Formwork system
11732472 · 2023-08-22
Assignee
Inventors
Cpc classification
E04B2/8629
FIXED CONSTRUCTIONS
International classification
Abstract
Disclosed is a form work system (100) that comprises first (102a) and second (102b) building formwork components that are connected by a building formwork connector (104) The connector (104) comprises a moveable portion (128) that is moveable from a closed position to an open position. In the closed position, one or more sidewalls of the connector (104) define a cavity (144) for receipt of cementitious material. The cavity (144) of the connector (104) is located with respect to cavities (110) of the first (102a) and second (102b) formwork components. In the open position, access is provided to the cavity (144) of the connector (104).
Claims
1. A building formwork connecting element for connecting first and second building formwork components that each comprise two spaced sidewalls having one or more webs extending therebetween defining a cavity for receipt of a cementitious material, the connecting element comprising: an internal corner comprising two internal sidewalls connected to define an internal corner structure, the internal corner structure connectable to the first and second building formwork components, the internal sidewalls of the internal corner structure each comprising engagement portions for engaging the two spaced sidewalls of a respective one of the first and second building formwork components such that, when engaged, the internal corner structure is locatable and retained at the first and second building formwork components respectively to thereby join the first and second building formwork components; a first set of the engagement portions of a first of the two internal sidewalls comprise at least one engaging flange extending therefrom to hook around the first building formwork component so as to engage with a corresponding groove of the first building formwork component, and wherein the engagement portions of a second of the two internal sidewalls comprise at least one outwardly facing groove at a distal end of the sidewall for receiving a corresponding flange of the second building formwork component; a second set of engagement portions configured to detachably mount a detachable element that, when engaged, defines the cavity for receipt therein of cementitious material, the cavity located with respect to the cavities of the first and second formwork components, and when the detachable element is detached, provides access to the cavity; wherein the detachable element is an external corner comprising one or more external sidewalls; wherein: the external corner is attached to the internal corner structure in a closed position of the connecting element to thereby define a connector cavity between the internal corner structure and the external corner, with the connector cavity located with respect to the cavities of the first and second building formwork components such that the cavities are in fluid communication; and the external corner is movable relative to the internal corner structure to an open position of the connecting element.
2. The building formwork connecting element according to claim 1 wherein the internal corner is engageable with at least one of the first and second formwork components by way of one or more of: a sliding arrangement; a snap-fit arrangement.
3. The building formwork connecting element according to claim 1 wherein the first of the two internal sidewalls extends across an end of the first formwork component when engaged thereto; and the second of the two internal sidewalls extends across an end of the second formwork component when engaged thereto.
4. The building formwork connecting element according to claim 1 wherein the external corner is detachably connectable to the internal corner by way of a snap-fit arrangement or is connectable to the internal corner by way of a sliding arrangement.
5. The building formwork connecting element according to claim 1 wherein the external corner is detachably connectable to at least one of the first and second formwork components.
6. The building formwork connecting element according to claim 1 wherein the external corner comprises two said external sidewalls and an internal sidewall, the internal sidewall extending between the external sidewalls, the internal sidewall partially defining the connector cavity.
7. The building formwork connecting element according to claim 6 wherein the external sidewalls and internal sidewall configure the external corner as a hollow section.
8. The building formwork connecting element according to claim 7 wherein support webs extend within the hollow section, between the internal sidewall and external sidewalls.
9. A building formwork connector for connecting first and second building formwork components that each comprise two spaced sidewalls having one or more webs extending therebetween defining a cavity for receipt of a cementitious material, the connector comprising: an internal corner comprising two internal sidewalls connected to define an internal corner structure, the internal corner structure connectable to the first and second building formwork components, the internal sidewalls of the internal corner structure each comprising engagement portions for engaging the two spaced sidewalls of a respective one of the first and second building formwork components such that, when engaged, the internal corner structure is locatable and retained at the first and second building formwork components respectively to thereby join the first and second building formwork components; the engagement portions of a first of the two internal sidewalls comprise at least one engaging flange extending therefrom to hook around the first building formwork component so as to engage with a corresponding groove of the first building formwork component, and wherein the engagement portions of a second of the two internal sidewalls comprise at least one outwardly facing groove at a distal end of the sidewall for receiving a corresponding flange of the second building formwork component; an external corner comprising one or more external sidewalls; wherein: the external corner is attached to the internal corner structure in a closed position of the connector to thereby define a connector cavity between the internal corner structure and the external corner, with the connector cavity located with respect to the cavities of the first and second building formwork components such that the cavities are in fluid communication; and the external corner is movable relative to the internal corner structure to an open position of the connector.
