Abstract
This disclosure refers to a formwork system which comprises: two or more insulating panels for receiving a fluid concrete structuring material between said panels; at least two sections to fit each other in a said panel; one or more connecting devices which comprise two extremities each for connection to a section to join two panels; wherein each panel has four ends including an upper end and a lower end opposite the upper end; wherein the panels comprise a cavity to fit one or more sections along the length of the upper end of each panel; wherein the panels comprise a cavity to fit sections along the length of the lower end of each panel; wherein the sections comprise a lateral flashing with a plurality of holes; wherein the connecting devices comprise a plurality of hooks, at their extremities, to enter in said holes of the section.
Claims
1. An insulating concrete formwork system with insulating panels and connection elements comprising: two or more insulating panels for receiving a fluid concrete structuring material between said panels; at least two sections to fit each one in one said panel; one or more connecting devices that comprise two extremities each one for connection to one section to join two panels; wherein each panel has four ends including an upper end and a lower end opposite the upper end; wherein the panels comprise a cavity to fit one or more sections along the upper end of each panel; wherein the panels comprise a cavity to fit one or more sections along the lower end of each panel; wherein the sections comprise a lateral flashing with a plurality of holes to fit the extremities of the connecting devices; wherein the connecting devices comprise a plurality of hooks, at their two extremities, to enter into said holes of the respective section.
2. The insulating concrete formwork system according to claim 1, wherein the connecting devices comprise at least two longitudinally parallel metallic rods to connect each one of their extremities to the respective section.
3. The insulating concrete formwork system according to claim 1, wherein said hooks are L-shaped at 90°.
4. The insulating concrete formwork system according to claim 3, said hooks have extremities in bend and reverse bend.
5. The insulating concrete formwork system according to claim 1, wherein each insulating panel comprises a left end and a right end, with recesses and protuberances in each of said ends, to fit contiguously with a right end of another panel and a left end of another panel respectively.
6. The insulating concrete formwork system according to claim 2, wherein the connecting devices comprise a plurality of transversal metallic rods to connect said longitudinally parallel metallic rods to each other.
7. The insulating concrete formwork system according to claim 6, wherein the connecting devices comprise a variable length between 100-1000 mm.
8. The insulating concrete formwork system according to claim 1, wherein the panels comprise a plurality of painted marks placed vertically on the outer face of the panel to define the location of fitting of said sections and the positioning of the panels.
9. The insulating concrete formwork system according to claim 1, wherein the panels comprise along the length of the lower end a protuberance and along the length of the upper end a recess, for superimposition of panels.
10. The insulating concrete formwork system according to claim 9, wherein the protuberance on the lower end of the panel is designed to abut on the upper end of another panel and by the compressing down of the extremity of the protuberance of said panel in the area of the connecting devices, make a seal so that the concrete remains within the formwork and does not leak to the area of the recess of the upper end of said panel.
11. The insulating concrete formwork system according to claim 9, wherein the protuberance or the recess are adapted to fit with the lateral flashing of said sections together with the hooks of said connecting device.
12. The insulating concrete formwork system according to claim 1, wherein the sections comprise a material partially made of metal.
13. The insulating concrete formwork system according to claim 1, wherein the length of the panels varies between 100-1300 mm.
14. The insulating concrete formwork system according to claim 1, wherein the height of the panels varies between 240-350 mm.
15. The insulating concrete formwork system according to claim 1, wherein the minimum thickness of the panel is 50 mm.
16. The insulating concrete formwork system according to claim 1, wherein the section is made of polyvinyl chloride.
17. The insulating concrete formwork system according to claim 1, wherein the connecting device is electrically welded raw steel.
18. (canceled)
19. (canceled)
20. a panel for assembly of an insulating concrete formwork system which comprises: four ends including an upper end and a lower end opposite the upper end, a vertical right end, a vertical left end, wherein the upper end comprises a protruding edge along the length of the panel, a recess along the length of the panel and a cavity arranged within said recess along the length of the panel; wherein the lower end comprises a protruding edge along the length of the panel ending in a funnel-shape to compress metallic connection rods when superimposed on another panel.
21. A connecting device for assembly of the insulating concrete formwork system which comprises: at least two longitudinally parallel metallic rods to connect each one of its extremities to a section; wherein each rod comprises a hook at each extremity to fit in holes of an assembly section of the insulating concrete formwork system; a plurality of transversal metallic rods to connect said longitudinally parallel metallic rods to each other.
