Compressible internal formwork assemblies for forming concrete building shafts

Abstract

An interior formwork assembly for forming a concrete building shaft includes quarter panels and corner posts therebetween. Each corner post has angled interface surfaces that converge toward an exposed orthogonal skin surface. The panel has corresponding angled interface surfaces that intersect the corresponding angled interface surfaces of the corner posts, such that the panel is orthogonally secured by the corner posts. The angled interface surfaces of the corner posts and panels slidably abut against each other and are mechanically interlocked with latches that slide along slots, such that the panels move inwardly together to form a compressed cross-sectional configuration when the corner posts are raised relative to the panels and outwardly to form an expanded cross-sectional configuration when the corner posts are lowered relative to the panels, wherein the orthogonal skin surfaces align with corresponding skin surfaces of adjacent panels.

Description

Technical Field

[0001] The present invention relates generally to forms, and more particularly, the present invention relates to compressible interior formwork assemblies for forming concrete building shafts. Background Art

[0002] Concrete forms used in the construction industry form concrete molds that are used to form various building elements such as walls, columns, shafts, etc. After the concrete has set, the forms are removed, leaving the set concrete in place.

[0003] When forming tubular building elements, compressible formwork is required, and various configurations thereof include US 5230907 A (Strickland) of July 27, 1993 [hereinafter referred to as D1] for off-site prefabrication of tubular concrete segments, which includes a horizontally acting hydraulic rammer and internal mold assembly for pulling in opposing corners for compression; US 4614326 A (Strickland) of September 30, 1986 [hereinafter referred to as D2], which also uses an arrangement of hydraulic rammers and is designed for forming sinking basins; SU 1361276 A2 (KAZAK PIORGANIZATSII T STR KA) of December 23, 1987 [hereinafter referred to as D3]; SU 939694 A1 (ALMA) of June 30, 1982, which uses vertically movable corner elements to pull in side panels; ATINSKIJDOMOSTROITEL) [hereinafter referred to as D4] and ITMI20092357 A1 (SETTEN GENESIO SPA) of March 31, 2010 [hereinafter referred to as D5] for pulling in beveled corner pieces using a pivoting arm.

[0004] The present invention seeks to provide a foldable formwork assembly to overcome the problems associated with forming multi-story building shafts which will overcome or substantially ameliorate at least some of the disadvantages of the prior art, or at least provide an alternative.

[0005] It should be understood that, if any prior art information is referred to herein, such reference does not constitute an admission that the information forms part of the common general knowledge in the art in Australia or any other country. Summary of the Invention

[0006] Provided herein is an interior formwork assembly for forming a concrete building shaft having quarter panels and corner posts therebetween. Each corner post has an angled interface surface that converges toward an exposed orthogonal skin surface. The panel has corresponding angled interface surfaces that intersect the corresponding angled interface surfaces of the corner posts, such that the panel is orthogonally secured by the corner posts. The angled interface surfaces of the corner posts and panel slidably abut one another, enabling the corner posts to travel perpendicularly relative to the panel and mechanically interlock with latches that slide along slots, thereby causing the panels to move inwardly together to form a compressed cross-sectional configuration when the corner posts are raised relative to the panel and outwardly to form an expanded cross-sectional configuration when the corner posts are lowered relative to the panel, wherein the orthogonal skin surfaces align with corresponding skin surfaces of adjacent panels.

[0007] The present formwork assembly may have a specific geometry particularly suitable for forming multi-story shafts (such as elevator shafts, stairwells, etc.) in situ, unlike the off-site precast assembly of D1, the sink forming device of D2, or the relatively short arrangements taught by D3 to D5.

[0008] In this regard, the height of the internal formwork assembly may be greater than 4 meters, so that an entire floor shaft section may be formed at once, and wherein the shaft formation in stages may facilitate lifting of the internal formwork assembly between floors using a crane.

