Concrete formwork assembly and method for assembling the same

Abstract

The present invention relates to an innovated concrete formwork for building’s walls and slabs, comprising a set of modular components that are assembled to form a temporary removable formwork’s skeleton for two consecutive floors with multistage props providing larger working area, reducing overlapped walls’ rebars, where the upper floor’s props can be a shade’s support during extreme weather. It comprises an invented T-shape malefemale soldiers, key-soldiers and male-female panels, all are composed of back part made of recycled plastic or wood and front part made of resilient rubber. Where the panels are installed gradually to allow for concurrent installation of rebars, MEP first fix, and pour the concrete of the wall from bottom. where the key-soldier is made to dismantle any part of the wall formwork. The invention includes a corner’s hinged soldier and an inflated tube with three compartments to create variable void spaces in the concrete wall.

Description

Concrete formwork assembly and method for assembling the same CROSS-REFERENCE TO RELATED APPLICATIONS

[0001] There are no cross-related applications. 5 FIELD OF THE INVENTION

[0002] The present invention generally relates to construction materials and, more particularly to a temporary removable concrete formwork for building’s walls and slabs system of an improved type. BACKGROUND OF THE INVENTION 10

[0003] Formwork is a temporary structure that is used to support the wet concrete until it hardens and gains enough strength to support itself. The use of formwork is a wellestablished practice in the field of building and construction, formwork for constructing concrete consists of spaced arrays of panels, typically fabricated of Metal, plywood, insulated forms, or plastic forms that are connected by rods, trusswork or other connecting 15 structure as mentioned in the following prior art patents examples: a. CA 3096182 (FORMWORK SYSTEMS AND RELATED METHODS - 2020) b. CA 3190589 (FORMWORK SYSTEM AND METHOD -2021) c. CA 2994076 (FORMWORK SYSTEM - 2018) 20 d. CA 2258985 (CONCRETE WALL FORMWORK MODULE - 1999) e. CA 2127319 (FORMWORK WITH FORM PANELS AND CONNECTING MEANS - 1994) f. CA 2049547 (FORMWORK SYSTEM - 1991) g. CA 2999778 (A FORMWORK PANEL ASSEMBLY - 2015) 25 h. CA 3047014 (CONCRETE FORM PANEL, AND CONCRETE FORMWORK COMPRISING SAME - 2019)File number: 14021-002 2 i. CA 2549483 (CONCRETE FORMWORK - 2009) j. CA 2595474 (CONCRETE WALL FORMWORK MODULE - 2006) k. CA 3014571 l. CA 2226497 ( MODULAR FORMWORK FOR CONCRETE - 1999) 5 m. CA 2988452 (STRUCTURAL WALL WITH A STRUCTURE EXOGENOUS TO THE LONGITUDINAL AXIS THEREOF FOR ENABLING THE INSIDE OF THE WALL TO BE FILLED ON SITE - 2016) n. US 2002 / 0007610A1 (Interlocking mortarless load bearing building block 10 system - Application US09 / 834,187 - 2001) o. CN202248392U (Cast-in-situ partition wall structure - Application CN2011203742058U – 2011) p. CN105625201B (A kind of method that culvert is reinforced using inflatable inner mold and self-compacting concrete - Application 15 CN201511033409.4A – 2015).

[0004] Several attempts have been made to develop such a system using different technics and materials trying to make balance between high cost of the forms, construction time, labor costs, complex assembly, and disassembly, reusability, and material waste. However, the existing formwork systems for the cast in situ concrete still have several drawbacks 20 such as:

[0005] Most of the existing formworks are laying side by side formwork panels in butt joints which make difficult to avoid leakage in between reused panels and can lead to the formation of honeycombs, water infiltration, corrosion of the reinforcement and other structural problems. 25

[0006] Lack of visibility, accessibility, and concrete vibration control. Most of the existing formworks are installed at full wall’s high imposing to cast the concrete in a deep confined area which may require special attention to the formwork stability during the concrete vibration and make difficult any correction or adjustment of any trade inside the formwork.File number: 14021-002 3 Moreover, the existing formworks necessitate working at outside area which cannot be always possible during extreme hot and cold weather conditions.

[0007] Most of the existing formworks do not have the capability to do in-situ hollow core walls with variable void spaces and constructing walls using prefab hollow core panels and 5 or hollow cement blocks (CMU) will need special manpower and equipment’s for transportation, loading, offloading, storage, erection in addition to the excessive service live load which may come from the storage of block pallets over the concrete floors’ slabs, moreover, making separations in the same formwork is difficult, combined walls necessitate of pouring higher grade of concrete in the non bearing walls which may lead to 10 unnecessary losses.

