FORMWORK ASSEMBLY

Abstract

This disclosure relates to a formwork element and a formwork assembly, that can be used to mould upwardly extending building features such as columns or walls that extend between adjacent floor slabs. In one form, the formwork assembly comprises at least two surface forming elements, wherein each surface forming element comprises a casting surface and a pair of lengthwise extending parallel edges. In use, the surface forming elements are stacked by abutting along these edges, and each of these edges comprises a means for interlocking the surface forming elements with respect to each other so that the resulting formwork assembly forms a single, continuous casting surface.

Claims

1. A formwork assembly for moulding an upwardly extending building feature, the formwork assembly comprising at least two surface forming elements for forming one side of said building feature, each surface forming element comprising a casting surface and a pair of lengthwise extending parallel edges having means for interlocking the surface forming elements with respect to each other, wherein, in use, the surface forming elements are stacked by abutting along the lengthwise extending parallel edges such that the resulting formwork assembly forms a single, continuous casting surface.

2. The formwork assembly of claim 1, wherein, in use, the surface forming elements extend substantially horizontally.

3. The formwork assembly of claim 1, wherein each surface forming element comprises a panel assembly.

4. The formwork assembly of claim 1, wherein the means for interlocking each lengthwise extending parallel edge comprises at least one projection and at least one recess, wherein, in use, interlock of the surface forming elements with respect to each other is effected by engagement of the projection of one element with the recess of the other.

5. The formwork assembly of claim 1, wherein the means for interlocking the abutting formwork elements comprises a profile shape of the lengthwise extending parallel edges.

6. The formwork assembly of claim 5, wherein the profile shape is substantially constant throughout the length of the surface forming element.

7. The formwork assembly of claim 6, wherein the profile shape comprises a single projection and a single recess.

8. The formwork assembly of claim 7, wherein the profile shape comprises a squared step and a step-shaped recess adjacent to the squared step, wherein the step-shaped recess is shaped to receive a step of another surface forming element.

9. The formwork assembly of claim 5, wherein, for each surface forming element, the profile shape of one of the pair of lengthwise extending parallel edges is an inversion of the other of the pair of lengthwise extending parallel edges.

10. The formwork assembly of claim 1, wherein each surface forming element comprises means for securing a pair of stacked surface forming elements with respect to each other.

11. The formwork assembly of claim 1, wherein each surface forming element comprises means for securing a pair of surface forming elements with respect to each other in an end to end relationship.

12. The formwork assembly of claim 1, wherein each of the surface forming elements comprises a rectilinear perimeter frame and an infill panel.

13. The formwork assembly of claim 12, wherein the perimeter frame comprises a border extending around a perimeter of the infill panel to form the continuous casting surface along with the infill panel.

14. The formwork assembly of claim 13, wherein the border comprises a material having more wear resistance than the material of the infill panel.

15. The formwork assembly of claim 12, wherein the frame comprises a pair of lengthwise extending parallel side members, a pair of end members, and a plurality of spaced apart bracing members bridging the side members.

16. The formwork assembly of claim 15, wherein the lengthwise extending parallel side members of the frame comprise a plurality of apertures spaced apart along the lengthwise extending parallel side members, the apertures configured for receiving at least one of threaded fasteners, pins, and the like to secure a pair of stacked surface forming elements with respect to each other.

17. The formwork assembly of claim 15, wherein the end members of the frame comprise apertures for receiving at least one of threaded fasteners, pins, and the like to secure a pair of surface forming elements with respect to each other endwise.

18. The formwork assembly of claim 1, further comprising an edge element at the bottom of each stack of surface forming elements.

19. The formwork assembly of claim 18, further comprising an edge element at the top of each stack of surface forming elements.

20. The formwork assembly of claim 18, wherein each edge element comprises a pair of lengthwise extending parallel side edges, wherein a first side edge comprises a square edge for forming an end edge, and wherein a second side edge comprises a profile shape identical to that of the surface forming element such that a surface forming element can be stacked above and interlock with the second side edge.