[0009] In particular, the interior formwork assembly of the present invention may include specific geometries to allow relatively large surface area panels to be peeled from the concrete and / or to provide sufficient clearance to lift the formwork assembly into the shaft using a crane.

[0010] Specifically, the ratio of the slot height to horizontal extent may be greater than 5, preferably about 7 or more, so as to balance vertical crane forces with horizontal forces sufficient to peel the panels from the interior concrete surface of the shaft using a crane alone.

[0011] Furthermore, compared to the arrangements taught by D1 or D2, the width of the exposed orthogonal skin surfaces of the corner posts can be relatively small to minimize surface contact area and prevent the posts from sticking to the concrete when lifted by a crane. In this regard, the width of each orthogonal skin surface can be less than 50 mm, preferably less than approximately 40 mm. Furthermore, the ratio of the width of each corner post interface surface to the width of the corresponding orthogonal skin surface can be greater than 4, preferably greater than 5, thereby allowing for ample interface surface to achieve structural integrity of the assembly.

[0012] Furthermore, the ratio of the horizontal extent of each slot to the width of each orthogonal skin surface can be greater than 1, such that each corner post can move more along a diagonal axis than along an orthogonal axis between an expanded and a compressed cross-sectional configuration. Preferably, this ratio is greater than 1.5.

[0013] Thus, the horizontal extent of each slot can be configured to allow each panel to move inwardly by more than 30 mm, preferably more than about 40 mm, thereby providing up to 80 mm of clearance along each axis of the formwork assembly. This is particularly useful because plywood nails may sometimes protrude 25 mm to 30 mm from the surface of the panel, which would otherwise prevent a crane from lifting the formwork assembly without such sufficient clearance.

[0014] Other aspects of the invention are also disclosed. BRIEF DESCRIPTION OF THE DRAWINGS

[0015] Although there may be any other forms that fall within the scope of the invention, preferred embodiments of the present disclosure will now be described, by way of example only, with reference to the accompanying drawings, in which:

[0016] Figure 1 showing an exploded internal view of a corner of an interior formwork assembly according to one embodiment;

[0017] Figure 2 an exterior perspective view showing the corner in an expanded configuration;

[0018] Figure 3 an exterior perspective view showing the corner in a compressed configuration;

[0019] Figure 4 showing an enlarged exterior view of the corner in the deployed configuration;

[0020] Figure 5 showing an enlarged interior view of the corner in the deployed configuration;

[0021] Figure 6 showing an enlarged exterior view of the corner in a compressed configuration;

[0022] Figure 7 showing an enlarged interior view of the corner in a compressed configuration;

[0023] Figure 8 showing a top plan view of the corner in a deployed configuration;

[0024] Figure 9 showing a top plan view of the corner in a compressed configuration;

[0025] Figure 10 Give example dimensions of angles;

[0026] Figure 11 a side elevational view showing the slots of the corner posts of the assembly;

[0027] Figure 12 a top plan view showing the assembly in a deployed configuration; and

[0028] Figure 13 A top plan view of the assembly is shown in a compressed configuration. DETAILED DESCRIPTION

[0029] refer to Figure 12 , the interior formwork assembly 100 includes a quarter panel 101 and a corner post 102. Figure 8 , each corner post 102 includes an angled interface surface 103 that converges toward an exposed orthogonal skin surface 104 .

[0030] The plate 101 has an angled interface surface 105 that intersects the corresponding angled interface surface 103 of the corner post 102, so that the plate 101 is Figure 12 The arrangement shown in FIG. 1 is orthogonally fixed by corner posts 102 .

[0031] refer to Figure 5 and Figure 7 The angled interface surfaces 103, 105 slidably abut against each other so that each corner post 102 can be Figure 5 In the manner shown in FIG. 1 , the adjacent plate 101 is vertically raised and Figure 7 The manner shown in FIG. 1 is vertically descending relative to the adjacent plate 101.