[0008] Most of the existing formworks which are made to pour the slab and walls together do not have an easy way to dismantling the wall formwork within 2 days after pouring of the concrete but should wait unnecessary more 6 to 8 days until the slab’s concrete is set and be ready for formwork removal, moreover, most of the existing formworks are made 15 for single floor, which will always require to do steel rebars overlapping for walls with the consecutive walls of the upper floor, and also, the next floor activities as of rebars, MEP first fix, and formwork can not start until and after the setting time of the slab’s concrete’s of the lower floor.

[0009] More of the existing formworks require major modification and special 20 arrangement to do curved walls and necessitate highly skilled labors.

[0010] Therefore, there is a need for an improved formwork system that can address the above-mentioned concerns, and to be environmentally friendly and cost-effective. SUMMARY OF THE INVENTION

[0011] The present invention provides a breathable, accessible, simultaneous double-levels 25 formwork system allowing to install simultaneously the formwork of one floor with partial extension to the next consecutive floor walls and slab, creating larger working areas for all construction activities, reducing overlapping of walls / column’s steel rebars and the upper formwork skeleton can be used to install outdoor fabric shade cloth for better working conditions during extreme hot or cold weather. The wall’s formwork’s is composed ofFile number: 14021-002 4 modular male-female T- form soldiers connected to the opposite wall side with tie-rods and rectangular walls’ panels gradually installed leaving always required spaces and openings for the installation of all other activities and access to do concrete pouring and vibration from the bottom of the wall. The slab’s formwork is done by the assembly of 5 standard props provided with head screw crossing the slab to hold standard twin joists, the formwork’s battens and sheeting with another standard twin joists above the level of the concrete of the slab serving as base for the next floor’s props. The invention comprises an inflated tube composed of three interconnected compartments and provided with special spacers to create variable hollow concrete voids and can be used as a barrier to separate 10 different grades of concrete if needed.

[0012] The main components, soldiers, and panels are composed of two parts. The back part is made of a solid material preferably hard recycled plastic, or wood and the front part facing the concrete is semi hard material preferably made of recycled rubber or plastic.

[0013] The present invention is also providing a novated hinged corner soldier designed to 15 form perpendicular, slightly deviated, or curved walls.

[0014] The formwork materials are environmentally friendly and made in major parts of lightweight, preferably recycled rubber from used tires and or recycled plastic, which makes them durable, reusable, and easy to transport, easy to assemble and disassemble.

[0015] The present invention provides a method of formwork’s skeleton installation up to 20 the next floor walls and slab providing a considerable time saving compared to the existing system, and an opportunity to use the formwork’s skeleton as a substructure to install an outdoor weather’s protection fabric shade and allow for the gradual installation of walls’ panels inserted between the T-soldiers frames to pour the concrete at lower level for walls as to reduce the concrete lateral pressure on the formwork. 25

[0016] In one aspect of the invention, a concrete scalable wall formwork system is provided. The system comprises upper and lower soldier assemblies, each assembly comprising a male soldier component and a matching female soldier component, a key assembly and one or more transversal bracing laterally for attaching the upper and lower soldier assemblies. The key assembly comprises a male key component, a matching femaleFile number: 14021-002 5 key component; and a bracket. The key assembly is connectable between the upper and the lower soldier assemblies with the bracket.

[0017] The concrete scalable formwork system may further comprise one or more wall panel mountable between two soldier assemblies or two key assemblies. The upper or lower 5 soldier assemblies may comprise back vertical member comprising attaching members connectable with the bracket of the key assembly. The back vertical member may be rectangular and may comprise slopped edges. The back vertical member may comprise apertures matching periphery of the transversal bracing.

[0018] The male and female soldier components of the upper and lower assemblies may 10 comprise a front surface, the front surface of the male soldier component matching the front surface of the female soldier component. The front surface of the male soldier component may be a protrusion and the front surface of the female soldier component may be a recess. The protrusion and the recess may be rounded to mate to one another. The front surface of the male and female soldier components may comprise top and bottom portions adapted to 15 mate to one another. The top mating portion may be a recess and the bottom mating portion may be a tongue.

[0019] The concrete scalable formwork system may further comprise one or more wall panel assemblies attachable to a side of an upper or a lower soldier assembly. The wall panel assembly may comprise a first portion and a second portion comprising a 20 substantially flat surface for facing concrete, the first portion mating with the second portion. The substantially flat surface may be made of semi-rigid material. The first portion of the wall panel assembly may comprise a recess and the second portion, the first portion of the wall panel assembly comprising a protuberance mating with the recess. The wall panel assembly may further comprise a wall panel key assembly. The wall panel assembly 25 may further comprise a sliding channel and a metallic lock-handle mounted to a back portion of the wall panel assembly.

