A mold for shaping cast-in-place concrete paving, a paving, a method of using a mold and a method of making a mold

Abstract

The invention provides a mold (101) for shaping cast-in-place concrete paving (702) that comprises a void former (102) and a base plane (105). The void former comprises a void former wall (103) and a void former cover (104). The base plane comprises a void former through hole. The void former cover lies transverse to the void former wall and the void former wall lies transverse to the base plane. The void former wall connects the void former cover to the base plane, respectively along a void former cover edge (106) delimiting the void former cover and a void former through hole edge (107) delimiting the void former through hole. The void former protrudes from the base plane, forming a hollow peak determining a void former volume. The mold is made from a plastic composite material. The invention further provides a paving comprising a mold, a method of using a mold and a method of making a mold.

Description

Technical field

[0001] The present invention relates to a mold for shaping cast-in-place concrete paving, a cast-in-place concrete paving, a method of using a mold for shaping cast-in-place concrete paving, a method of making a mold for shaping cast-in-place concrete paving.Background art

[0002] Permeable paving is a type of pavement that allows water to penetrate through its surface and infiltrate the underlying soil. By allowing the water to infiltrate in the underlying soil, it contributes to environmental sustainability by preserving natural water systems and soil ecosystems. It further aids with flood and draught alleviation, by avoiding stormwater runoff.

[0003] One type of permeable paving is a combined concrete / grass paving. It combines a concrete mesh filled with soil in which grass or other ground covering plants can grow. It combines the load-bearing functionality of concrete pavement with the aesthetics of greenery. It can manage heavy traffic, while maintaining green space and reducing heat island effects in heavily paved environments, such as cities.

[0004] Patent FR2960568 describes a water-degradable formwork mold for producing alveolate concrete paving. It has a void former, comprising a void former wall with a void former wall height and a void former cover, and it has a base plane, comprising a void former through hole. The void former cover lies transverse to the void former wall at the void former wall height. The void former wall lies transverse to the base plane and connects the void former cover to the base plane, respectively along a void former cover edge delimiting the void former cover and a void former through hole edge delimiting the void former through hole. The void former protrudes from the base plane in a protruding direction, forming a hollow peak that is substantially closed at the void former wall and void former cover and substantially open at the base plane, the hollow peak determining a void former volume.

[0005] This formwork mold known from the state of the art is made from a biodegradable material that degrades when in contact with water. This has the disadvantage that this mold is not suitable for creating washed concrete or polished concrete paving, as these concrete treatment processes require the use of water or wet concrete. The mold known from the state of the art will not be able to retain its shape under these conditions. An additional drawback is that polishing the concrete is done with a heavy machine before the concrete will have set. This exacerbates the problem of the mold known from the state of the art not retaining its shape. This degradation might lead to a paving that collapses in places, destroying the cavities for grass or other ground covering plants. In addition, the edges of the cavities for grass or other ground covering plants are be less regular, and will withstand less the impact of traffic, leading to unnecessary damage and reducing the lifetime of the paving. Lastly, the paving might not be level or smooth due to the degradation of the mold during the concrete curing and treatment process, reducing the comfort of driving on it.Disclosure of the invention

[0006] It is an aim of the present invention to provide a solution for at least part of the abovementioned problem that exists in the state of the art. It aims to provide a mold that is suitable for creating a combined washed-or-polished-concrete / grass paving.

[0007] This aim is achieved according to the invention with a mold for shaping cast-in-place concrete paving according to claim 1.

[0008] In particular, the invention discloses a mold for shaping cast-in-place concrete paving that comprises a void former and a base plane. The void former comprises a void former wall with a void former wall height and a void former cover. The base plane comprises a void former through hole. The void former cover lies transverse to the void former wall at the void former wall height and the void former wall lies transverse to the base plane. The void former wall connects the void former cover to the base plane, respectively along a void former cover edge delimiting the void former cover and a void former through hole edge delimiting the void former through hole. The void former protrudes from the base plane in a protruding direction, forming a hollow peak that is substantially closed at the void former wall and void former cover and substantially open at the base plane, the hollow peak determining a void former volume. The mold is made from a plastic composite material.

[0009] This has the advantage that the application of water in the process of washing the concrete or the use of a concrete with a high water / concrete ratio and / or with additives or films to retain more water in the concrete to allow the polishing process, does less or even not degrade the former. The mold hence allows the creation of concrete paving with a particular appearance. An additional advantage is that the mold has a load-bearing capacity sufficient to support a human or a machine, for example a concrete-polishing machine, even when the mold is not filled with concrete. Its load-bearing capacity ensures that operators can freely walk over it during the construction of the paving, and that a concrete polishing machine can be applied before the concrete has set. Therefore the speed of the process of making the pavement is increased and additional treatment steps, such as polishing the concrete, are enabled. Additionally, the load-bearing capacity of the mold ensures that the molds can be placed in any orientation with a reduced risk of breaking under their own weight during transportation or storage, especially when stacked. This reduces the amount of unintended scrap.