22. (canceled)
23. A method for assembly of the insulating concrete formwork system with insulating panels and connection elements according to claim 1 which comprises at least two panels; at least two sections; one or more connecting devices; wherein the method comprises the following steps: placing at least two opposite panels in parallel between them to define a space between the panels to receive said fluid concrete structuring material; fitting the sections in the cavities of said panels; fitting the connecting devices in said sections to connect the respective panels to each other; repeating the assembly of the system so that the panels are mounted contiguously and superimposed in an intercalated manner; and filling the space between the two panels with the fluid structuring material.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
[0043] For easier understanding of this disclosure the figures below are herein attached, which represent preferred embodiments, but which are not however intended to limit the object of the present disclosure.
[0044] FIG. 1: Representation of an embodiment of the formwork of a wall being assembled, in the form and aspect of this ICF system (insulating concrete form), wherein: [0045] (1) represents a panel; [0046] (2) represents a connecting device; [0047] (3) represents a section; [0048] (4) represents a corner section; [0049] (5) represents a panel; [0050] (6) represents the space to receive the fluid structuring material; [0051] (7) represents a connecting device.
[0052] FIG. 2: Representation of an embodiment of a panel, wherein, FIGS. 2a) identifies a representation with a view of the outer face in particular and 2b) the representation with a view of the inner face in particular: [0053] (8) represents a recess at the upper end along the length of said panel; [0054] (9) represents a protuberance at the lower end along the length of said panel; [0055] (10) represents a cavity along the length of said panel; [0056] (14) represents a protuberance at the height of the vertical right end of said panel; [0057] (15) represents a recess at the height of the top vertical left end of said panel.
[0058] FIG. 3: Representation of an embodiment of a section, wherein, in FIGS. 3a) and 3b), in particular:
[0059] (11) represents a lateral flashing;
[0060] (12) represents a hole;
[0061] (13) represents a film or painting of metallic material.
[0062] FIG. 4: Representation of an embodiment of a connecting device, in which (16) represents a hook.
[0063] FIG. 5: Representation of an embodiment of a complete junction with a connecting device and opposite sections in FIGS. 5a) and 5b).
[0064] FIG. 6: Representation of an embodiment of cut, folded and holed sections with view of creating/embodiment of one corner.
[0065] FIG. 7: Representation of various embodiments of the system with perspective view of: corner, crossing, T-trunk and end/finalization/closure of the formwork.
[0066] FIG. 8: Representation of an embodiment with frontal view of the system with the identification of lines represented by broken lines, which in the fabrication will be painted, which will indicate intuitively the correct placement and interconnection of the panels and respective position of the sections.
[0067] FIG. 9: Representation of an embodiment with a top view of how the junction of two contiguous panels is made.
[0068] FIG. 10: Representation of an embodiment with a perspective view from above of the placement of the opposite panels in parallel with the sections fitted and interconnected with the connecting devices so as to construct a formwork.
[0069] FIG. 11: Representation of an embodiment with a side view of the fitted sections and the respective flashings connected to the hooks of the connecting device lodged into the recess along the length of the respective panel.
[0070] FIG. 12: Representation of an embodiment with a side view of the junction of superimposed panels with the extremity of the lower protuberance along the length of the upper panel compressed in the area of the connecting devices.
[0071] FIG. 13: Representation of an embodiment with a side view in particular of a thicker panel for placement on the formworks corresponding to the outer part of the constructions that require greater thermal insulation.
DETAILED DESCRIPTION
[0072] This disclosure refers to a simplified system in regard to the way an insulating concrete formwork system is assembled for fabrication of walls or structures in civil construction. Just three types of raw materials are used: EPS (expanded polystyrene), PVC (Polyvinyl chloride) and Steel.
[0073] FIG. 1 shows an embodiment of the insulating concrete formwork system with insulating panels and connection elements that comprises: at least two panels (1,5); one or more connecting devices (2,7) for connection of the panels (1,5) so as to create/provide the space (6) to receive the fluid structuring material; at least two sections (3) to fit into the panels (1,5) interconnected by said connecting devices (2,7); wherein the panels (1,5) comprise a cavity (10) along the length in said panel (1,5) to fit one or more sections (3); wherein the sections (3) comprise a lateral flashing (11) with a plurality of holes (12) to fit the connecting devices (2,7); wherein the connecting devices (2,7) have a plurality of hooks (16) adapted to enter axially in the holes (12) of said sections (3).
[0074] The EPS for fabrication of the panels (1,5), as in FIG. 2, may be supplied in large blocks. The PVC for fabrication of sections (3), as in FIG. 3, may be supplied in sections already. The steel for fabrication of the connecting devices (2,7), as in FIG. 4, may be supplied in electrically welded sheets of raw steel.