21. A formwork assembly for moulding an upwardly extending building feature, the formwork assembly comprising at least two surface forming elements, each surface forming element comprising a casting surface and a pair of lengthwise extending parallel edges having means for interlocking the surface forming elements with respect to each other, wherein, in use, the surface forming elements are stacked by abutting along these lengthwise extending parallel edges such that the resulting formwork assembly forms a single, continuous casting surface.

22. A surface forming element for a formwork assembly for moulding an upwardly extending building feature, the surface forming element comprising at least two surface forming elements, each surface forming element comprising a casting surface and a pair of lengthwise extending parallel edges having means for interlocking the surface forming elements with respect to each other, wherein, in use, the surface forming elements are stacked by abutting along these edges such that the resulting formwork assembly forms a single, continuous casting surface.

Description

BRIEF DESCRIPTION OF DRAWINGS

[0048] Embodiments of the present invention will be discussed with reference to the accompanying drawings wherein:

[0049] FIG. 1 illustrates a front view of a surface forming element;

[0050] FIG. 2 is an end view of the surface fainting element of FIG. 1;

[0051] FIG. 3 is a cross-sectional view through the surface forming element of FIG. 1, taken at C-C;

[0052] FIG. 4 is a cross-sectional view through the surface forming element of FIG. 1, taken at A-A;

[0053] FIG. 5 illustrates a front view of a formwork assembly for moulding an upwardly extending building feature, the formwork assembly comprising a plurality of the surface forming elements of FIG. 1;

[0054] FIG. 6 is a cross-sectional view through the formwork assembly of FIG. 5, taken at 1-1;

[0055] FIG. 7 illustrates a front view of a surface forming element according to a further embodiment;

[0056] FIG. 8 is an end view of the surface fainting element of FIG. 7;

[0057] FIG. 9 is a cross-sectional view through the surface forming element of FIG. 7, taken at C-C;

[0058] FIG. 10 is a cross-sectional view through the surface forming element of FIG. 7, taken at A-A;

[0059] FIG. 11 is a detail view taken at Detail 3 in FIG. 8;

[0060] FIG. 12 is a detail view taken at Detail 4 in FIG. 8;

[0061] FIG. 13 is a detail view taken at Detail 5 in FIG. 9;

[0062] FIG. 14 is a detail view taken at Detail 6 in FIG. 9;

[0063] FIG. 15 is a front view of an edge element;

[0064] FIG. 16 is a cross-sectional view through the edge element of FIG. 15, taken at A-A; and

[0065] FIG. 17 is a detail view taken at Detail A in FIG. 16;

[0066] FIG. 18 illustrates a front view of a formwork assembly for moulding an upwardly extending building feature, the formwork assembly comprising a plurality of the surface forming elements of FIG. 1;

[0067] FIG. 19 is a side view of the formwork assembly of FIG. 18;

[0068] FIG. 20 is a cross-sectional view through the formwork assembly of FIG. 18, taken at C-C;

[0069] FIG. 21 illustrates a front view of a further formwork assembly for moulding an upwardly extending building feature, the formwork assembly comprising a plurality of the surface forming elements of FIG. 1;

[0070] FIG. 22 is a plan view of an end bracket of a first type, from the assembly of FIG. 21;

[0071] FIG. 23 is a side view of the end bracket of FIG. 22;

[0072] FIG. 24 is a plan view of an end bracket of a second type, from the assembly of FIG. 21;

[0073] FIG. 25 is a side view of the end bracket of FIG. 24;

[0074] FIG. 26 is a plan view of a panel joiner from the assembly of FIGS. 21; and

[0075] FIG. 27 is a side view of the panel joiner of FIG. 26.

[0076] In the following description, like reference characters designate like or corresponding parts throughout the figures.

DESCRIPTION OF EMBODIMENTS

[0077] Referring now to FIGS. 1 through 4, where there is illustrated a surface forming element 1 according to an embodiment.

[0078] The surface forming element 1 comprises a generally rectilinear and elongate panel, a perimeter frame 10 and an infill panel 20. The frame 10 comprises a pair of lengthwise extending parallel side members 12, a pair of end members 14, and a plurality of spaced apart bracing members 15 bridging the side members 12.