10. The building formwork connector according to claim 9 wherein said external corner is detachable such that, when detached from the internal corner, provides access to the cavity defined by the connector.
11. The building formwork connector according to claim 9 wherein the internal corner is engageable with at least one of the first and second formwork components by way of one or more of: a sliding arrangement; a snap-fit arrangement.
12. The building formwork connector according to claim 9 wherein the first of the two internal sidewalls extends across an end of the first formwork component when engaged thereto; and the second of the two internal sidewalls extends across an end of the second formwork component when engaged thereto.
13. The building formwork connector according to claim 9 wherein an outer surface of the external corner is configured to be flush with corresponding outer surfaces of the first and second formwork components when engaged to the internal corner.
14. The building formwork connector according to claim 9 wherein the first or second of the two internal sidewalls of the internal corner comprise at least one aperture for receipt of a reinforcement member therethrough, the reinforcement member able to extend from the cavity defined by the sidewalls and into a cavity of an engaged one of the first and second formwork components.
15. The building formwork connector according to claim 9 wherein the cavity defined by the sidewalls is in fluid communication with a cavity of at least one of the first or second building formwork components.
16. A building formwork system comprising: first and second building formwork components, each comprising spaced sidewalls having one or more webs extending therebetween so as to define cavities within the first and second formwork components for receipt of a cementitious material; and the building formwork connector of claim 9 connecting the first and second formwork components.
17. The building formwork system according to claim 16 wherein the first and second formwork components and connector together form a corner of a wall structure.
18. The building formwork system according to claim 16 wherein the first or second of the two internal sidewalls of the internal corner comprise at least one aperture for receipt of a reinforcement member therethrough, with the system further comprising at least one reinforcement member, the at least one reinforcement member extending through the at least one aperture and into the cavity of a respective one of the first and second formwork components, an end of the reinforcement member disposed in the cavity defined by the one or more sidewalls of the connector.
19. The building formwork system according to claim 18 wherein the reinforcement member is U-shaped, legs of the reinforcement member extending through apertures in the sidewalls and into the cavities of the building formwork components, a central portion of the reinforcement member, connecting the legs, being disposed in the cavity defined by the connector.
20. A method of building a structure, the method comprising: providing the building formwork system as defined in claim 16 with the external corner in the closed position; configuring the external corner so as to be in the open position to access the cavity defined by the connector; configuring the external corner so as to be in the closed position; and at least partially filling the cavity defined by the connector with the cementitious material.
21. The method according to claim 20 wherein the external corner is configured so as to be in the open position to perform one or more of: inspecting the cavity defined by the connector; installing one or more elongate reinforcement members through apertures of the first and second formwork components and connector.
22. The method according to claim 21 wherein the one or more reinforcement members are installed so as to extend perpendicular to a longitudinal axis of the cavity defined by the connector.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
(1) Embodiments will now be described, by way of example only, with reference to the accompanying drawings, in which:
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DETAILED DESCRIPTION
(9) In the following detailed description, reference is made to accompanying, drawings which form a part of the detailed description. The illustrative embodiments described in the detailed description, depicted in the drawings and defined in the claims, are not intended to be limiting. Other embodiments may be utilised and other changes may be made without departing from the spirit or scope of the subject matter presented. It will be readily understood that the aspects of the present disclosure, as generally described herein and illustrated in the drawings can be arranged, substituted, combined, separated and designed in a wide variety of different configurations, all of which are contemplated in this disclosure.