[0075] The panel (1,5), as in FIG. 2, may be fabricated from blocks supplied in large sizes with the help of a foam cutter, which may be a pantograph. This is a peculiar characteristic in the fabrication of the panels of this publication, as it is the first solution to use the cutting system for fabrication of panels in insulating formwork systems. Various types of densities can be used in accordance with the type of mechanical resistance necessary for the formwork depending on the execution of the respective thicknesses of the constructions. It is important to mention that the panels may comprise other types of polystyrene compounds, such as, EPS X, graphited polystyrene etc., in order to satisfy other needs, such as, greater impermeability, protection against UV rays or other specifics. Other types of foams can also be used that include the possibility of cutting in these kinds of machines and which provide the low thermal conductibility and mechanical resistance for the intended effect.
[0076] The EPS panel was created, designed and developed specifically for this insulating formwork system, with no similar ones being available. The panel (1,5) has two faces, the outer face which comprises a plurality of marks on the vertical, preferably between 3 and 5 marks, facing out of the formwork, opposite to the inner face facing into the formwork. Said panel (1,5) also has four ends, an upper horizontal end, having a cavity along its length (10) and a lower horizontal end opposite the upper one which also has a cavity along its length (10) opposite the cavity of the upper end as in FIG. 2.
[0077] The upper horizontal end also comprises a recess (8) along its length, and the lower end comprises a protuberance (9) along its length as in FIG. 2. The vertical left end opposite the right end comprises a recess and a protuberance along its height (15,14), and the vertical right side comprises a protuberance and a recess along its height (15,14) opposite the left end as in FIG. 2. It is understood as the upper end, the horizontal end facing upwards, as the lower end, the horizontal end facing downwards, as the left end, the vertical end facing left and as the right end, the vertical end facing right, this when we look at the outer face frontally which should have a plurality of marks, preferably 3 to 5, painted on the vertical. The panel (1,5) can be 1200 mm in length. This length has the objective of having the same width as the plasterboard panels (Pladur), and it is imperative that the measures match so that the installation is easy and intuitive without having to make unnecessary cuts in the respective plasterboard. In panels (1,5) the shorter lengths needed are cut using a saw or with a manual foam cutter when assembling the system in the execution of the work, thus enabling an infinite plurality of variants, making the system versatile and adaptable to any situation. The length is understood to be the distance that separates the left end from the right end. The minimum thickness of the panel (1,5) may be 63 mm so that the deepest electrical junction boxes can be placed without difficulties within this thickness and may be more than 200 mm, as in FIG. 13, so as to make the formwork with greater thermal insulation that could be applied where the climate so demands. It should be mentioned that this is one of the many characteristics that differentiates this system from the existing ones, as it enables a choice and the adaptation of the intended insulation in the formwork to all types of climates and to the most demanding clients, taking into account that the client practically will only have to pay more for the raw material corresponding to the greater volume of EPS. The thickness is understood to be the distance comprised between the outer face and the inner face of said panel (1,5). The height of the normal panel (1,5) may be 250 mm or 333 mm, with the latter being to execute constructions of smaller thicknesses where the need for mechanical resistance of the formwork is lower. The height is understood to be the distance comprised between the upper end and the lower end.
[0078] In the embodiments described above, the measures presented may vary, i.e. may be slightly altered so as to make better use of the raw material and with the reduction of product costs in the fabrication.
[0079] As shown in FIG. 2, the panels (1,5) comprise 3 marks painted vertically, represented by the broken line, located every 300 mm, which serve as a reference for the placement of the connecting devices (2,7), for the correct positioning of the intercalating of the panels (1,5), and so that the electrician and the plumber know where the sections are placed (3), avoiding them when making the cuts to insert the respective tubing without loss of time. Lastly, so that the plasterboard can be fixed/screwed to the sections (3) in a simple, intuitive and quick manner.
[0080] As shown in FIG. 2, the panel (1,5) comprises a recess along the length on the upper end which serves to house the lateral flashing of the section. The panels (1,5) also comprise a protuberance (9) along the length on the lower end, so as to make a filter, as in FIG. 12, as when one panel is pressed on another, the extremity of said protuberance is pressed in the area of the wires, of the connecting devices (2,7), making a seal and impeding the passage of the concrete placed in the space (6) between the walls of the formwork for the areas of the recesses (8) of the panels (1,5) so as not to compromise the thermal insulation of the set.