[0020] The concrete scalable formwork system may further comprise a hinged wall panel soldier assembly. The hinged wall panel soldier assembly may comprise an inner portion and an outer portion connectable to one another using tie-rods. Each of the inner and outer 30 portions may comprise a rotating member adapted to assemble at an angle a first sideFile number: 14021-002 6 portion of one of the inner or outer portion to a second side portion of the said inner or outer portion. The rotating member may be a rigid bracket comprising a junction member adapted to assemble at an angle a first side portion of an inner or outer portion to a second side portion of the inner or outer portion. 5

[0021] The concrete scalable formwork system may further comprise an inflatable tube for creating hollow core concrete. The inflatable tube may comprise a plurality of interconnected compartments. The interconnected compartments may comprise a central portion and two edges tubes. The inflatable tube may comprise squeezable variable sections to create a variable void volume. The concrete spacer may comprise a cable tie adapted to 10 squeeze the inflatable tube core to create a variable void volume.

[0022] In another aspect of the invention, a method of installing of a wall formwork is provided. The method comprises installing a first pair of lower soldier assembly and key assembly on a first side of a wall, the key assembly forming an external portion of the wall, installing a second pair of lower soldier assembly and key assembly on a second side of a 15 wall to create a gap with the first pair of lower soldier assembly and key assembly, installing a first pair of upper soldier assembly and key assembly on the first side of the wall over the first pair of lower soldier assembly and key assembly to create a sealed arrangement, installing a second pair of upper soldier assembly and key assembly on the second side of the wall over the second pair of lower soldier assembly and key assembly 20 to create a sealed arrangement while creating a gap with the first pair of upper soldier assembly and key assembly;, maintaining the gap between the first and second pairs of upper and lower soldier and key assemblies with a rigid member and attaching the upper key assemblies to the respective lower key assemblies.

[0023] The attachment of the upper key assemblies to the respective lower key assemblies 25 further may comprise locking a bracket over wedge portions of the respective upper and lower key assemblies.

[0024] The method may further comprise sealingly joining a wall panel assembly to a side of the upper or the lower soldier assembly, sealingly joining the wall panel assembly to a second side of another upper or the lower soldier assembly and / or sealingly joining a 30 second wall panel assembly over or below the wall panel assembly. The joining of theFile number: 14021-002 7 second wall panel assembly over or below the wall panel assembly may lock a bracket over wedge portions of the respective wall panel assemblies.

[0025] In yet another aspect of the invention, a method for multi-levels of slabs of formworks members is provided. The method comprises positioning a first extremity of a 5 props over a base surface, supporting a first joist on a lower head of the prop while allowing passage of an elongated portion of the prop through the joist and supporting a second joist on an upper head of the prop, the upper head being over a rigid sleeve of the props.

[0026] The first joist may be a twin joist. The method may comprise supporting an upper props on a top portion of the second joist as a base for an upper floor. The method may 10 comprise supporting a soldier assembly or a wall panel assembly over a top portion of the second joist. The supporting the soldier assembly or the wall panel assembly may be performed using stud runners and Z-bracket.

[0027] It should be appreciated that this summary is provided to introduce a selection of concepts in a simplified form that are further described below in the detailed description. 15 This summary is not intended to be used to limit the scope of the claimed subject matter.

[0028] Other and further aspects and advantages of the present invention will be obvious upon an understanding of the illustrative embodiments about to be described or will be indicated in the appended claims, and various advantages not referred to herein will occur to one skilled in the art upon employment of the invention in practice. 20 Advantages of the present formwork invention:

[0029] Soldiers and panels are installed in an overlapping male-female manner to almost avoid leakage, honeycombs, and water infiltration which’s frequently happening in the reused panels’ butt joints of others concrete’s formworks.

[0030] The present formwork invention is ensuring direct visibility and accessibility, as 25 the panels can be installed gradually leaving openings maintaining closer control of the concrete vibration, contrary to others concrete’s formworks, which require special attention to the formwork stability during the concrete vibration in a deep confined area with the difficulty to de any correction or adjustment of any trade after closing the formwork.File number: 14021-002 8

[0031] The present formwork invention has the particularity to provide top substructure to install an outside fabric shade during extreme hot and cold weathers.

[0032] The present formwork invention has the particularity to do in-situ variable void space hollow core walls as an alternative of using prefab hollow core panels and or hollow 5 cement blocks (CMU) which need special manpower and equipment’s for transportation, loading, offloading, storage, erection in addition to the excessive service live load which may come from the storage of block pallets over the concrete floors’ slabs.

[0033] The present formwork invention has the particularity to provide an incorporated solution within the same installed formwork providing separation between bearing and 10 non-bearing walls which do not need same grade of concrete saving manpower, equipment and avoiding pouring higher grade of concrete in the non bearing walls which may lead to unnecessary losses.

[0034] The present formwork invention has the particularity to provide a component which serve as a key to dismantle the wall’s soldiers and panels in an easy way, with a great time 15 saving where slabs and walls are cast together, where almost others concrete’s formworks do not have an easy way to dismantling the wall formwork within 2 days after pouring of the concrete but should wait unnecessarily more 6 to 8 days until the slab’s concrete is set and be ready for formwork removal.

