Building Structure
The present invention relates to the construction of buildings as well as elements, structures and methods used in their construction. There is described a pre-fabricated formwork module (12) for a building portion. The module 12 includes two or more panels (14) each including a boundary portion (18) and one or more projecting structures (16). In the module (12) the panels are arranged such that their boundary portions (18) together define a first substantially continuous boundary for forming concrete and the projecting structures (18) project from the boundary into the concrete. The module (12) also include one or more reinforcing bars (30A) fixed, e.g. fixed to the projecting structures, in position relative to the boundary for transport and to reinforce the concrete.
The present invention relates to the construction of concrete buildings as well as elements, structures and methods used in their construction. The invention will be described in relation to the construction of high rise buildings. However, single storey and low rise buildings can also be constructed using aspects of the present invention.
BACKGROUND OF THE INVENTIONBuildings having concrete elements are constructed using formwork to create a temporary or permanent cast into which the concrete to form the structure of the building is poured. Temporary formwork is removed after curing of the concrete, whilst permanent formwork remains as part of the structure of the building after the concrete has cured. Current methods of providing concrete formwork are very labour intensive and potentially dangerous for workers.
Traditionally, timber formwork has been used. Timber formwork is built on site by a carpenter who uses timber to create a mould into which concrete can be formed. Typically plywood boards are used to define the sides and bottom of the moulds, and more solid timber frames and bracing used to hold the plywood in place. The use of timber for formwork has certain disadvantages, e.g. timber formwork is only able to be re-used a very limited number of times, it also has the inherent dimensional and structural irregularities associated with a natural product. Moreover, because the formwork is manually installed on-site, tolerances for installation are relatively loose.
Conventional timber formwork for a vertical wall will typically consist of a pair of boards spaced apart by the thickness of the wall to be created. The boards define the opposite surfaces of the wall. The boards are supported and braced on their external sides by timber beams and other bracing to hold them in place. The boards are also tied to each other at intervals to hold the walls of the formwork from moving apart under the pressure of the concrete being poured into the formwork. The ties can be located along the edges of the board or be placed such that they project through the wall of the board to the opposite facing board.
For horizontal structures, such as a floor, the underside of the floor is defined by one or more sheets of timber (eg. made from plywood) that are supported on timber beams. For elevated floors a temporary support structure needs to be erected before the floor of the formwork can be installed. Such installation is very time consuming and potentially hazardous, particularly when the workers are installing timber panels on the bottom of the formwork section for horizontally extending structures like floors or beams onto the support beams.
Around the edges of the timber floor, walls are erected to define a volume into which concrete will be poured. Prior to pouring concrete however, many other elements need to be laid into the formwork so that they can be cast into the concrete. Chief among these are reinforcing bars and conduits for post tensioning tendons, apertures and connections for plumbing and other services.
The placement of each of these additional elements is performed onsite after the formation of the formwork, with each additional job becoming progressively more difficult and hazardous for workers as the working area becomes more cluttered with other elements. For example, in order to install plumbing connections in a floor it may be necessary for the installer to place components between many layers of reinforcing steel or other elements of the building. These elements will also need to be carried or manoeuvred across a surface of the formwork that is criss-crossed by reinforcing bars, associated ligatures holding the steel together and other elements.
After the concrete has cured the temporary formwork then needs to be removed. This is also time consuming and potentially dangerous. In this case workers are removing supports, and structures positioned above their heads.
More recently modular temporary formwork systems have been devised. These include panels which have a frame, typically of metal, for providing structural strength. The panel surface defines the inside of the concrete mould. These systems include, corner modules, flat panels etc and the desired formwork shape can be made by joining these together. These systems can be quicker to place than conventional timber formwork because they can be clipped or bolted together and are typically able to be used many times more than conventional timber formwork, but in other respects have similar drawbacks.
One way of partly avoiding work associated with temporary formwork is the use of permanent formwork. For example steel panels can replace the floor of the formwork on horizontal surfaces. These panels are positioned in a very similar manner to that of the timber floor panels of conventional timber formwork but need not be removed afterward as they are formed into the underside of the concrete which they have been used to create. However, in other respects these systems are similar to conventional timber formwork.
There also exists framing systems used for creating vertical walls such as the AFS system, which comprises a series of vertically extending studs to which cement sheet is attached on each side to define a wall cavity. These wall structures can be used as-is or filled with concrete to create a structural wall. If they are used as formwork the panels are first erected on site and braced. If reinforcing is needed, reinforcing bars are then inserted into the internal cavity as required. Services can be inserted through the wall before the concrete is finally poured. They can then be finished as required.