[0032] Furthermore, the angled interface surfaces 103, 105 are mechanically interlocked with a latch 106 that slides along a slot 107. The slot 107 is inclined outwardly towards its upper end. Figure 5 and Figure 7 In the embodiment shown in FIG, the slots 107 are arranged in pairs, each slot engaging a corresponding lock 106 therethrough. Figure 1 , a slot 107 may be arranged along the length of the corner post 102. Figure 1 In the embodiment shown in , the corner post 102 includes four pairs of slots 107 .

[0033] When the corner post 102 has Figure 5 When the plate 101 is raised in the manner shown in FIG. 1 , the arrangement of the slots 107 and the catches allows the plates 101 to move inwardly together to form a Figure 9 and Figure 13 Furthermore, when the corner post 102 is lowered relative to the plate 101 and the orthogonal skin surface 104 is Figure 8 When aligned with the corresponding skin surface 108 of the plate 101 in the manner shown in FIG, the plate 101 moves outward to form Figure 8and Figure 12 The expanded cross-sectional configuration is shown in .

[0034] In the deployed configuration, the orthogonal skin surface 104 is exposed.

[0035] Each corner post 102 may include a lifting lug 109. The lifting lug 109 may, in use, be attached to a crane hook via a respective chain to pull up the corner post 102 to allow the formwork assembly 100 to assume the compressed configuration.

[0036] like Figure 1 As shown in FIG, each corner post 102 may be formed from a metal plate to form Figure 1 1. Furthermore, panel 101 may be formed from a corresponding wedge 110, which may also be formed from sheet metal. A latch 106 may be attached to an inner interface surface 105 of the metal wedge 110. Wood strips 111 may be attached to orthogonal edges 115 of the wedge 110, to which other components of panel 101 may be attached. In this regard, panel 101 may comprise wood panel pieces on 300 mm centers having 18 mm plywood panels secured together using 3 inch nails.

[0037] The wedge 110 may include a window 116 to allow access to the face of the lath 111 for driving a wood screw 117 into the wood workpiece. The corner post 102 may include a corresponding window 118.

[0038] The interface surfaces 103 , 105 may include additional retaining latches 119 that interconnect with corresponding notches 120 to further strengthen and structurally support the assembly 100 when the assembly 100 is in the deployed configuration.

[0039] The height of each corner post 102 may be greater than 4 meters, preferably 4.5 meters, to allow for the formation of a shaft spanning an entire floor.

[0040] This arrangement of metal and wood components imparts structural resilience at the interacting corners of assembly 100, but exposes plywood skin surfaces that are more suitable for stripping from concrete.

[0041] refer to Figure 11 , each slot 107 may include a vertical extent v and a horizontal extent h. The ratio of the vertical extent v to the horizontal extent h may be greater than 5, preferably greater than 7. In the embodiment shown, the vertical extent is about 450 mm and the horizontal extent is about 65 mm, resulting in a ratio of about 6.9.

[0042] This ratio balances the vertical force applied by the crane with a horizontal force sufficient to peel the panel 101 from the concrete.

[0043] refer to Figure 10, the width of each orthogonal skin surface 104 may be less than 50 mm, preferably less than about 40 mm. Thus, when the assembly 100 is in the deployed configuration, the relatively narrow orthogonal skin surfaces 104 expose a smaller surface area in contact with the concrete, thereby allowing for peeling when the corner post 102 is initially pulled upward by a crane during use.

[0044] like Figure 10 As further shown in FIG, the ratio of the width of the corner post interface surface 103 to the width of the corresponding orthogonal skin surface 104 can be greater than 4, and preferably greater than 5. Thus, the assembly 100 includes sufficient interface surface contact area between the interface surfaces 103, 105 to achieve structural integrity while minimizing exposure of the skin surface 104.

[0045] Furthermore, the ratio of the horizontal extent h of each slot 107 to the width of each orthogonal skin surface 104 can be greater than 1, such that each corner post 102 is more movable along the orthogonal axis 113 than each panel 101 is movable along the orthogonal axis 113 between the expanded and compressed cross-sectional configurations. Figure 9 The range of movement of the diagonal axis 112 shown in FIG is greater. The ratio is preferably greater than 1.5.