[0035] The present formwork invention has the particularity to provide an easy and safe 20 solution to be installed for two consecutive floors, providing larger working area to do the next floor activities as of rebars, MEP first fix, reducing the steel rebars overlapping for walls which can be great factor for time, manpower and material saving.

[0036] The present formwork invention has the particularity to provide a rotating wall corner’s soldier for slightly curved walls, while others concrete formworks require major 25 modification and special arrangement to do curved walls and necessitate highly skilled labors.

[0037] The present formwork invention main components, soldiers, and panels are composed of two parts, made in major parts of recycled material from tires, rubber orFile number: 14021-002 9 plastic and where the front part facing the concrete is preferably made of rubber which reduce the sticking to the concrete and the use of oiled release agent for the panel’s faces.

[0038] The present formwork invention components are made from multiple parts providing the possibility to replace any damaged part without be obliged to replace the full 5 component as it’s the case in others concrete’ formwork.

[0039] The present formwork invention has the particularity of using modular segmented soldiers and panels which reduce the cost of transportation, installation, and maintenance. BRIEF DESCRIPTION OF THE DRAWINGS

[0040] The above and other aspects, features and advantages of the invention will become 10 more readily apparent from the following description, reference being made to the accompanying drawings in which:

[0041] FIG. 1 is an isometric view of an embodiment of temporary formwork components for wall and slab, assembled in accordance with the principles of the present invention.

[0042] FIG. 2 is a perspective view of an embodiment of T-soldier assemblies for a wall 15 with associated components, transversal bracing and connecting tie-rods in accordance with the principles of the present invention.

[0043] FIG. 3 is a perspective view of embodiments of wall’s panels with associated components and lock-handle device in accordance with the principles of the present invention. 20

[0044] FIG. 4 is a perspective view of embodiments of a secondary key soldier assembly for a wall in accordance with the principles of the present invention..

[0045] FIG. 5 is a perspective view of embodiments of the formwork of FIG. 1 having one side assembly of T-soldier assemblies and transversal bracing mounted to the panels.

[0046] FIG. 6 is a rear perspective view of the wall soldiers and wall panels being installed 25 to form the formwork of FIG. 1.

[0047] FIG. 7 is a front perspective view of wall soldier assemblies and panel assemblies being installed to form an embodiment of a formwork in accordance with the principle of the present invention.File number: 14021-002 10

[0048] FIG. 8 is a rear perspective view of the wall soldier assemblies and panel assemblies of FIG. 5 being dismantled of the formwork.

[0049] FIG. 9 is a top view of an embodiment of a hinged soldier adapted for a wall corner with an exploded view for the associated components in accordance with the principles of 5 the present invention.

[0050] FIG.10 is a top view of an embodiment of an outer component of a corner soldier in accordance with the principles of the present invention shown being rotated.

[0051] FIG. 11 and FIG. 11A are a perspective views of an embodiment of an inflated tube comprising three compartments in accordance with the principles of the present invention. 10

[0052] FIG. 12 is a perspective of an embodiment of formwork’s prop with associated components in accordance with the principles of the present invention.

[0053] FIG.13 is a perspective view of a step for transition from wall to slab of an embodiment of a method for installing slab-wall over the formwork in accordance with the principles of the present invention. 15 DETAILED DESCRIPTION OF THE INVENTION

[0054] A novel removable concrete formwork system and method will be described hereinafter. Although the invention is described in terms of specific illustrative embodiments, it is to be understood that the embodiments described herein are by way of example only and that the scope of the invention is not intended to be limited thereby. 20

[0055] Referring now to FIG. 1, an embodiment of a temporary formwork and components for wall, slab and above slab are illustrated. The temporary formwork comprises main a male-female wall’s T-soldier assembly 1 and male-female secondary key-soldier assembly 2. The secondary key-soldier assembly 2 is used to connect lower and upper main T-soldier assemblies 1 via metallic bracket 204. The formwork further comprises a transversal 25 bracing 13 adapted to connect the main T-soldier assemblies 1 longitudinally.

[0056] The formwork further comprises male-female wall panel assemblies 3. The wall panel assemblies 3 are typically of a rectangular shape but may be of any other desirable shape. The wall assemblies 3 are inserted in between the T-soldiers.File number: 14021-002 11

[0057] The formwork further comprises male-female 5 wall corner’s hinged soldiers.

