (30) comprising: at least three shuttering plates (40, 50, 60) configured to be arranged in a channel type design and jointed in mutual perpendicular direction; a closing shuttering plate (70) configured to close ends of the at least three shuttering plates, wherein the at least three shuttering plates (40, 50, 60) and the closing shuttering plate (70) are configured to fit at the time of casting and comprising: a first movable plate (80) comprising a first width and a second movable plate (90) comprising a second width, wherein the first width is greater than the second width, wherein the first movable plate (80) and the second movable plate (90) are movable along a perpendicular direction to each other to achieve a sectional dimensional variability; and a screwing and locking arrangement (100, 110) configured to move and lock the corresponding first movable plate (80) and the corresponding second movable plate (90) at a user preferred location on the external frame (30) for column casting, wherein the first movable plate (80) and the second movable plate (90) along with the screwing and locking arrangement (100, 110) are adjusted to required column size to form a rectangular or a square formwork.

2. The system (20) as claimed in claim 1, wherein the external frame (30) is composed of a material comprising steel any rust proof metals, glass reinforced plastic, fabric, wood, plywood, Aluminum or iron.

3. The system (20) as claimed in claim 1, wherein the external frame (30) comprises a height in the range of 150-250 cm, width in the range of 50-100 cm and thickness in the range of 50-100 cm.

4. The system (20) as claimed in claim 1, wherein the external frame (30) comprising the at least three shuttering plates (40, 50, 60) comprises a plurality of holes (120) arranged along height and width of the channel type design, wherein the plurality of holes (120) is configured to accommodate the screwing and locking arrangement (100, 110).

5. The system (20) as clamed in claim 1, wherein the screwing and locking arrangement (100, 110) comprises a set of locking plates (100) and a set of screws and bolts (110).

6. The system (20) as claimed in claim 5, wherein the set of locking plates (100) comprises a plurality of perforations (130) and a set of screw arrangement (140) to adjust the size.

7. The system (20) as claimed in claim 1, wherein the first movable plate (80) and the second movable plate (90) are coupled inside the external frame (30).

8. The system (20) as claimed in claim 1, comprising a space filler block (150) configured to fill a space left between the first movable plate and the second movable plate created during movement due to geometrical configuration.

9. The system (20) as claimed in claim 8, wherein the space filler block (150) comprises a plurality of sizes used as per column size.

10. A method (200) comprising: providing an external frame comprising at least three shuttering plates configured to be arranged in a channel type design and closing ends of the at least three shuttering plates using a closing shuttering plate; (210) adjusting a first movable plate and a second movable plate fitted to the at least three shuttering plates arranged before erecting formwork for column casting; (220) locking the first movable plate and the second movable plate at a user preferred location on the external frame using a screwing and locking arrangement; (230) placing a space filler block in a predefined arrangement such that a space left due to movement of the first movable plate and the second movable plate is covered; (240) and erecting the at least three shuttering plates arranged in the channel type design around column reinforcement and a remaining side is closed by the closing shuttering plate for casting. (250)