One way of ameliorating the complexity, cost and risk of using formwork as described above is to precast the concrete elements off site, but this is only viable in certain situations.
Accordingly, it is an object of the present invention to address one or more of the drawbacks of the prior art systems and/or provide a useful alternative to them.
It is not admitted that any of the information in this specification is common general knowledge, or that the person skilled in the art could be reasonably expected to have ascertained or understood it regarded it as relevant or combined it in any way at the priority date.
SUMMARY OF THE INVENTIONThe present inventor has realised that structures similar to those described in the applicant's previous patent applications can be used as permanent formwork in the construction of concrete structures. For example, formwork modules for a building core, room or structure can be formed from elements similar in construction to the building units described in PCT/AU2009/001236 in the name of the Applicant. Moreover particular advantages can also be obtained if prefabricated formwork modules, e.g. formwork modules for floors, beams, band beams, walls and cores, include panel assemblies similar to that described in International patent application PCT/AU2011/000298.
Accordingly in its various aspects the invention provides buildings and building portions and various components and methods for building buildings.
One aspect of the present invention provides a pre-fabricated formwork module for a building portion; the module including:
two or more panels each including a boundary portion and one or more projecting structures, the panels being arranged such that their boundary portions together define a first substantially continuous boundary for forming concrete, the projecting structures projecting from the boundary to project into the concrete; and
one or more reinforcing bars fixed, e.g. fixed to the projecting structures, in position relative to the boundary for transport and to reinforce the concrete.
The projecting structures preferably include one or more receiving voids opening outwardly from the first boundary to receive one or more reinforcing bars. The projecting structures defining the receiving voids may be shaped to carry a reinforcing bar at a predetermined spacing from the boundary, or more preferably to carry at least two reinforcing bars at, at least two, different predetermined spacings from the first boundary.
Preferred forms of the module further include a retaining structure to capture the reinforcing bars in the receiving voids. The retaining structure preferably includes a plurality of apertures which in use contact the projecting structures of respective panels and through which the retaining structure is welded to the projecting structures. The retaining structure, or further structure, preferably defines a second substantially continuous boundary, for forming concrete, spaced from the first boundary.
The receiving voids are shaped such that the panels may be formed from blanks cut from a common sheet of material, said blanks being arranged on the sheet such that at least one projecting structure portion of one blank is interleaved with a similar projecting structure of a neighbouring blank and located within the receiving voids of the other blank.
The module may further include two or more spaced beam members supporting the panels.
The beams members preferably have a profiled cross section including face which is arranged to form the concrete. The profile can be, but is not limited to, an L, C or S or Z shaped profile.
Preferably at least a portion of each projecting structure spans the space between the beam members. The projecting structures can (but are not limited to having) an L, C, S or Z shaped profile.
The projecting structures may include apertures carrying the reinforcing bars. Optionally each projecting structure terminates in a hook formation for keying into the concrete. The projecting structures may further include concrete flow apertures through which the concrete may encircle a portion of the projecting structure to engage the projecting structure.
Preferably each projecting structure defines a supporting structure carrying a reinforcing bar. Optionally the supporting structure includes a channel.
Another aspect of the invention provides a pre-fabricated formwork module for a building portion; the module including:
a form defining a substantially continuous boundary for forming concrete; and
one or more projecting structures;
the projecting structures projecting from the boundary to project into the concrete and defining a supporting structure carrying a reinforcing bar.
The supporting structure may include a channel. Preferably the supporting structure and the reinforcing bar carried thereby are positioned to reinforce a lower stratum of the concrete.
Another aspect of the invention provides a floor including one or more of the modules and concrete. In floors including modules having projecting structures, the boundary portions may be positioned horizontally so that the projecting structures project upwardly and the concrete may cover an upper extent of the projecting structures.
Another aspect of the invention provides a wall including one or more of the modules and concrete there between. In walls including modules having projecting structures, the projecting structures may each be connected to a respective projecting structure of the other module to tie the modules to each other.
Another aspect of the invention provides a pre-fabricated formwork module for a building portion, the module including
one or more forms defining a void for forming concrete; and
locating structure by which the module may be located relative to a vertically adjacent like or similar module.
Optionally the locating structure includes a locating element including an engagement portion by which it is fixed relative to the forms, and a lead-in portion to locate the vertically adjacent like or similar module. Preferably the forms are complementary to the forms of the like module when mounted atop the like module. The module may further include an inner form and an outer form. The outer form may at least partly encircle the inner form to define the void about the inner form, in which case, each of the forms might be tubular whereby said defined void is tubular.