[0058] The formwork may further comprise two levels of joists 9, such as but not limited to twin joists, held above one another. The formwork may comprise multi staged props 8 holding the joists 9 one above the other. Lower twin joists 9 may hold slab’s batten 7. The 5 batten 7 may be adapted to receive slab’s tiles 6 and / or edge’s tiles 15. The edge slab tile 15 may rest on the wall’s top cut soldiers and / or panels 4. The higher twin joists 9 may be used as a base for the second floor’s props 8 and / or to fix the second-floor wall’s soldiers 1 and / or wall panels 3. The soldier assemblies 1 and / or wall panel assemblies may be attached using stud runners 11 and / or rigid Z-bracket 12. 10

[0059] The formwork system may further comprise an inflated tube 10 comprising three interconnected compartments. The different components may be attached or connected to one another using any fastening methods, such as fasteners, connecting screws or any other attachment method known in the art. The fasteners have been omitted from the figures for sake of clarity. 15

[0060] Referring now to FIG. 2, an embodiment of a male-female T-soldier assembly 1 is illustrated with an exploded view of embodiments of T-soldier assemblies 1 comprising a transversal bracing 13, tie-rods 20 comprising a sleeve 14 as a wall’s space separation between two opposite T-soldiers.

[0061] In such embodiment, the T-soldier assembly 1 comprises one or more transversal 20 bracing 27 with bracket 28, which are made of rigid material, such as wood and / or metal material. The T-soldier 1 further comprises back T-shaped member 101 and front side member 102. The back member 101 comprises a vertical portion 26 adapted to attach the T-soldier assembly 1 to an upper or lower T-soldier assembly 1. The vertical portion 26 may also be adapted to receive the transversal bracing 27. The vertical portion 26 may be 25 embodied as a rectangular T-web with back slopped edges 99 made to adhere with the Ksoldier 2 back side slopped part (see FIG-5). The vertical portion 26 may comprise apertures 29 matching the periphery of the bracing 27. and the vertical portion 26 may further comprise upper and lower apertures 30 adapted to receive and retain wedge members 25. The back member 101 may further comprise a flange flatbed 24. The flatbed 30 24 may be connected to a first portion 23 adapted to mate with the front member 102. TheFile number: 14021-002 12 first portion 23 may be shaped as a protrusion comprising rounded ends 23. The front member 102 may be shaped as a round recess, as illustrated, to mate with the first portion 23.

[0062] The T-soldier assembly 1 further comprises a front member 102 positioned to face 5 the concrete and create a desired concrete surface (typically flat). The front part 102 generally comprises a top protruded tongue 31 and bottom cavity 32 made as to ensure male-female installation. The front member 102 further comprises a small face recess 33 mating with the protruded side tongue 21 of the panels 3 (See Fig.7)

[0063] The T-soldier 1 back member 101 is generally made of rigid material, such as but 10 not limited to hard recycled plastic or wood. The front member 102 facing the concrete is typically made of semi hard material, such as but not limited to rubber or plastic. The rubber may be made of recycled tires and the plastic may be recycled plastic.

[0064] Referring now to FIG. 3, an embodiment of male-female wall panel assemblies 3 15 is illustrated. In such embodiment, the wall panel assembly 3 comprises a plurality of subcomponents. In a preferred embodiment, the subcomponents are similar to the subcomponents of the T-soldier 1 (see FIG. 2). The subcomponents may comprise front portions 302, which may include a top tongue 31, a bottom cavity 32 for male-female installation and a side tongue 21 adapted to mate with the side recess 34 of the front part 20 102 of the T-soldier assembly 1 and the key-soldier 2 (see FIG. 7). The front portions 302 are generally positioned to face the concrete and to create a desired concrete surface (typically flat). The concrete facing panel 302 is typically made of semi hard material, such as but not limited to rubber from recycled tires or recycled plastic.

[0065] The back part 301 generally comprises at front rounded portion 23 adapted to mate 25 with the back side 34 of the front part 302. The back part 301 is preferably made of a solid material such as hard recycled plastic, or wood.

[0066] The assembly of the panels 3 may comprise a sliding channel 304 and a lock-handle 303 mounted to the back part 301.

[0067] Referring now to FIG. 4, an embodiment of an exploded male-female key-soldier 30 assembly 2 is illustrated. In the illustrated embodiment, the subcomponents of the keyFile number: 14021-002 13 soldier assembly 2 are similar to the subcomponents of the T-soldier assembly 1 with back part 202 which have protruded rounded part 23 mating to the back side 34 of the front part 201which have a top tongue 31 and bottom cavity 32 for male female installation and a small face recess 33 mating with the side protruded tongue 21 of the front part 302 of the 5 panels 3(See FIG-7) . In the illustrated embodiment, the T-web member of the back part 202 is generally shaped as a key. In the illustrated embodiment, the T-web member of the back part 202 comprises two triangular slopped sections 22 designed as backing support for the T-soldier assembly 1. (See Fig.5).

[0068] In some embodiments, the back part 202 of the key assembly 2 is made of a solid 10 material such as but not limited to hard recycled plastic, or wood. The front part 201 is positioned to generally face the concrete and is typically made of semi hard material such as but not limited to rubber from recycled tires or recycled plastic.