[0046] Thus, the horizontal extent h of the slot 107 can be configured to allow movement of each panel 101 along the orthogonal axis by more than 30 mm, preferably more than about 40 mm, thereby providing a total clearance of 80 mm along each orthogonal axis 113. Thus, the assembly 100 can be withdrawn from the shaft with sufficient clearance to avoid protruding nail heads and the like.

[0047] refer to Figure 11 In the embodiment, with a horizontal range of 65 mm, each corner post 102 will move 65 mm along the diagonal axis 112 and the panel 101 can move along the orthogonal axis 113 defined by the width of each orthogonal skin surface 104, in this case 40 mm. Figure 9 In the illustrated embodiment, the assembly 100 can be arranged so that the distal tips 114 can be within 10 mm of each other, or even as Figure 9 Make contact as shown.

[0048] Forming a vertical building shaft using the assembly 100 may include placing the assembly 100 in place and erecting an external form around it, defining a rectangular mold therebetween into which rebar may be inserted.

[0049] Concrete may be poured into the mold and allowed to set.

[0050] Then, a quarter of the chain can be interconnected to each lifting lug 109 of the corner post 102 and attached to the crane hook. As the crane hook is pulled up, each corner post 102 is also pulled up. As described above, the relatively small surface area of ​​the exposed orthogonal skin surface 104 allows the exposed surface of the corner post 102 to be peeled away from the concrete, so that the corner post 102 does not stick when initially lifted by the crane.

[0051] As further described above, the angle ratio of the slots 107 may provide sufficient counterbalancing action to convert the lifting force applied by the crane into a larger horizontal force sufficient to peel the panel 101 from the concrete.

[0052] exist Figure 13 In the compressed configuration shown in FIG, the assembly 100 may have a maximum clearance of 80 mm along each orthogonal axis 113, thereby allowing a crane to lift the assembly to the next higher location without being obstructed by any protrusions such as plywood nails.

[0053] At the next higher position, the corner post 102 can be lowered relative to the plate so that the assembly 100 presents Figure 12 The expanded configuration is shown and the process is repeated.

[0054] It will be appreciated that this process avoids the use of specialized hydraulic rams, screw jacks, etc., minimizes human intervention, and essentially allows the crane itself to quickly lift the assembly 100 and simply raise each position as the shaft is gradually formed.

[0055] For the purpose of explanation, the foregoing description uses specific terms to achieve a thorough understanding of the present invention. However, it will be apparent to those skilled in the art that specific details are not required to practice the present invention. Therefore, for the purpose of illustration and description, the foregoing description of specific embodiments of the present invention is presented. These embodiments are not intended to be exhaustive or to limit the present invention to the precise form disclosed, as it is apparent that many modifications and variations can be made in view of the foregoing teachings. The embodiments are selected and described in order to better explain the principles of the present invention and its practical application, thereby enabling others skilled in the art to better utilize the present invention and various embodiments with various modifications suitable for the intended specific use. The following claims and their equivalents are intended to define the scope of the present invention.

[0056] Unless otherwise indicated, the term "about" or similar terms used herein should be interpreted as within 10% of the stated value.

Claims

1. An internal template assembly comprising: a quarter of a board; and Corner posts between the panels, each corner post having: An angled interface surface facing The exposed orthogonal epidermal surfaces converge where: The plate has an angled interface surface that intersects a corresponding angled interface surface of the corner post such that the plate is orthogonally secured by the corner post; The angled interface surfaces of the corner post and the panel slidably abut against each other and mechanically interlock with a lock that slides along a slot When the corner posts are raised relative to the panels, the panels move inwardly together to form a compressed cross-sectional configuration; and The panels move outwardly to form an expanded cross-sectional configuration as the corner posts are lowered relative to the panels and wherein the orthogonal skin surfaces are aligned with corresponding skin surfaces of an adjacent panel.