(10) Referring firstly to
(11) The building formwork components 102a, 102b, and the connector 104, are formed of an extruded polymer, such that the features of each of these components are generally integrally formed with one another. However, flatpack (disassembled) versions of the building formwork components 102a, 102b can be provided.
(12) The first 102a and second 102b building formwork components are substantially identical to one another. Each building formwork component 102a, 102b comprises two parallel spaced sidewalls 106 and four webs 108 extending therebetween. The sidewalls 106 and webs 108 define cavities 110 that, in use, are able to receive a cementitious material therein. The cementitious material is able to flow between the cavities 110 by way of apertures 112 that are formed in the webs (i.e. the cavities are in fluid communication—fluidly connected). The cementitious material (when set) in the building formwork components 102a, 102b and the connector 104, define a portion or section of a building structure. In the illustrated embodiment, this structure is a corner section of a wall.
(13) Each building formwork component 102a, 102b comprises a first end 114 and an opposing second end 116. The first end 114 comprises opposing grooves 118 formed along the edges of the spaced parallel sidewalls 106 and the second end 116 comprises opposing flanges 120 that extend inwardly (towards one another) from the edges of the sidewalls 106. The grooves 118 correspond to the flanges 120 such that two formwork components 102a, 102b can be connected to one another by positioning of the flanges 120 to be received in the grooves 118 (e.g. by way of sliding or snap-fitting of the formwork components 102a, 102b relative to another).
(14) In the illustrated embodiment, the building formwork components 102a, 102b are oriented so as to be generally perpendicular to one another, and are connected to one another by the connector 104.
(15) More specifically, the first building formwork component 102a is oriented such that its first end 114 is engaged by a first set of engagement portions 122 of the connector 104. Further, the second building component 102b is oriented such that its second end 116 is engaged by a second set of engagement portions 124 of the connector 104. In this way, the building formwork components 102a, 102b and the connector 104 can be generally arranged to form the corner section of a wall.
(16) The connector 104, which is disposed between the building formwork components 102a, 102b, is formed of two elements: a connecting (inner) element 126 and a detachable (outer) element 128. The connecting element 126 generally locates against to be retained at the building components 102a, 102b, whilst the detachable element 128 defines a removable external corner of the connector 104.
(17) The connecting element 126 comprises two sidewalls 130, 132 that are perpendicular to one another so as to form the connecting element 126 as a generally L-shaped profile. The L-shaped profile corresponds to an internal corner that is defined by the proximate ends 114, 116 of the two perpendicular building formwork components 102a, 102b. That is, the two sidewalls 130, 132 of the connecting element 126 locate against (and partially cap) the ends 114, 116 of the building formwork components 102a, 102b respectively.
(18) Although not shown in the figures, the sidewalls 130, 132 can each comprise apertures that align with apertures 112 that are formed in the webs 108 of the building formwork components 102a, 102b. These apertures allow e.g. reinforcement bars, cabling, plumbing, etc. to pass into (or to be passed from) the connector 104 from/into the building formwork components 102a, 102b. They also allow cementitious material to flow between the cavities 110 of the building formwork components and a connector cavity 144 that is defined between the connecting element 126 and detachable element 128 of the connector 104.
(19) Whilst the connecting element 126 is depicted in
(20) A first 130 of the two sidewalls of the connecting element 126 comprises a generally planar surface with an engagement portion in the form of hook- or L-shaped flange 122 that projects in the direction of the first building formwork component 102a. Flange 122 hooks around the first building formwork component 102a so as to engage with a corresponding groove 118 of the first building formwork component 102a.
(21) The first sidewall 130 also comprises a U-shaped flange 136 extending therefrom. Flange 136 projects from an opposing surface (i.e. the surface facing away from the first building formwork component 102a at an opposite side to the flange 122 and at a distal end of sidewall 130 (i.e. distal from its intersection with the second sidewall 132). The U-shaped flange 136 engages with and retains the detachable element 128 of the connector 104 (which will be described in more detail below).