[0069] The key-soldier assembly 2 may comprise a rigid bracket 204. The rigid bracket 204 may be made of metal and may comprise holes or apertures 29 shaped to hold the 15 wedge 25 of the back part 202 and the extremity wedges 25 of the T-soldiers 1 back member 101. In such an embodiment, the bracket 204 is fixed on each side of the T-web 202 via wedge 25 and bolt 203 and is used to connect to the upper and lower wedges 25 of the T-soldiers 1 (See FIG. 6).

[0070] Referring to FIGS. 5 to 8, a step-by-step installation method of different walls 20 components of an embodiment of a formwork is illustrated.

[0071] Referring now to FIG. 5, two opposite sides assembly of walls’ T-soldiers 1 & keysoldiers 2 and panels 3 are illustrated. In the illustrated embodiment, the key-soldier 2 is installed between the T-soldiers 1 while maintaining a gap 222 to facilitate the dismantling (see FIG. 8). The two triangular slopped sections 22 of the key-soldier assemblies 2 are 25 positioned to support the T-soldier assembly 1 at the lower and upper external edges. The bracket 204 of the key soldier assembly 2 is fixed to the extremity wedge 25 of the top and bottom T-soldiers 1 (see FIG. 6).

[0072] Referring now to FIG. 6, a back view of the male-female installation of wall T and key soldier assemblies 1 and 2 and panels 3 is illustrated. The panel assemblies 3 are set 30 on bedsides 24 of wall soldiers 1 and 2. The lock-handle 303 slides to the back of the TFile number: 14021-002 14 soldier flange 26 to fix the panels 3 in between two consecutive vertical arrangement of soldiers 1 & 2. The bracket 204 of the key soldier 2 is fixed to the extremity wedge 25 of the top and bottom T-soldiers 1.

[0073] Referring now to FIG. 7, a step to install a male-female of wall soldier assemblies 5 1 and 2 and panel assemblies 3 is shown. The panel assemblies 3 are set on sides 24 of wall soldier assemblies 1 and 2. Each of the wall soldiers 1 and 2 comprise one or more recesses 33 mating with one or more side tongues 21 of the panels 3 showing a typical sealed assembly aiming at avoiding any leakage of poured concrete thru the joints’ formwork.

[0074] Referring to FIG. 8, an embodiment of the dismantling process of the wall soldiers 10 1 and 2 and of the panels 3 is illustrated. The formwork soldiers comprise two complimentary top front elongated members 102, 201 adhering by friction to each other which make it difficult to move, however the back parts of the soldiers 202 and 101 are made to be easily striped backward.

[0075] After the removing of the tie-rods 20 and the transversal bracing 13 is completed, 15 the bracket 204 of the key-soldier 2 may be dismantled from the upper and lower T-soldiers 2. The back part 202 of the key-soldier assembly 2 is pushed towards the back while retaining the front part 201 in place. The back parts 101 may also be pushed backward while front parts 102 remain still. As the parts 102, 201 are unmounted, said parts may be removed. In some embodiments, to ease removal, the parts 102, 201 may be made of 20 resilient material, such as but not limited to rubber. The back parts of the panels may be dismantled consequently.

[0076] Referring now to FIG.9, an embodiment of a male-female hinged soldier 5 assembly is illustrated. The hinged soldier assembly 5 is typically used to create a formwork for wall corner. The hinged soldier assembly 5 comprises an inner portion 501 25 and an outer portion 502. The two portions 501 and 502 are generally connected one to the other using rigid members 20, such as tie-rods, and have similar subcomponents and male female installation procedure as the T-soldier’s 1 and key-soldier 2 for walls. In some embodiments, each of the portions 501 or 502 comprises structural members 503, 504, 505, 509 typically made of rigid material such as wood-metal composition. The portions 501 or 30 502 may further comprise two sides back parts panels 507, 52, 57 & 509, 52, 57. The backFile number: 14021-002 15 parts panels 507, 509 are typically made of recycled plastic, or wood. The portions 501 or 502 may further comprise a front panel 508 or 506 facing the concrete. The front panels 508 & 506 may be made of rubber or recycled plastic. The inner 501 and outer 502 portions comprise a rotating member 504. The rotating member 504 may be embodied as a rotating 5 bracket made of rigid material, such as metal. The rotating bracket 504 may comprise Usection 505 with bolt 58, double hinges 54,55 and plates 53 adapted to assemble the left and the right sides 507 and 509 allowing a slight rotation for curved walls. The hinged soldier 5 further comprise a transversal bracing 27,56 comprising bracket for the corner.

[0077] Referring to FIG. 10, an example of rotation of an embodiment of the outer 10 component 502 of a hinged corner soldier assembly 5 is illustrated. To create a desired angle, bolts 203 of the curved bracket 504 are tightened or loosened to maintain the assembly 5 at the desired angle. The concrete facing panel 506 may be customized to adapt to different angles or a different concrete wall’s pattern.