A portion of one the forms may project upwardly beyond another portion of the forms to form an inner edge of a concrete structure above the other form portion.
Another aspect of the invention provides a locating element including, an engagement portion configured to engage with a formwork module in use; and a lead-in portion to locate a vertically adjacent like or similar module in use.
The engagement portion can include, a flange insertable to engage a formwork module; and a stop portion to limit the insertion of the flange. The lead-in portion and the stop portion can form respective sides of a triangular portion. The triangular portion may be tubular.
The module preferably includes one or more reinforcing bars fixed in position relative to the forms for transport and to reinforce the concrete.
At least one of the forms may include two or more panels. Each panel may include a boundary portion and one or more of the projecting structures. Each panel is preferably at least predominantly integrally formed of sheet material. Most preferably the panels within each form are arranged such that their boundary portions together define a substantially continuous boundary for forming the concrete.
Each panel may include an edge portion of the sheet material deflected relative to the boundary portion to form a projecting structure projecting from the boundary to project into the concrete.
A region adjacent the deflected edge portion may be recessed relative to a presentation surface of the sheet to receive an edge portion of a like adjacent panel opposite the adjacent panel's deflected edge whereby the presentation surfaces of the adjacent panels substantially align.
The receiving voids can be shaped for the panels to be formed from interleaved blanks. Portions of the projecting structures defining the receiving voids can be shaped to carry a reinforcing bar at a predetermined spacing from the boundary. The portions of the projecting structures defining the receiving voids can be shaped to carry at least two reinforcing bars at, at least two different predetermined spacings from the boundary.
Each projecting structure can define a supporting structure carrying a reinforcing bar. The supporting structure can includes a channel.
Another aspect of the invention provides a building portion including the module with locating structure and concrete.
Another aspect of the invention provides a panel for a building portion; the panel including:
-
- a boundary portion for forming concrete, and
- projecting structure projecting from the boundary portion to project into the concrete and including apertures for receiving reinforcing bars; and
- being at least predominantly integrally formed of sheet material.
Each projecting structure may terminate in a hook formation for keying into the concrete.
An edge portion of the sheet material may be deflected relative to the boundary portion to form the projecting structure. A region adjacent the deflected edge portion may be recessed relative to a presentation surface of the sheet to receive an edge portion of a like adjacent panel opposite the adjacent panel's deflected edge whereby the presentation surfaces of the adjacent panels substantially align.
The projecting structures preferably include concrete flow apertures through which the concrete may encircle a portion of the projecting structure to engage the projecting structure.
Another aspect of the invention provides an assembly including two or more of the panels arranged such that their boundary portions together define a substantially continuous boundary for forming the concrete.
Another aspect of the invention provides a beam for a building including one or more forms for forming concrete and concrete formed by the forms. The beam may include, and at least one of the forms be the form of, the module with reinforcing bar(s).
Another aspect of the invention provides a panel for a building portion; the panel including:
a boundary portion for forming concrete, and
one or more projecting structures projecting from the boundary portion to project into the concrete and defining one or more receiving voids opening outwardly from the boundary to receive one or more reinforcing bars.
In some examples the projecting structure(s) can be shaped so as to allow the boundary to be folded transverse to the projecting structures of the panel. To allow this, the projecting structure(s) can have notches therein. The panels (either before or after joining to a neighbouring panel) can be folded through the notches to create a recess within the panel, for example a channel shaped recess.
Another aspect of the invention provides a building portion including, one or more panels and concrete formed by the panels;
each panel including
-
- a boundary portion; and
- projecting structure projecting from the boundary portion into the concrete.
Another aspect of the invention provides a pre-fabricated module for a wall; the module including
two spaced forms each defining a respective boundary of a void for forming concrete;
each form including one or more projecting structures projecting from the boundary into the void;
wherein the projecting structures are each connected to a respective projecting structure of the other form to tie the forms.
Another aspect of the invention provides a method of building a building portion including: installing one or more of the above modules at a building site to create at least part of a concrete formwork structure; filling the concrete formwork structure with wet concrete; allowing the concrete to cure. Another aspect of the invention provides a method of building a building portion including; installing the module with locating structure at a building site to provide a formwork structure for at least part of a building; filling the concrete formwork structure with wet concrete; installing a like module atop the module.
Preferably the concrete is allowed to at least partially cure to strengthen the building portion before installing the like module. Optionally, the module may be left in place to protect the cured concrete during the life of the building.