[0079] With reference to FIGS. 3 and 4, it can be seen that each of the side members 12 and end members 14 of the perimeter frame 10 comprises a rebate 16 (or step-shaped recess) shaped to receive an edge of the infill panel 20. In this way, the perimeter frame 10 comprises a border extending about a perimeter of the infill panel 20 so as to form a flush, continuous casting surface C along with the infill panel 20.

[0080] In this embodiment, the infill panel 20 is made of a material such as plywood, having a thickness of approximately 12 millimetres, but other materials (such as corflute or FRP) of varying thicknesses (depending on strength) may also be used.

[0081] Referring now to FIGS. 5 and 6, where there is illustrated a formwork assembly 100 according to an embodiment. The formwork assembly 100 comprises six of the surface forming elements 1, arranged into two abutting stacks of three surface forming elements 1 each, wherein each surface forming element 1 comprises a pair of lengthwise extending parallel side edges 12A, and wherein the surface forming elements 1 are stacked by abutting along these side edges 12A.

[0082] It should be understood that a formwork assembly 100 can comprise as many surface forming elements 1 arranged in as many stacks as is required for the particular application.

[0083] To facilitate this stacking, each of these edges 12A comprise a means for interlocking the surface forming elements 1 with respect to each other so that the resulting formwork assembly 100 forms a single, continuous casting surface C.

[0084] With reference to FIGS. 2 and 3, it can be seen that in this embodiment, the interlocking means comprises a profile shape of the edges 12A, and more specifically, a cross-sectional shape of the side members 12, where this cross-sectional shape is substantially constant throughout the length of the side members 12, and the surface forming element 1.

[0085] In this embodiment, each profile shape comprises a squared, step-shape comprising a (male or projecting) step 30, and a (female) step-shaped recess 40 adjacent to the step 30, where this step-shaped recess 40 is shaped to receive a step 30 of a further surface forming element 1.

[0086] For each surface forming element 1, the profile shape of the two edges 12A differs inasmuch as a profile shape of a first of the edges 12A1, is an inversion of the other of the edges 12A2. That is to say, for a profile shape of a first of the edges 12A1 the male step 30 extends along the continuous casting surface C, and the step-shaped recess 40 of the other of the edges 12A2 extends along the continuous casting surface C, and vice-versa.

[0087] In use, the male step 30 extending along edge 12A1 of a first surface forming element 1, is received in the recess 40 along the lower edge 12A2 of a further surface forming element 1 stacked atop of the first surface forming element 1. In this way, overlapping joints are formed that prevent egress of concrete while at the same time providing a smooth and flush continuous casting surface C against which concrete can be moulded, when the surface forming elements 1 are assembled.

[0088] The frame 10 is constructed primarily from a tubular aluminium (although other materials may be used), because this material can be extruded to produce the required cross-sectional shapes.

[0089] Being made of a harder, more wear resistant material than that of the infill panel 20 means that the perimeter frame 10 is less susceptible to damage resulting from normal handling and positioning of surface forming elements 1, than would be the infill panel 20 if this extended beyond the edge of the perimeter frame 10.

[0090] The lengthwise extending side members 12 of the frame 10 comprise a plurality of apertures 24 spaced apart there along, for receiving threaded fasteners, pins or the like.

[0091] As can be seen in FIG. 6, each aperture 24 extends through the step 30, and in use, the apertures 24 in adjacent surface forming elements 1 align when they are stacked, so that threaded fasteners or pins (not illustrated) can be inserted through the aligned apertures 24 to secure an upper and a lower stacked surface forming element 1 together. The dowels may be threaded (such as by use of Z-tie threads) to clamp the components together.

[0092] Similarly, the end members 14 of the frame 10 comprise apertures 34 for receiving threaded fasteners or pins. As illustrated in FIG. 6, these apertures 34 would enable a pair of surface forming elements 10 to be abutted end to end and secured together using threaded fasteners or pins.