(22) A second 132 of the two sidewalls of the connecting element 126 comprises a generally planar surface with two engagement portions (i.e. a second set of engagement portions) in the form of hook- or L-shaped flanges 124 that project in the direction of the second building formwork component 102b. One of the engagement portions 124 is disposed at an end of the second sidewall 132 that is proximate its intersection with the first sidewall 130. The other engagement portion 124 is disposed at an opposite (distal) end of the second sidewall 132. The engagement portions 124 of the second sidewall 132 engage with corresponding flanges 120 of the second building formwork component 102b.
(23) The second sidewall 132 also comprises a further flange 138 disposed on the opposing surface (i.e. the surface facing away from the second building formwork component 102b) at the distal end of the second sidewall 132. This flange 138 is U-shaped and engages the detachable element 128 of the connector 104 (which will be described in more detail below).
(24) Together, the U-shaped flange 138 of the second sidewall 132 and the U-shaped flange 136 of the first sidewall 130, retain the detachable element 128 at a corner of the first 102a and second 102b of the building formwork components.
(25) When retained in this way, the connector 104 is in a closed configuration so as to define a cavity 144 that is in fluid connection/communication with the cavities 110 of the building formwork components 102a, 102b (i.e. such that cementitious material can flow between the connector 104 and the building formwork components 102a, 102b, and such that the resultant cured cementitious material is contiguous in the connector 104 and components 102a, 102b).
(26) The detachable element 128 can also be detached from the connecting element 126, such as by sliding the detachable element 128 relative to the connecting element 126 (alternatively, this detachment/attachment may be by way of a snap-fit). This opens the cavity 134 of the connector 104 and allows access by a user to the cavity 134. Such access can be desirable as it can allow an operator to inspect and/or maintain various internal features of the building formwork system 100 prior to cementitious material being supplied to (and filling) the cavities 110, 144 of the building formwork components 102a, 102b and the connector 104.
(27) One such internal feature of the system that can require inspection and/or maintenance is reinforcement elements, in the form of reinforcement bars 140. The bars 140 are arranged to extend through the apertures 112 in the building formwork components 102a, 102b.
(28) In the illustrated embodiment, the reinforcement bars 140 are generally U-shaped. In this regard, the ‘legs’ of the of the reinforcement bars 140 extend into the building formwork components 102a, 102b (through the apertures 112), while the central (U-) portions of the reinforcement bars 140 locate within the cavity 144 of the connector 104. Hence, detachment of the detachable element 128 can allow an operator to inspect the portions of the reinforcement bars 140 that are located within the cavity 144, prior to filling the cavity 144 with a cementitious material.
(29) Another benefit of the detachable element 128 is that it facilitates construction of the system 100. In practice, a wall is generally built outwardly from the corner. First, the corner (i.e. the connector 104) is installed. Then, the building formwork components 102a, 102b are connected to the connector. These components 102a, 102b, 104 are then braced for extra support while further building formwork components are connected (i.e. to form respective walls).
(30) Once the walls are formed, reinforcement bars 140 are positioned in the cavities 110, 144, through the apertures 112. Where these reinforcement bars 140 meet (i.e. in the corner cavity 144) it can be desirable for them to overlap so as to define a vertically extending passage (i.e. between the curved central portions of the reinforcement bars 140) through the corner cavity 144. A vertical reinforcement bar (not shown) can also be arranged and received in this vertical passage.
(31) Removal (i.e. by detaching) of the detachable element 128 makes it easier to install the horizontal reinforcement bars 140, because they can be pushed into the apertures 112 from the open corner cavity 144. It also makes it easier for an operator to ensure that the reinforcement bars 140 overlap appropriately to define the vertical passage.
(32) As best illustrated in
(33) In the closed configuration, and when the connector 104 is engaged with the building formwork components 102a, 102b, the outer surfaces of the first 142 and second 143 sidewalls of the detachable element 128 are generally flush with the corresponding outer surfaces of the building components 102a, 102b. In this way, the outer surfaces of the formwork components 102a, 102b and connecter 104 form generally continuous planar surfaces. Hence, in some circumstances further finishing of the surfaces may not be required, or the surfaces may only require minimal finishing.