Another aspect the invention provides a pre-fabricated formwork module for a building portion; the module including: a form defining a substantially continuous boundary for forming concrete; and one or more reinforcing bars fixed in position relative to the form for transport and to reinforce the concrete.
The pre-fabricated formwork module preferably includes one or more projecting structures, projecting from the boundary to project into the concrete and defining a supporting structure carrying a reinforcing bar.
In a further aspect there is provided a pre-fabricated module for a wall; the module including, two spaced forms each defining a respective boundary of a void for forming concrete; at least one of the forms including one or more projecting structures projecting from the boundary into the void; wherein at least some of the projecting structures are connected to the other form to tie the forms.
The various aspects on the invention are complementary. It will be appreciate that each aspect may incorporate features described in respect of one or more of the other aspects.
As used herein, except where the context requires otherwise, the term “comprise” and variations of the term, such as “comprising”, “comprises” and “comprised”, are not intended to exclude further additives, components, integers or steps.
Preferred embodiments of the present invention will now be described by way of non-limiting example only, with reference to the accompanying drawings, in which:
The building 1 includes various building portions including floors 2, beams 4, columns 6, walls 8 and a central core 10. As shown in
As will be described, the floor portions 2 and beam portions 4 have a similar construction. As best illustrated in
The floors 2 are formed from a plurality of pre-fabricated floor modules corresponding to floor portions 2.1 to 2.9. Similarly the beams 4 are formed from a plurality of pre-fabricated beam modules corresponding to beam portions 4.1 to 4.4. The core portions 10A and 10B are formed of separate pre-fabricated formwork modules and are separated by a beam module 4. The columns e.g. 6A to 6C are also formed from individual pre-fabricated formwork modules.
Although not illustrated in
The process for constructing a portion of a building of this type runs generally as follows:
1. Pre-fabricate formwork modules that are needed for the building. The formwork modules will typically include all or a majority of the concrete reinforcing members needed for the completed construction pre-located in them. Ducting to carry other elements, e.g. post tensioning tendons etc. that need to extend through or along the final concrete form are preferably pre-installed in the pre-fabricated formwork modules. Apertures or fittings that extend through the final concrete forms are also preferably pre-placed in the formwork modules during manufacture.
2. Transport the modules to the site. For efficiency, delivery will preferably take place in the order of installation.
3. Place the formwork modules on-site to construct the required formwork structure. Installation may require some temporary propping of formwork modules.
4. Connect formwork modules to neighbouring modules if required. Connections can be made by welding, bolting or other suitable mechanical fastening, alternatively neighbouring modules can be configured to interlock sufficiently well to not need additional fastening prior to concrete being poured. As will be described, certain modules are design to cooperate to be permanently interlocked by a continuous phase of concrete.
5. Connect reinforcing, services, ducts or other elements between abutting modules if required.
6. Pour concrete into the assembled formwork either section by section or for an entire floor at a time; and finish concrete as required;
7. After sufficient curing of the concrete, remove temporary props.
As will be appreciated other steps in the construction of a building will run in a generally conventional manner.
In the example of the building of
On top of the core and column formwork already in place the band beam formwork modules of the floor above are next mounted thereto. These may need propping from below during curing of the concrete. The floor formwork modules can be placed between the beams to complete the floor formwork for the upper floor. The floor formwork may also need temporary propping. Concrete can then be poured into the upper floor formwork and lower columns and core formwork. This process can continue to create additional levels.
The construction of an exemplary floor module 12 is illustrated in
The panels can be formed using any suitable technique, e.g. roll-forming, pressing, bending or moulding etc. Moreover the panels could be initially formed so as to have the deflected shape, e.g. by moulding or extruding, or may be formed initially from planar material that is subsequently bent to form the deflected shape, e.g. in a press brake or roll forming operation.
In this embodiment the panel 14 is roll formed to include a planar boundary portion 18 and a projecting structure 16. The projecting structure 16 runs along one of the long edge portions of the panel 14. In the assembled module the panel is placed such that the projecting structure 16 projects into the concrete. Each projecting structure 16 includes a vertical (i.e. perpendicular to the boundary portion 18) web 16A extending from the boundary portion 18 to a horizontal flange portion 16B projecting away from the boundary portion 18. The horizontal flange 16B terminates in a short downward return 16C. The flange 16B and return 16C together constitute a hook formation.