[0093] With reference to FIGS. 5 and 6, it can be seen that the formwork assembly 100 further comprises a pair of edge elements 50, one each at the bottom (although these could also be used at the top) of the two abutting stacks of three surface forming elements 1. Each edge element 50 comprises a rail of extruded aluminium, and a pair of lengthwise extending parallel side edges 50A.

[0094] A first of the lengthwise extending parallel side edges 50A1 comprises a square edge for resting atop of a floor or other surface, and the other lengthwise extending parallel side edges 50A2 comprises a profile shape identical to that of the surface forming element 1, so that a surface forming element 1 can be stacked atop of, and interlock with, the lengthwise extending parallel side edge 50A2.

[0095] The formwork assembly 100 further comprises a pair of narrowed surface forming elements 1A, one each at the top of (although these could be used anywhere) the two abutting stacks of three surface forming elements 1. These narrowed surface forming elements 1A are almost identical to the surface forming elements 1 described above, differing in that the distance between the side edges 12A is less. These narrowed surface forming elements 1A can be used in conjunction with the standard surface forming element 1, and enable a required height to be achieved using a combination of these.

[0096] With reference to FIG. 6, it can be seen that the formwork assembly 100 further comprises a plurality of couplers 60. Each coupler 60 comprises a generally C-shaped bracket comprising a recess which is sized and shaped to receive a portion of a pair of interlocked side members 12. Each coupler 60 further comprises a pair of apertures 64 for receiving the threaded fasteners or pins that join abutting end members 14. While optional, use of the couplers 60 adds strength and stability to the formwork assembly 100.

[0097] As will be seen from the above description, the formwork assembly 100 can be easily assembled from the bottom up so as to put in place formwork which can mould vertical building features between floor slabs. Once the formwork assembly is in place, the formwork forming the underside surface of the upper floor can abut against the upper edge of the formwork assembly 10.

[0098] When no longer required, the formwork assembly 100 can be dis-assembled from the top down.

[0099] Referring now to FIGS. 7 through 14, where there is illustrated a surface forming element 1A according to a further embodiment. Those parts of the surface forming element 1A which are identical (or near-identical) to corresponding parts shown in the surface forming element 1 of FIGS. 1 through 6, will be denoted by the same reference numerals and will not be described again in detail.

[0100] With reference to FIGS. 11 through 14, it can be seen that the lengthwise extending side members 12 of surface forming element 1A differ in that these comprise an internal wall 13 at the point where the step in the profile cross-sectional shape occurs. This internal wall 13 divides the previously L-shaped cavity inside of the lengthwise extending side members 12, into two cavities comprising a generally rectangular cross-sectional shape. In use, the internal wall 13 will both strengthen and stiffen the lengthwise extending side members 12 of surface forming element 1A.

[0101] In addition to the apertures 24, the lengthwise extending side members 12 of surface forming element 1A comprise a further set of apertures 44 spaced apart there along, for receiving threaded fasteners, pins or the like. Whereas the apertures 24 extend between inner and outer (relative to the continuous casting surface C) surfaces of the lengthwise extending side members 12, the apertures 44 extend perpendicular to the apertures 24, between upper and lower edges of each lengthwise extending side member 12.

[0102] As can be seen in FIGS. 18 through 20 (which illustrate a formwork assembly 100A), similar to the apertures 24, each aperture 44 extends through the step 30, and in use, the apertures 44 in adjacent surface forming elements 1A align when they are stacked, so that bolts or pins (not illustrated) can be inserted through the aligned apertures 44 to secure an upper and a lower stacked surface forming element 1A together. This improves the strength and the stability of the stacked formwork assembly illustrated in FIGS. 18 through 20.

[0103] Referring now to FIGS. 15 through 17, where there is illustrated an edge element 50A. Those parts of the edge element 50A which are identical (or near-identical) to corresponding parts shown in the edge element 50 of FIGS. 5 and 6, will be denoted by the same reference numerals and will not be described again in detail.

[0104] Similar to the lengthwise extending side members 12 of surface forming element 1A, the edge element 50A comprises a first set of apertures 24, and a second set of apertures 44, which in use, align with the apertures 24 and 44 respectively, of surface forming elements 1A stacked atop of the edge element 50A, to receive bolts or pins which secure these together.