(34) It will also be seen in
(35) In this regard, engagement of the detachable element 128 with the first building formwork component 102a is by way of a formwork-engaging flange 152 that extends inwardly from the second sidewall 143 of the detachable element 128. This flange 152 is formed such that it engages one of the outer grooves 118 of the first building formwork component 102a.
(36) Further in this regard, engagement of the detachable element 128 with the sidewall 130 is via an outwardly projecting hook- or L-shaped flange 148 located at an end of the third sidewall 146 of the detachable element 128. This hook-flange 148 engages with (i.e. hooks around) the corresponding flange 136 (previously described) of the sidewall 130.
(37) In a somewhat similar manner; engagement of the detachable element 128 with the second building formwork component 102b is by way of an outer flange 150 that extends inwardly from the first sidewall 142 of the detachable element 128. However, outer flange 150 is formed such that it engages into an outwardly facing groove 153 that is defined between the L-shaped engagement portion 124 and the U-shaped flange 138 at the distal end of the sidewall 132.
(38) The outer flange 150 also abuts a corresponding flange 120 of the second building formwork component 102b (i.e. they are both received in the groove 153 defined between the U-shaped flange 138 and the L-shaped engagement portion 124 of the sidewall 132. The insertion of outer flange 150 into the groove 153 thus locks the flange 120 of the first building formwork component 102a against the L-shaped engagement portion 124 of the sidewall 132.
(39) Again, in a somewhat similar manner, further engagement with the connecting element 132 is provided by an opposite end of the third sidewall 146 of the detachable element 128 being provided with an outwardly projecting hook- or L-shaped flange 148. This hook-flange 148 engages with (i.e. hooks around) the corresponding flange 138 (previously described) of the sidewall 132.
(40) Referring now to
(41) Another difference is that webs 254 are formed between the first 242 and second 243 (external) walls of the detachable element 228 and the third curved wall 246. These webs 254 provide rigidity and strength to the detachable element 228 (i.e. in addition to the strength provided by the hollow shape defined by the sidewalls of the detachable element 228).
(42) The flanges 220 of the building formwork components 202a, 202b (at their respective second ends 216) extend inwardly from the sidewalls 206 and at an angle such that an outer surface of each flange 220 generally defines a ramp surface. The grooves 218 of the building formwork components 202a, 202b (at their first ends 214) have a generally V-shaped profile that correspond to the flanges 220. To connect two building formwork components 202, they are moved laterally towards one another such that the ramp surfaces of the flanges 220 contact the ends of the sidewalls adjacent the grooves 218. Further movement causes the flanges 220 and/or sidewalls 206 to flex until the flanges 220 snap into the grooves 218. In other words, the building formwork components 202a, 202b are configured to snap-engage with one another.
(43) This difference in configuration somewhat necessitates an alternative connector 204 (i.e. to that described above and illustrated in
(44) The connector 204 again comprises an (inner) connecting element 226 and an (outer) detachable element 228. Unlike the previously described embodiment, these elements 226, 228 are generally symmetrical about a diagonal line of symmetry. As a result, the detachable component 228 is engaged solely with the connecting element 226, and not with either of the building formwork components 202a, 202b. This engagement is by way of hook-shaped flanges 256 extending from respective distal ends of first 242 and second 243 sidewalls of the detachable component 228, and corresponding hook-shaped flanges 258 extending from distal ends of first 230 and second 232 sidewalls of the connecting element 226. The nature (shape) of the hook-shaped flanges 256, 258 is such that the engagement between the detachable 228 and connecting 226 elements is a sliding engagement.
(45) The engagement of the connection element 226 with the building formwork components 202a, 202b also differs. Each sidewall 230, 232 of the connecting element 226 comprises two engagement portions 222, 224, in the form of flanges extending therefrom, for engagement with a respective building formwork component 202a, 202b. First engagement portions 222, in the form of a first pair of flanges, extends from the first sidewall 230 of the connecting element 226. Each of this first pair of engagement portions 222 comprises a secondary flange that extends inwardly in an angled manner (i.e. similar to flanges 220) so as to snap engage a corresponding groove 218 of the first formwork component 202a.