The boundary portion 18 includes 3 stiffening ribs 20 running along the length of the panel 14. Each rib 20, in this embodiment, is a shallow depression (i.e. deformation toward the concrete side of the panel 14) about 50 mm wide by about 2 mm deep. The stiffening ribs 20 serve to stiffen the boundary portion 18 and resists drumming.
The boundary portion 18 includes a presentation surface 18A on the non concrete side of the panel 14. In this embodiment the presentation surface 18A is relatively flat and only includes minor deformations in the form of the small recesses associated with the ribs 20.
As best shown in
It will be appreciated that the panels 14 of the assembly 26 together present an attractive common presentation surface. In a completed building this surface can be left as-is or receive various surface treatments as required.
The projecting structure 16 of each panel 14 constitutes a purlin integrally formed with the panel 14 to strengthen the panel against bending about an axis transverse to its length (i.e. about an axis parallel to the length of the module 12). The panels 14, and the assembly 26, is therefore relatively strong in this direction. The projecting structure 16 is ideally dimensioned such that it provides sufficient strength to the panel so that a formwork module which incorporates the panel 14 can be self supporting.
Returning to
The beams 28 perform a dual role. They strengthen the module by resisting bending about an axis transverse to the module and provide an edge to form concrete, as will be described in more detail below.
Each web 16A includes a series of apertures 30 spaced along its length (i.e. across the module 12). Each aperture 30 carries a respective reinforcing bar 30A. Thus the position of the apertures 30 of the projecting structure 16 dictates the location of the reinforcing bars 30A within the concrete 34. As illustrated, within the floor 2 the apertures 30 are positioned low down on the web 16A so that the reinforcing bars 30A are carried towards the bottom of the concrete 34 to resist tensile forces associated with a weight carried on the floor 2.
A series of concrete flow apertures 32 are arranged along the length of the web 16A. In this embodiment the concrete flow apertures 32 are spaced at the same pitch as the apertures 30 and are inter-leaved therewith. The apertures 32 each have a triangular form the apex of which is downwardly directed. As such the apertures 32 are relatively narrower thereby leaving more material in the lower portions of the web 16A about the apertures 30. The concrete flow apertures are relatively large to permit wet concrete to flow therethrough and to form a continuous phase of solid concrete when cured. Thus the concrete flow apertures 32 allow stress to be transmitted between portions of concrete floor through the web 16A and allow a portion of the projecting structure 16 to be encircled by a continuous phase of concrete to interlock the concrete and the projecting portion 16. The horizontal flange portions 16B of the variant at
As has been described the underside of the floor 2 presents a reasonably attractive presentation surface 18A forming a ceiling for a lower floor of the building.
The module 12 is pre-fabricated, i.e. is manufactured at a manufacturing facility and is transportable to the site of the building. In this embodiment the reinforcing bars 30A are fixed relative to the panels 14 for transport by virtue of the fit with the apertures 30. The apertures 30 are about 1 mm per side larger than the external diameter of the reinforcing bar 30A. Whilst this would usually be regarded as a rather loose fit, by virtue of the rough textured nature of reinforcing bar and the tolerances on its straightness, when a reinforcing bar engages with multiple apertures 30 along the length of the module 12 there is found to be a sufficient fixation between the bars 30A and the panels 14 for the module 12 to be transported on site with an acceptable degree of movement of the bars 30A. If slippage of the reinforcing bar is excessive they can be tied to one or more of the projecting portions 16 of the panels using wire, in the manner in which reinforcing bars are conventionally tied to other such bars or ligatures. Other bar fastening structures are also contemplated.
The engagement between the reinforcing bars 30A and the apertures 30 also serves a function in use. As the reinforcing bars 30A are located at multiple points along their length, they are restrained against buckling outwardly when placed under compression. As such the apertures 30 replace the time consuming ligatures associated with prior art reinforcing structures.
The floor 2 is formed by supplying the module 12, including its panels 14, bars 30A and beams 28 to the building site as a pre-assembled unit. The module 12 is placed in situ. For larger spans, such as within the building 1 of
It will be appreciated that the panel structures of preferred versions of the invention can form a protective skin about the concrete. In particular, the skin can be relatively impermeable and thereby help to guard against degradation of the concrete over time, for example, by reducing the penetration of moisture into the concrete. Another advantage is that the metal skin can prevent moisture loss from the concrete and reduces the shrinkage normally associated with concrete structures.