2. The assembly of claim 1, wherein: A ratio of the vertical extent to the horizontal extent of the slot is greater than 5.

3. The assembly of claim 2, wherein: The height of the assembly is greater than 4 meters.

4. The assembly of claim 3, wherein: The ratio is about 7.

5. The assembly of claim 4, wherein: The vertical length is about 450 mm, and the horizontal length is about 65 mm.

6. The assembly of claim 1, wherein: The ratio of the width of the corner post interface surface to the width of the corresponding orthogonal skin surface is greater than 4.

7. The assembly of claim 6, wherein: The ratio is greater than 5.

8. The assembly of claim 6, wherein: Each of said orthogonal skin surfaces comprises a width of less than 50 mm.

9. The assembly of claim 8, wherein: The width is less than 40 mm.

10. The assembly of claim 1, wherein: Each of said orthogonal skin surfaces comprises a width of less than 50 mm.

11. The assembly of claim 10, wherein: The width is less than 40 mm.

12. The assembly of claim 1, wherein: The ratio of the horizontal extent of each slot to the width of each orthogonal skin surface is greater than 1, so that each corner post moves along a diagonal axis to a greater extent than each panel moves along an orthogonal axis between the expanded and compressed cross-sectional configurations.

13. The assembly of claim 12, wherein: The ratio is greater than 1.

5.

14. The assembly of claim 13, wherein: Each plate moves over 30 mm along orthogonal axes.

15. The assembly of claim 14, wherein: Each plate moves over 40 mm along orthogonal axes.

16. The assembly of claim 1, wherein: Each column includes a lifting lug which, in use, is attached to a crane to pull up the column to allow the formwork assembly to assume the compressed configuration.

17. The assembly of claim 1, wherein: Each post is formed from sheet metal to form and open a channel member.

18. The assembly of claim 1, wherein: The plate includes a wedge.

19. The assembly of claim 18, wherein The wedge is formed from sheet metal.

20. The assembly of claim 18, wherein: The locker is attached to the interior interface surface of the wedge.

21. The assembly of claim 18, wherein Wooden slats are attached to the orthogonal edges of the wedges.

22. The assembly of claim 21, wherein Wood plank workpieces are attached to the planks.

23. The assembly of claim 22, wherein: The wedge includes a cutout to allow access to the face of the plank for driving a wood screw into the wood workpiece.

24. The assembly of claim 23, wherein: Each corner post includes a window corresponding to the window of the wedge.

25. The assembly of claim 1, wherein The interface surface includes additional retention latches that interconnect with corresponding notches when the assembly is in the deployed configuration.

26. The assembly of claim 1, wherein: The slots are arranged such that when the assembly is in the compressed configuration, the distal tips are within 10 mm of each other.

27. A method of forming a vertical building shaft using the assembly of claim 1.

28. The method of claim 27, further comprising placing the assembly in position and erecting external forms therearound to define a rectangular mould therebetween and pouring concrete therein, allowing the concrete to set, and then lifting the corner posts by a crane so that the assembly assumes the compressed configuration, enabling the assembly to be lifted to the next higher location.

29. The method of claim 28, wherein: At the next higher position, the corner posts are lowered relative to the panels so that the assembly assumes the deployed configuration.

30. The method of claim 28, wherein The height of the assembly is greater than 4 meters and wherein the width of each of the orthogonal skin surfaces is less than 50 millimeters.

31. The method of claim 28, wherein The height of the assembly is greater than 4 meters and wherein the ratio of the vertical extent to the horizontal extent of the slot is greater than 5.

32. The method of claim 28, wherein: The assembly has a height greater than 4 meters, and wherein the ratio of the horizontal extent of each slot to the width of each orthogonal skin surface is greater than 1, so that each corner post moves along the diagonal axis to a greater extent than the extent of movement of each panel along the orthogonal axis between the expanded cross-sectional configuration and the compressed cross-sectional configuration, and wherein each panel moves more than 30 millimeters along the orthogonal axis.

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