[0010] In an embodiment of the invention, the plastic composite material is a thermoplastic composite material, preferably with a thermal expansion coefficient below 0.20 mm / m°C and more preferably below 0.17 mm / m°C. It has the advantage that it can be processed using methods such as extrusion, injection molding, thermoforming and blow molding, which ensure an accurate control of product quality when doing large production runs. Moreover a low thermal expansion coefficient ensures that the size variability of an injection molding process can be controlled better and that large structures with areas of thin thickness can be made up to strict quality standards.

[0011] In an embodiment of the invention, the plastic composite material comprises polypropylene. The polypropylene can serve as a matrix material. This has the advantage is that the mold is impact-resistant, while retaining properties that enable its manufacturing with an injection molding process. The impact-resistance ensures that handling during installation leads to less inadvertent damaging of part of the mold or of the whole mold, leading to less unintended scrap.

[0012] In a further embodiment of the invention, the plastic composite material comprises talcum powder. The talcum powder can serve as a structural component and as a reinforcement agent. Preferably the talcum powder occupies 0.5 wt% to 20.0 wt% of the composite material, more preferably 1 wt% to 10 wt%, and most preferably 7 wt%. This has the advantage that the impact-resistance and the stiffness of the mold is increased, while retaining properties that enable manufacturing with an injection molding process. An additional advantage is that it facilitates the injection molding process, by facilitating taking out the mold for shaping cast-in-place concrete paving from an injection molding mold suitable for making a mold for shaping cast-in-place concrete paving.

[0013] In an embodiment of the invention, the base plane thickness is the same or substantially the same as the void former wall thickness, and it is larger than the void former cover thickness. This has the advantage that the load-bearing capacity of the mold is increased, while facilitating the removal of the void former cover in the process of creating permeable combined concrete / grass paving.

[0014] In an embodiment of the invention, the void former cover comprises an area of weakness, for example a void former cover sheet adjacent to the void former cover edge wherein the void former cover sheet thickness is smaller than the void former cover thickness. This facilitates the removal of the void former cover in the process of creating permeable combined concrete / grass paving, while avoiding that holes appear in the void cover when operators walk over the mold in the process of creating permeable combined concrete / grass paving. Through these holes concrete might pour into the void former volume in the process of creating permeable combined concrete / grass paving, decreasing the quality of the resulting permeable paving.

[0015] In an embodiment of the invention, the void former cover further comprises multiple void former cover sheets, wherein the void former cover sheet thickness is smaller than the void former cover thickness. The void former cover sheets are adjacent to the void former cover edge, have a similar shape to each other and are spaced regularly along the full length of the void former cover edge. The ratio between the length of the void former cover edge that is adjacent to a void former cover sheet and the length of the void former cover edge that is not adjacent to a void former cover sheet is smaller than 2.5, preferably between 1.5 and 2.5, preferably 2.0. This has the advantage that an area of weakness is created in the void former cover, facilitating the removal of the void former cover, while improving the material flow during the injection molding process used to create the mold.

[0016] In an embodiment of the invention, the void former cover comprises a void former cover through hole configured for allowing the passage of air while preventing the passage of concrete aggregate, called a suction hole. This has the advantage that, when two molds that were nested and / or stacked during transport or storage have to be separated, they will stick less to each other due to the appearance of a (partial) vacuum between their respective stacked or nested void formers, while preventing concrete from seeping into the void former volume in the process of creating permeable combined concrete / grass paving. This effect is increased when the suction hole is combined with a mold spacer described below. As a result, the quality of the resulting permeable paving can be ensured, while avoiding installation difficulties due to sticky stacked molds.

[0017] In an embodiment of the invention, the mold comprises a mold spacer for maintaining a distance between two molds when they are stacked. By preference, the mold spacer comprises a protrusion, by preference a planar protrusion, for example on the concrete-facing side of the mold. Preferably, it protrudes between the base plane and the void former wall, the mold spacer being transverse to the base plane and transverse to the void former wall. This ensures that when two molds are nested and / or stacked during transport or storage, a gap filled with air remains between the two molds. When they have to be separated, they will stick less or even not stick to each other due to the appearance of a (partial) vacuum between them. This avoids installation difficulties due to sticky stacked molds. This effect is increased when combined with a suction hole described above. Preferably, the mold spacer has sufficient strength, for example from its thickness, to hold the weight of multiple stacked molds. This has the advantage that when multiple molds are stacked, the less-sticky effect is maintained between all pairs of stacked molds.

[0018] In an embodiment of the invention, the mold comprises a reinforcing bar support structure for supporting a concrete-reinforcing bar or concrete-reinforcing mesh. Preferably, the reinforcing bar support structure has a height that will position the concrete-reinforcing bar or concrete-reinforcing mesh at a location in the concrete where the tensile forces are greatest when loading the paving, for example with heavy traffic. This will increase the tensile strength of the paving and extend the paving's lifetime.

[0019] In an embodiment of the invention, the shape of the reinforcing bar support structure is such that the reinforcing bar support structure serves as a reinforcing bar support structure while also serving as a mold spacer described above. This has the advantage that the mold contains less protrusions, which increases the ease of installation, and increases the quality of the molds created by an injection molding process.