The beam module 12′ of
Unlike the L shaped beams 28 of the floor module 12, the beam module 12′ includes more complex “Z-shaped” beams 28′ running along each of its sides. Each beam 28′ includes an L shaped portion arranged in a similar fashion to the L shaped beams 28, and also includes a horizontal flange portion 28A′ which projects outwardly on either side of the module 12′. The horizontal flanges 28A′ are arranged at a height somewhat below the upper extent of the projecting structures 16′. The flanges 28A′ constitute structure co-operable with another module such as the floor module 12.
In use a floor module 12 may be arranged in a direction transverse to the beam module 12′ with its end seated upon one of the flanges 28A′. As such the open concrete receiving area of the floor module 12 opens into the open concrete receiving area of the beam module 12′. When filled with wet concrete the concrete is able to flow between the modules to form a continuous concrete phase. The relative heights of projecting structures 16 and 16′ and the flanges 28′ is selected so that the upper extent of the projecting structure 16 and 16′ is at about the same height when installed and both are buried about 30 mm under the surface 2A of the concrete.
As best illustrated in
It is also contemplated that the extent of projection of the projecting structures into the concrete on each of the panel assemblies 26′ could vary, along with a complementary variation in the corresponding dimension of its paired projection 16″, so that the relative location of the connection between the paired projecting structures 16″ varies from pair to pair. In this way weaknesses associated with the connection do not align along the length of the wall. As in the previous embodiments the projecting structures of one or both wall structures forming the core module can have apertures for carrying reinforcing bars.
Stand alone wall formwork modules may or may not incorporate pre-assembled reinforcing bars. Wall modules could be configured to form a simple planar wall, or might form part of a more complex structure such as the module 50 for forming a core of a building. Curved walls are also able to be made using non-planar wall portions of the formwork structure.
In this embodiment the upper extent of the inner form 36A terminates in location structure 46 about its upper periphery. The location structure 46 in this embodiment takes the form of a portion outwardly flared at an angle to define a lead in for guiding to an aligned position a similar module that is placed on top of it. The lower extent of the inner form 36A of the like module 36 will have a correspondingly shaped lead in such that when the top core module is lowered it is urged into alignment with the module 36. The void 40 defined by the module 36 complements, as in co-operates with, the void formed by the upwardly adjacent like module 36. In this embodiment the voids co-operate to form a continuous tubular structure about the lift wells.
The cage 56 includes vertically extending reinforcing bars 57 embraced by a set of ligatures 59. The vertical bars 57 are tied to the ligatures 59 in conventional fashion to resist outward buckling.
The sleeve structure 58 includes a pair of sleeve wall portions 12′″ analogous to the floor module portions 12 excepting that the relative positioning of the apertures within the web 16 have been reversed to move the reinforcing bars of the module 12′″ towards the centre of the column 6. The module 58 further includes a pair of narrow elongate panel assemblies 26′″ which co-operate with extended L shaped portions of the module portions 12′″ to form a continuous sleeve carrying reinforcing bars. Note that the apertures of the webs and the reinforcing bars of the module 58 are not shown in
The cages 56 have a height corresponding to the height of a building level but are off-set at half a pitch so that the join between vertically adjacent cages occurs about mid-way between the floor and ceiling of each respective building level corresponding to a mid point of the sleeve so that weakness associated with joints between cages are offset from weakness associated with joints between vertically adjacent modules 58. As such when the floor of each building level is formed a portion of cage 56 projects upwardly from below.
It will be observed in
The assembly 2300 includes the plurality of panels 2200 from
Next, when forming a wall it is necessary to provide second boundary portion or skin to the formwork module. An initial phase of this process is illustrated in
Next, as illustrated in
a lower formwork module 3400
an upper formwork module 3402
a pair of like locating elements 3404 and 3406.
The formwork modules 3402 and 3400 are similar to each other, as will usually be the case when forming a building with multiple storeys. As described in the previous embodiments, the formwork modules have first and second skins e.g. 3400A and 3400B. Each module additionally includes projecting structures e.g. 3400C which extend, in this case all the way across the concrete forming void within the formwork module and are adapted to carry reinforcing bars in the manner illustrated in
Locating element 3404 is shown in more detail in
Turning now to
The formwork module formed using a panel described in connection with
It should be noted that the lower reinforcing bars 3600 and 3606 are located at a position within the formwork module such that they will be at the bottom of the building portion formed with the formwork module. This means that these reinforcing bars will typically be under tension in the building. Depending on the thickness of the beam being formed, the upper reinforcing bars 3602 and 3604 may also be in tension. Clearly, additional levels of reinforcing bars could be provided by changing the profile shape to some degree.