(46) Second engagement portions 224, in the form of a second pair of flanges, extend from the second sidewall 232 of the connecting element 226 (in the direction of the second building formwork component 202b). Each of this second pair of engagement portions 224 comprises a V-shaped groove that is similar (or identical) to those formed at the first end 214 of each building formwork component 202a, 202b. In this way, the flanges 220 of the second building formwork component 202b can engage with the engagement portions (i.e. grooves) 224 of the connecting element 226 in the same way that they engage with another like-building formwork component. That is, the flanges 220 of the second building component 202b snap-engage with the grooves 224 of the connecting, element 226.
(47) A further difference between the present embodiment and that described above derives from the differently shaped apertures 212. In this regard, the obround shape of apertures 212 requires that just the end of the illustrated reinforcement members 240 be hook-shaped (U-shaped). That is, one leg is longer than the other, with the short leg having a length such that it just extends back through e.g. a discrete aperture provided in the sidewall 230 (see
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(49) The only significant difference in the embodiment of
(50) To facilitate connection of the first part 360 (comprising the first sidewall 330) to the second part 362 (comprising the second sidewall 332), the first part 360 comprises a hook-shaped flange 366 and the second part comprises a corresponding L-shaped flange 364 that defines a move 365. The hooked flange 366 located in the groove 365.
(51) In practice, the hook-shaped flange 366 of the first part 360 is hooked into (or interlocks with) the groove 365 formed by the L-shaped flange 364 of the second part 362 so as to interlock the first 360 and second 362 parts together to form the connecting element 326. The flanges 322 of the first part 360 are connected to the grooves 218 at the first end 214 of the first building formwork component 202a (i.e. by way of snap-engagement). Likewise, the grooves 324 of the second part 362 are connected to the flanges 220 at the second end 216 of the second building formwork component 302b.
(52) The use of three pieces, instead of two, may allow the connector 304 to be transported as a smaller (e.g. flat) package. It may also facilitate interchanging of the parts of the connecting element where two building components of a different type (e.g. one engageable by way of snap engagement, and another by way of sliding) are to be connected to one another.
(53) A further embodiment of the system is illustrated in
(54) The system 400 of
(55) The system 400 of
(56) Another two-piece connector 504 is illustrated in
(57) A further embodiment is illustrated in
(58) Variations and modifications may be made to the parts previously described without departing from the spirit or ambit of the disclosure.
(59) One such variation or modification may be that the connector only connects to the outermost flanges or grooves of the formwork component and the entire connector is detachable from the formwork components to allow access to the cavity. In such case, it may be that the formwork components are configured such that they connect to one another at their innermost flanges/grooves (i.e. adjacent one another at the interior corner). Such connection of formwork components at their innermost flanges/grooves located at the interior corner may, for example, be facilitated e.g. by an elongate connection strip.
(60) Further, the manner of engagement between the connector and the formwork components may differ from that described above. Other than being a slideable or snap-fit engagement, the connection may be by way of fasteners or even adhesive.
(61) The form of the connector may be modified so as to be suitable for various connection shapes (e.g. various corner angles). In this respect, the connector may be capable of connection to more than two building formwork components. For example, the connector may connect three or four building components.
(62) The detachable element may also differ from that described above. For example, the detachable element may be in the form of a hinged door or hatch located in or forming a sidewall of the connector. In this case the element can be moveable rather than being detachable. Alternatively, the detachable element may be a removable piece in a sidewall of the connector so as to form a window in the sidewall when removed or detached therefrom.
(63) In the claims which follow and in the preceding description of the building formwork connector and associated system and methodology, except where the context requires otherwise due to express language or necessary implication, the word “comprise” or variations such as “comprises” or “comprising” is used in an inclusive sense, i.e. to specify the presence of the stated features but not to preclude the presence or addition of further features in various embodiments of the connector, system and methodology.