[0078] Referring now to FIGS. 11 and 11A, an embodiment of an inflatable tube 10 with 15 three compartment is illustrated. The illustrated inflatable tube comprises three compartment interconnected tubes made of resilient material, such as but not limited to rubber, a central portion 133, typically having a prismatic section with size approximately four (4) times more than the two edges portions 132. The central portion 133 may comprise an air-valve 130 and a cup 131. The inflatable tube 10 may further comprise a concrete 20 spacer 135. The concrete spacer 135 may be made of rigid material such as but not limited to plastic. In some embodiments, the inflatable tube may further have variable sections, as illustrated at FIG. 11A, allowing the installation of the steel rebars 221, the concrete spacer 135 may be fixed on the edges portions 132 and may be connected by a self-closing cable tie 134 squeezing the inflatable inner core 10 to ensure the required concrete cover around 25 the steel rebars. In the illustrated embodiment, a typical section of concrete wall 400 with the variable shaped hollow core void after removing the inflated inner core 10 is shown.

[0079] The inflated tube 10 may act as a concrete barrier A to separate different type of concrete if any, where the lightweight concrete is poured at first stage and the heavy strength concrete is poured at second stage after setting of the lightweight concrete.File number: 14021-002 16

[0080] Referring now to FIG. 12, an embodiment of an assembled multi staged prop 8 with associated components. The illustrated embodiment is showing the assembly method of a multi-staged prop made of standard elements and comprises a bottom base plate 81, bottom screw 82 & tie-nut 83, standard prop tube 84, head screw 80 holding a prop head 85 , the 5 prop head 85 is holding twin joists. The head screw is crossing the slab with a sleeve 86 and top prop head 85 to hold another higher twin joists 9. The higher standard twin joists 9 above the level of the concrete of the slab are serving as base for the next floor’s props.

[0081] Referring now to FIG. 13, an embodiment of an assembled formwork for slab and above slab, comprising props 8, joists 9, such as twin joists, props heads 81, 85, concrete 10 sleeve 86, slab’s battens 7, slab’s tiles 6, 15, stud runners 11, brackets 103, 12, such as a Z-bracket and slab’s wall’s soldiers 1 and panels 3 is illustrated.

[0082] In such an embodiment, the formwork may further comprise a multi staged props 8 with props heads 85 adapted to receive two levels of joists 9 held above. The joist 9 may be twin joists or any joists allowing vertical passage of the props 8. In such an 15 embodiment, the lower twin joists 9 are supporting the battens 7 of the slab. The battens 7 are adapted to receive tiles 6 and edge’s tiles 15 of the slab. As such, the edge slab tile 15 is rested on the wall’s top cut soldiers and panels 4 (See Fig. 11). The upper twin joists 9 are used as a base for the second floor’s props 8 and may also be adapted to fix the second-floor wall’s soldiers 1 and panels 3. In such embodiment, the second-floor wall’s 20 soldiers 1 and panels 3 are mounted using stud runners 11 and Z-bracket 12, such as a bracket made of rigid material such as metal.

[0083] The props head screws 80 cross over the slab’s and holds the props heads 85 where the lower prop head 85 is comprising a rigid sleeve 86, such as plastic sleeve embedded in the concrete slab. 25

[0084] In other embodiments, the higher twin joists 9 may be used as above slab support to strengthening the formwork in case of cantilever or of slab openings.

[0085] While the preferred embodiments of the present invention have been described, it should be understood that the invention is not limited to details of the illustrated invention shown in the figures and that a number of variants may be made even if they have a 30 fundamentally different design without departing from the scope thereof as defined by theFile number: 14021-002 17 appended claims. Furthermore, it is to be understood that the inventive concepts may be otherwise variously embodied and employed and that the appended claims are intended to be construed to include such variations except insofar as limited by the prior art.