It will be appreciated, that the reinforcing rods held by the retaining structure 3906 are located in a lower stratum of the concrete formed by the formwork module such that in use the lower portion of the panel structure, and importantly, the reinforcing bars retained by it are under tension when the slab is formed. It should be understood that the lower stratum of concrete discussed is a portion of the concrete forming the building portion which lies below a neutral line in the concrete which notionally defines those portions of the structure which are under tension or under compression when loaded.
The panel 4500 is formed (e.g. by roll-forming, pressing or other means) to include a planar boundary portion 4518 and a projecting structure 4516. The projecting structure 4516 runs along one of the long edge portions of the panel 4500. Each projecting structure 4516 includes a vertical (e.g. perpendicular to the boundary portion 4518) web 4516A extending from the boundary portion 4518 to a horizontal flange portion 4516B projecting away from the boundary portion 4518. The horizontal flange 4516B terminates in a short downward return 4516C. The boundary portion 4518 can also includes stiffening ribs (not shown) running along the length of the panel. The panel 4500 also includes an engagement region 4522 that extends along the length of the panel 4500 and is located immediately adjacent to the projecting structure 4516. The engagement region 4522 is recessed by about 2 mm and is about 50 mm wide, and is adapted to receive a tail portion 4524 of a like adjacent panel when the formwork structure is complete.
The panel 4500 additionally includes a pair of notches 4510 and 4512 that are cut into the projecting structure 4516. The notches 4510 and 4512 are generally triangular in shape and cut at around 90 degrees.
These notches allow the panel 4500 to be folded through the apex of the notches 4510 and 4512 to form a channel shaped formwork module in the manner show in
The final formwork module 4600, illustrated in
As can be seen this embodiment allows single panels of the type described herein to be formed into channel shaped formwork modules, suitable for floors, beams, band beams, but preferably without the need to attach separate vertical side walls. The structure formed can also be stood upright, and closed off on its open side to define a formwork module for a wall or portion of a wall.
As will be appreciated, the plurality of panels 4500 may be joined together, then have their side walls folded once a panel assembly is formed, or each panel 4500 can be formed into a channel before joining it to the next like panel 4500.
Any number of notches can be cut into the projecting portion 4516 the panel 4500 such that shapes other than a rectangular channel can be formed. Moreover the notches can be cut at any shape or angle to allow different wall angles to be formed.
In an alternative form, the side walls of a formwork module similar to that of
It will be appreciated that the various aspects of the invention allow for the pre-fabrication of various components in an industrial manufacturing environment which may present significant advantages. For example safety can be improved since less on-site work needs to be performed. In particular much of the working at height or overhead is eliminated. Cost could also be lowered since automation techniques can be employed during manufacture, delays due to wet weather on site are reduced and speed of installation on site is increased. The placement of installed elements is simplified since placement of reinforcing, ducting and services can either be performed by machine, or if performed by hand these can be performed by a worker at ground level, at a comfortable working height and safe manner.
Moreover tolerances for formwork can be improved over that for most conventional formwork (particularly timber formwork) since the tolerances in a manufacturing environment can be controlled better than the manual formwork creation process. Ultimately this may transfer to improved building quality.
The pre-fabricated modules can be quickly and relatively easily transported and placed on site. It is anticipated that a floor of a building could be formed and poured within 2-3 days and with appropriate back propping, additional floors added at a similar rate.
For simplicity the term concrete has been used herein throughout to refer to a building material that is delivered in a flowable form, but which subsequently sets to form a portion of a building. It will be appreciated that aspects of the invention are able to be used with materials other than conventional concrete and thus ‘concrete’ should be interpreted in a broad sense to encompass a wide range of such flowable, settable building materials.
It will be understood that the invention disclosed and defined in this specification extends to all alternative combinations of two or more of the individual features mentioned or evident from the text or drawings. All of these different combinations constitute various alternative aspects of the invention.
Claims
1.-46. (canceled)
47. A pre-fabricated formwork module for a building portion; the module including:
- two or more panels each including a boundary portion and one or more projecting structures, the panels being arranged such that their boundary portions together define a first substantially continuous boundary for forming concrete, the projecting structures projecting from the boundary to project into the concrete; and
- one or more reinforcing bars fixed in position relative to the boundary for transport and to reinforce the concrete.
48. The module of claim 47 wherein each panel is at least predominantly integrally formed of sheet material.
49. The module of claim 47 wherein the projecting structures include one or more receiving voids opening outwardly from the first boundary to receive one or more reinforcing bars.