[0081] In an embodiment, the sections (3) have a lateral flashing (11) with a plurality of holes (12) to fit the connecting devices (2,7).
[0082] The panels (1,5) are adapted with the cavities (10) along the length of the upper end and along the length of the lower end in opposite manner for fitting the sections (3) together and interconnecting said panels (1,5) to each other in a superimposed and intercalated manner forming a wall of said formwork, which together with the hooks (16) of the extremities of said connecting devices (2,7), i.e. the ends of the rods/hooks (16), which pass through the holes (12), located in the lateral flashing (11) of the sections (3), thus interconnecting with another opposite wall and making up the formwork as shown in FIG. 1. As shown in FIG. 11, the recess (8) is also useful if the water penetrates with residues of concrete, so that these do not go up and enter the cavity (10) created to lodge the section (3). On the other hand, it also serves to allow said residues to be deposited and stay there, as shown in FIG. 12, so as not to compromise the thermal insulation of the system.
[0083] In an embodiment a panel (1,5) is provided with a protuberance (14) at the height of the right end and a recess (15) at the height of the left end, vertically opposite close to the inner face of said panel (1,5), which when the panels (1,5) are joined contiguously, form a perfect fit so that the concrete does not leak from the wall of the formwork even if there is some slack in the joint, as shown in the lower part of FIG. 9, and remains in the space (6) in contact with the inner faces of said panels (1,5).
[0084] In an embodiment, a panel (1,5) is provided with a protuberance and recess (14,15) at the height of the right end and a recess and protuberance (15,14), at the height of the left end, vertically opposite so that when the panels (1,5) are joined contiguously, they form a perfect fit so that the concrete does not leak to the wall of the formwork even if there is some slack in this joint.
[0085] The section (3) fabricated in PVC is a section with unique characteristics as there is no other like it and it was designed specifically for this ICF solution. The PVC used in this embodiment may be stiffened to guarantee a mechanical resistance not just for the purposes of loading of the formwork, but also to be able to withstand significant loads it may be subjected to in the placement of the various elements referred to previously. For the detection of these elements, a metallic material (13) is placed, preferably an aluminium band and/or paint, as illustrated in FIG. 3, which allows the detection with a proximity “pinpointer” metal detector after the walls have been finished.
[0086] The function of detection will only be necessary after the conclusion and painting of the walls. The conjoining of the painted lines on the panel beforehand referred to makes the system intuitive, it not being necessary to use this feature whilst the walls are being constructed until the placement of the plasterboard.
[0087] In an embodiment, the section (3) may be of 3 mm in thickness and in a format like a T lying down, where the “leg” makes an S-shape, i.e. a bend and a reverse bend, which is given the name of lateral flashing and which at its extremity may be of 4 mm in thickness (the area where soon afterwards the holes will be made (12)) for the placing of the connecting devices (2,7) so that its mechanical resistance is strengthened. It should be pointed out that each complete join (connecting devices (2,7)+section (3)), as in FIG. 5, due to the stiffened PVC and greater thickness referred to previously will have the particular characteristic of bearing a tension force (lateral) close to 200 kg at a temperature of 20° C.
[0088] The section (3) may be cut and drilled so that together with the connecting devices (2,7), as in FIG. 4, the joints are formed as in FIG. 5 and which fitted into the cavities (10) of the panels (1,5) placed opposite in parallel, make up the formwork (ICF), as in FIGS. 1 and 10.
[0089] It is important to refer that for the corners, ends, crossings and trucking of walls the same section (3) is used, cut with the respective sizes, folded and drilled, as illustrated in FIG. 6, which together with the connecting devices (2,7) and the panels (1,5) will make the formats referred to, as shown in FIG. 7.
[0090] In an embodiment, as in FIG. 4, the connecting devices (2,7) may be fabricated in electrically welded raw steel. The transversal metallic rods of about 100 mm shown in these connecting devices serve to maintain these and the system squaring, but also to be able to tie the structural iron rebar when assembling this insulating formwork system. The dimensions of these rods are merely indicative and are related to the cost and speed of fabrication. If during assembly and/or placement of the structural iron rebar the dimension of the beams referred to previously conditions the speed of execution, this measure will come to have the minimum and executable possible by the cutting and fabrication machines.
[0091] In an embodiment, the connecting devices (2,7) may be fabricated in electrically welded raw steel. The transversal metallic rods, i.e. perpendicular of about 100 mm shown in these connecting devices serve to maintain the wires in parallel and the squaring of these and of the system.