Claims

CLAIMS 1) A concrete scalable wall formwork system comprising: upper and lower soldier assemblies, each assembly comprising a male soldier component and a matching female soldier component; 5 a key assembly comprising: a male key component; a matching female key component; and a bracket; the key assembly being connectable between the upper and the lower 10 soldier assemblies with the bracket; and one or more transversal bracing laterally for attaching the upper and lower soldier assemblies. 2) The concrete scalable formwork system of claim 1 further comprising one or more wall panel mountable between two soldier assemblies or two key assemblies. 15 3) The concrete scalable formwork system of claim 1, the upper or lower soldier assemblies comprising back vertical member comprising attaching members connectable with the bracket of the key assembly. 4) The concrete scalable formwork system of claim 3, the back vertical member being rectangular and comprising slopped edges. 20 5) The concrete scalable formwork system of claim 3, the back vertical member comprising apertures matching periphery of the transversal bracing. 6) The concrete scalable formwork system of claim 1, the male and female soldier components of the upper and lower assemblies comprising a front surface, the front surface of the male soldier component matching the front surface of the female 25 soldier component.File number: 14021-002 19 7) The concrete scalable formwork system of claim 6, the front surface of the male soldier component being a protrusion and the front surface of the female soldier component being a recess. 8) The concrete scalable formwork system of claim 7, the protrusion and the recess 5 being rounded to mate to one another. 9) The concrete scalable formwork system of claim 6, the front surface of the male and female soldier components comprising top and bottom portions adapted to mate to one another. 10) The concrete scalable formwork system of claim 9, the top mating portion being a 10 recess and the bottom mating portion being a tongue. 11) The concrete scalable formwork system of claim 1 further comprising one or more wall panel assemblies attachable to a side of an upper or a lower soldier assembly. 12) The concrete scalable formwork system of claim 11, the wall panel assembly comprising a first portion and a second portion comprising a substantially flat 15 surface for facing concrete, the first portion mating with the second portion. 13) The concrete scalable formwork system of claim 12, the substantially flat surface being made of semi-rigid material. 14) The concrete scalable formwork system of claim 12, the first portion of the wall panel assembly comprising a recess and the second portion, the first portion of the 20 wall panel assembly comprising a protuberance mating with the recess. 15) The concrete scalable formwork system of claim 11, the wall panel assembly further comprising a wall panel key assembly. 16) The concrete scalable formwork system of claim 11, the wall panel assembly further comprising a sliding channel and a metallic lock-handle mounted to a back 25 portion of the wall panel assembly. 17) The concrete scalable formwork system of claim 1 further comprising a hinged wall panel soldier assembly.File number: 14021-002 20 18) The concrete scalable formwork system of claim 17, the hinged wall panel soldier assembly comprising an inner portion and an outer portion connectable to one another using tie-rods. 19) The concrete scalable formwork system of claim 18, each of the inner and outer 5 portions comprising a rotating member adapted to assemble at an angle a first side portion of one of the inner or outer portion to a second side portion of the said inner or outer portion. 20) The concrete scalable formwork system of claim 19, the rotating member being a rigid bracket comprising a junction member adapted to assemble at an angle a first 10 side portion of an inner or outer portion to a second side portion of the inner or outer portion. 21) The concrete scalable formwork system of claim 1 further comprising an inflatable tube for creating hollow core concrete. 22) The concrete scalable formwork system of claim 21, the inflatable tube comprising 15 a plurality of interconnected compartments. 23) The concrete scalable formwork system of claim 22, the interconnected compartments comprising a central portion and two edges tubes. 24) The concrete scalable formwork system of claim 22, the inflatable tube comprising squeezable variable sections to create a variable void volume. 20 25) The concrete scalable formwork system of claim 24, the concrete spacer comprising a cable tie adapted to squeeze the inflatable tube core to create a variable void volume. 26) A method of installing of a wall formwork, the method comprising: installing a first pair of lower soldier assembly and key assembly on a first 25 side of a wall, the key assembly forming an external portion of the wall; installing a second pair of lower soldier assembly and key assembly on a second side of a wall to create a gap with the first pair of lower soldier assembly and key assembly;File number: 14021-002 21 installing a first pair of upper soldier assembly and key assembly on the first side of the wall over the first pair of lower soldier assembly and key assembly to create a sealed arrangement; installing a second pair of upper soldier assembly and key assembly on the 5 second side of the wall over the second pair of lower soldier assembly and key assembly to create a sealed arrangement while creating a gap with the first pair of upper soldier assembly and key assembly; maintaining the gap between the first and second pairs of upper and lower soldier and key assemblies with a rigid member; and 10 attaching the upper key assemblies to the respective lower key assemblies. 27) The method of claim 26, wherein the attachment of the upper key assemblies to the respective lower key assemblies further comprises locking a bracket over wedge portions of the respective upper and lower key assemblies. 28) The method of claim 26 further comprising sealingly joining a wall panel assembly 15 to a side of the upper or the lower soldier assembly. 29) The method of claim 28 further comprising sealingly joining the wall panel assembly to a second side of another upper or the lower soldier assembly. 30) The method of claim 28 further comprising sealingly joining a second wall panel assembly over or below the wall panel assembly. 20 31) The method of claim 30, the joining of the second wall panel assembly over or below the wall panel assembly locking a bracket over wedge portions of the respective wall panel assemblies. 32) A method for multi-levels of slabs of formworks members, the method comprising: positioning a first extremity of a props over a base surface; 25 supporting a first joist on a lower head of the prop while allowing passage of an elongated portion of the prop through the joist; and supporting a second joist on an upper head of the prop, the upper head being over a rigid sleeve of the props.File number: 14021-002 22 33) The method of claim 32, the first joist being a twin joist. 34) The method of claim 32 further comprising supporting an upper props on a top portion of the second joist as a base for an upper floor. 35) The method of claim 32 further comprising supporting a soldier assembly or a wall 5 panel assembly over a top portion of the second joist. 36) The method of claim 32, the supporting the soldier assembly or the wall panel assembly being performed using stud runners and Z-bracket.