50. The module of claim 49 wherein portions of the projecting structures defining the receiving voids are shaped to carry a reinforcing bar at a predetermined spacing from the boundary.
51. The module of claim 49 wherein the portions of the projecting structures defining the receiving voids are shaped to carry at least two reinforcing bars at at least two different predetermined spacings from the first boundary.
52. The module of claim 49 wherein the module further includes a retaining structure to capture the reinforcing bars in the receiving voids.
53. The module of claim 52 wherein, the retaining structure includes a plurality of apertures which in use contact the projecting structures of respective panels and through which the retaining structure is welded to the projecting structures.
54. The module of claim 52 wherein the retaining structure defines a second substantially continuous boundary, for forming concrete, spaced from the first boundary.
55. The module of claim 47 including further structure defining a second substantially continuous boundary, for forming concrete, spaced from the first boundary.
56. The module of claim 49 wherein the receiving voids are shaped such that the panels may be formed from blanks cut from a common sheet of material, said blanks being arranged on the sheet such that at least one projecting structure portion of one blank is interleaved with a similar projecting structure of a neighbouring blank and located within the receiving voids of the other blank.
57. A pre-fabricated formwork module for a building portion; the module including:
- a form defining a substantially continuous boundary for forming concrete; and
- one or more projecting structures; the projecting structures projecting from the boundary to project into the concrete and defining a supporting structure carrying a reinforcing bar.
58. The module of claim 57 wherein the supporting structure and the reinforcing bar carried thereby are positioned to reinforce a lower stratum of the concrete.
59. A pre-fabricated formwork module for a building portion, the module including
- one or more forms defining a void for forming concrete; and
- locating structure by which the module may be located relative to a vertically adjacent like or similar module.
60. The module of claim 59 wherein the locating structure includes a locating element including
- an engagement portion by which it is fixed relative to the forms; and
- a lead-in portion to locate the vertically adjacent like or similar module.
61. The module of claim 59 wherein the forms are complementary to the forms of the like module when mounted atop the like module.
62. The module of claim 59 wherein a portion of one the forms projects upwardly beyond another portion of the forms to form an inner edge of a concrete structure above the other form portion.
63. The module of claim 59 including one or more reinforcing bars fixed in position relative to the forms for transport and to reinforce the concrete.
64. The module of claim 59 wherein at least one of the forms includes two or more panels; and each panel: the panels within the, or each, form being arranged such that their boundary portions together define a substantially continuous boundary for forming the concrete.
- includes a boundary portion and one or more of the projecting structures; and
- is at least predominantly integrally formed of sheet material;
65. A building portion including the module of claim 47 and concrete.
66. A locating element including
- an engagement portion configured to engage with a formwork module in use; and a lead-in portion to locate a vertically adjacent like or similar module in use.
67. A locating element as claimed in claim 66 wherein the engagement portion includes:
- a flange insertable to engage a formwork module; and
- a stop portion to limit the insertion of the flange.
68. A panel for a building portion; the panel including:
- a boundary portion for forming concrete, and
- one or more projecting structures projecting from the boundary portion to project into the concrete and defining one or more receiving voids opening outwardly from the boundary to receive one or more reinforcing bars.
69. The panel of claim 68 being at least predominantly integrally formed of sheet material.
70. The panel of claim 68 wherein the receiving voids are shaped for the panels to be formed from interleaved blanks.
71. The panel of claim 68 wherein portions of the projecting structures defining the receiving voids are shaped to carry a reinforcing bar at a predetermined spacing from the boundary.
72. The panel of claim 68 wherein the portions of the projecting structures defining the receiving voids are shaped to carry at least two reinforcing bars at at least two different predetermined spacings from the boundary.
73. A method of building a building portion including
- installing one or more modules of claim 47 at a building site to create at least part of a concrete formwork structure;
- filling the concrete formwork structure with wet concrete;
- allowing the concrete to cure.
74. A method of building a building portion including
- installing the module of claim 59 at a building site to provide a formwork structure for at least part of a building;
- filling the concrete formwork structure with wet concrete;
- installing a like module atop the module.
75. The method of claim 74 wherein the concrete is allowed to at least partially cure to strengthen the building portion before installing the like module.
Type: Application
Filed: May 6, 2011
Publication Date: Feb 28, 2013
Inventor: Epaminondas Katsalidis (Southbank)
Application Number: 13/696,247
International Classification: E04B 1/16 (20060101); E04G 11/06 (20060101); E04G 11/02 (20060101); E04G 11/36 (20060101); E04B 2/86 (20060101); E04B 2/84 (20060101);