[0105] While not illustrated, a wall or column can be formed by positioning a pair of formwork assemblies in an opposing relationship, and extending horizontal ties between them. Each horizontal tie locates in one of the apertures 24 in the surface forming elements, comprises a Z-tie rod, and resists the weight of the concrete pushing the adjacent formwork panel assemblies apart.

[0106] In some instances it will be necessary to form an edge or end of a wall or column between a pair of formwork assemblies 100 arranged in an opposing relationship. In order to facilitate this, a plurality of end brackets 120 and 140 are secured with respect to the surface forming elements 1A, and these end brackets 120 and 140 support beams 160 which bridge (i.e. extend between) the brackets 120 and 140 associated with each of the pair of opposing formwork assemblies 100, and these beams 160 in turn support vertically extending formwork (not illustrated) such as planks or sheets of a suitable material (such as plywood), which will form the edge or end of the wall once the concrete is poured.

[0107] Each of the end brackets 120 and 140 comprises a pair of parallel spaced apart arms 150, and a connector 152 which bridges the arms 150, so that collectively, the arms 150 and the connector 152 define a slot 154 therebetween. In use, each of the arms 150 is inserted into an end of one of the contiguous tubular side members 12. An end of one of the beams 160 is then received in the slot 154. The arms 150 comprise holes 158 via which the arms 150 can be pinned or bolted in the side members 12.

[0108] With reference to FIGS. 22 and 23, it can be seen that a first type of end bracket 120 comprises arms 150 of square hollow section (SHS) steel, and a connector 152 of SHS steel which is welded at its ends to the arms 150. Each of the arms 150 of end bracket 120 comprises a depth guide 156 which limits the depth to which the arms 150 can be inserted into the tubular side members 12. In this embodiment, this depth guide 156 comprises a length of outwardly projecting steel plate 156 which in use will abut against the rebate 16 for the infill panel 20.

[0109] With reference to FIGS. 24 and 25, it can be seen that a second type of end bracket 140 comprises arms 150 of flat steel bar, and a connector 152 of SHS steel which is welded at its ends to the arms 150. The arms 150 of this end bracket 140 are thinner, and so the slot 154 therebetween is wider than that of the first type of end bracket 120, so that a larger, thicker beam 160 can be accepted within the slot 154 of the second type of end bracket 140. This end bracket 140 further comprises an end plate 159 via which this end bracket 140 can be secured with respect to other structure or formwork.

[0110] With reference to FIGS. 26 and 27, where there is illustrated a panel end connector 180 for joining surface forming elements 1A end to end, as illustrated in FIG. 21. The panel end connector 180 comprises an elongate body 182 comprising a pair of opposing ends. In this embodiment, the elongate body 182 comprises a length of SHS steel. In use, a first end of the panel end connector 180 is inserted into an end of one of the tubular side members 12 of a first surface forming element 1A, and a second end of the panel end connector 180 is inserted into an end of one of the tubular side members 12 of a second surface forming element 1A. The panel end connector 180 further comprises a depth guide 186 which limits the depth to which the body 182 can be inserted into the tubular side members 12. In this embodiment, this depth guide 186 comprises a length of outwardly projecting steel plate which in use will abut against the rebate 16. The body 182 of the connector 180 further comprise holes 188 via which the connector 180 can be pinned or bolted in the side members 12.

[0111] Throughout the specification and the claims that follow, unless the context requires otherwise, the words comprise and include and variations such as comprising and including will be understood to imply the inclusion of a stated integer or group of integers, but not the exclusion of any other integer or group of integers.

[0112] The reference to any prior art in this specification is not, and should not be taken as, an acknowledgement of any form of suggestion that such prior art forms part of the common general knowledge.

[0113] It will be appreciated by those skilled in the art that the invention is not restricted in its use to the particular application described. Neither is the present invention restricted in its preferred embodiment with regard to the particular elements and/or features described or depicted herein. It will be appreciated that the invention is not limited to the embodiment or embodiments disclosed, but is capable of numerous rearrangements, modifications and substitutions without departing from the scope of the invention as set forth and defined by the following claims.