[0092] The connecting devices (2,7) may have various measures on length which serve together with the section (3) to form the joint between the walls of the formwork, as shown in FIG. 5. It is important to mention that it is the length of these connecting devices that defines the space in the interior of the formwork and consequently the thickness of the wall and/or construction. The fabrication of the connecting devices (2,7) is planned in various lengths as in FIG. 4, so as to enable that the walls/constructions are approximately 10, 15, 20, 25, 30, 35 cm in thickness. These are the standard measures, and other measures may be made to order, whether for thicker walls, or for the execution of formwork for pillars of greater size with the use of ICF or another specific type of formwork for the works/construction in question.
[0093] Another purpose of the connecting devices (2,7) is the support for and tying of the structural iron rebar helping in its placement and becoming part of the same.
[0094] In an embodiment, as illustrated in FIG. 5, the complete join (connecting device with sections (3) opposite), with the sections (3) interconnected by the connecting devices that fit into the cavities (10) of the panels (1,5) which guarantee the safety of the system and all the elements can be screwed to these: Plasterboard, shelves, television screens, pictures, cupboards, phenolics and it will even be possible to place heavy coatings as each one of these joints will be able to bear weights close to 200 kg. The sections (3) will also be able to have the plumb checks screwed to them when assembling the formwork, which guarantee the verticality of the system and the safety of the formwork until the concrete has dried. It should also be pointed out that when the door and window frames are done with formwork using the ends shown in FIG. 7, we enable the possibility of fixing the windows and doors directly to the system with the maximum of safety and speed without having to make holes and/or to place bushes.
[0095] In an embodiment, as shown in FIG. 8, the panels (1,5) can be placed superimposed and intercalated contiguously, where the vertical marks allow the placement of the joints with precision and the correct position for their intercalation. This makes everything much more intuitive in the assembly as well as in the placement of the plasterboard as at each crossing point between the lines and the extremity of the panel there will be a section (3) where the plasterboard can be screwed.
[0096] FIG. 8 shows the dotted lines of the vertical marks to facilitate the assembly of the formwork of the present embodiment. It is important to mention that this embodiment does not comprise the extremities of the panel (1,5) signalled, as indicated in FIG. 8, and the marks will be coloured and thick, preferably from 2 to 3 mm.
[0097] In this embodiment and as shown in FIG. 8, in an embodiment, the system can allow fixing points like no other system in the present state of the art. It is important to mention that after the finishing and painting, one can always find out where the sections (3) are by using a metal detector so that the supports for placement can be screwed, for example, for a picture or a television screen. It is important to mention that no system of this type of formwork allows this particular detail.
[0098] In an embodiment, as indicated in FIG. 9, we can see how the panels (1,5) are joined sequentially and contiguously, with this positive/negative type effect, i.e. salience/protuberance (14) and cavity/recess (15) so that even with some slack there is no leaking of concrete.
[0099] In an embodiment, as shown in FIG. 10, the placement of two opposite interconnected panels with the complete joints as in FIG. 5, the set of sections (3) plus connecting devices (2,7) form a block, the simplest form of the formwork. In practice the placement of these contiguous, superimposed and intercalated blocks sequentially, will make up the formwork.
[0100] In an embodiment, as shown in FIG. 11, the cavity is filled by the section (3), and the recess (8) of the upper end, houses the lateral flashing (11) together with the extremities of the hooks (16) of the connecting devices which also serve to house/deposit and solidify there in isolation, some residues of concrete which may pass to the interior of the recess, so as not to compromise the thermal insulation of the set.
[0101] In an embodiment, as shown in FIG. 13, the non-standard panel (1,5) of 150 mm in thickness serves as an example and is projected to be applied only on the side of the formwork corresponding to the exterior of the construction, adaptable to the local climate. For example, in very cold countries or just to satisfy more demanding clients who want greater thermal insulation.
[0102] It should be pointed out that in this case the client will practically only pay for the difference corresponding to the greater quantity of EPS, as the speed and cost of fabrication is almost unaltered.
[0103] When the term “comprises” or “comprising” is used in this document, this is to indicate the presence of characteristics, elements, integers, steps and components mentioned, but does not preclude the presence or the addition of one or more other characteristics, elements, integers, steps and components, or groups thereof.
[0104] This invention is not, naturally, in any way restricted to the embodiments described in this document and anyone with average knowledge in the art could foresee many possibilities for modification of the same and for substitutions of technical characteristics by other equivalents, depending on the requirements of each situation, such as is defined in the appended claims. The following claims define additional embodiments of this description. The embodiments presented are combinable between each other. The following claims also define embodiments.