[0020] In an embodiment of the invention, the mold comprises a first void former and a second void former, wherein their respective void former walls substantially have the same void former wall height, and the first void former and the second void former protrude from the base plane in a single protruding direction. The mold also comprises a reinforcing bar support structure, that protrudes in the protruding direction. The reinforcing bar support structure has a reinforcement bar centering means for ensuring that a concrete-reinforcing bar on its own or as part of a concrete-reinforcing mesh is positioned in between the first void former and the second void former at substantially equal, preferably equal, distances from the first void former and the second void former. This had the advantage that the concrete-reinforcing bar or concrete-reinforcing mesh is placed such that the strength of the concrete paving is increased.

[0021] In an embodiment of the invention, the mold comprises a rectangular array of void formers, wherein the respective void former walls have substantially the same, preferably the same, respective void former wall height and all void formers protrude from the base plane in the protruding direction. This is an array that consists of rows and columns of void formers, preferably with at least 3 rows and at least 3 columns. The rectangular array comprises outer void formers, void formers on the edge of the array, not having row-wise and / or column-wise neighboring void formers on all sides, and optionally inner void formers, that have row-wise and column-wise neighbors on all sides. The mold further comprises multiple reinforcing bar support structures, wherein each reinforcing bar support structure protrudes from the base plane in the protruding direction and connects a pair of void formers that are arranged adjacently in the rectangular array of void formers, either column-wise or row-wise, the connections made by the reinforcing bar support structures respectively called a column-wise connection and a row-wise connection. Each void former is connected to at most two reinforcing bar support structures, each inner void former is connected to exactly two reinforcing bar support structures, and if a void former is connected to two reinforcing bar support structures, one reinforcing bar support structure makes a column-wise connection and the other reinforcing bar support structure makes a row-wise connection. This has the advantage that the reinforcing bar support structures and the void formers protruding from the base plane do not jointly enclose an area on the base plane. If the base plane is placed on the ground, with the protrusions protruding upwards, and it rains before the concrete is poured, the water can run of the mold and infiltrate in the ground between the molds. Therefore, the composition of the concrete is not inadvertently changed, and hence the quality of the poured concrete can be controlled.

[0022] In a further embodiment of the invention, the mold comprising a rectangular array of void formers, connected by reinforcing bar support structures as explained above, further comprises at least two through holes in the base plane for each reinforcing bar support structure, called drainage holes. The drainage holes lie on either side of the reinforcing bar support structure wall. This has the advantage that water that might run-off against a reinforcing bar support structure will have the opportunity to infiltrate in the ground through a drainage hole.

[0023] The invention also discloses a cast-in-place paving comprising a mold for shaping cast-in-place concrete paving and concrete, for example a concrete with a high water / concrete ratio, for example a C30 / 37 grade concrete of environmental class EE3, with concrete slump class S4 or S5.

[0024] In an embodiment of the invention, the paving comprises a cast-in-place permeable paving, that comprises a mold for shaping cast-in-place concrete permeable paving in which the void former covers have been removed and in which the void former volumes have been filled with earth, suitable for planting and growing grass or other ground covering plants.

[0025] In an embodiment of the invention, the paving is washed or polished.

[0026] The invention also discloses a method of using a mold for shaping cast-in-place concrete paving.

[0027] In an embodiment, the method of using a mold for shaping cast-in-place concrete paving comprises the steps of mold placing and concrete pouring. The step of mold placing comprising placing a mold, that comprises a subgrade-facing side, in particular the side from which the void formers do not protrude, subgrade-facing side down on a ground. The ground is preferably prepared for receiving paving, for example by leveling the subgrade, by applying a foundation and / or by applying, compacting and leveling a subbase or other road layers, prior to the step of mold placing. The step of concrete pouring comprises pouring unset concrete onto the mold that is placed on the ground. The concrete is for example a concrete with a high water / concrete ratio, for example a C30 / 37 grade concrete of environmental class EE3, with concrete slump class S4 or S5. Preferably, the concrete is poured with a height substantially equal or equal to the void former wall height. Preferably, expansion joints are foreseen when large areas of paving are cast. This step preferably follows the step of mold placing. Optionally, the embodiment comprises a step of mold anchoring, wherein the mold is anchored to the ground, the subbase or the subgrade, using a ground anchor, for example a picket. The ground anchor can be applied through a drainage hole in the base plane, if present. The step of mold anchoring preferably follows the step of mold placing and preferably precedes the step of concrete pouring. Optionally, the embodiment comprises a step of concrete-reinforcement application. The step of concrete-reinforcement application preferably comprises applying a concrete-reinforcing bar or a concrete-reinforcing mesh between the void formers, preferably at equal distances or substantially equal distances from the void formers and supported by the reinforcing bar support structure if present on the mold. The step of concrete-reinforcement application preferably follows the step of mold placing and / or the step of mold anchoring and preferably precedes the step of concrete pouring. Optionally, the embodiment comprises a step of concrete leveling, in which the concrete is leveled, preferably at a height substantially equal or equal to the void former wall height. Preferably, the step of concrete leveling is executed after the step of concrete pouring. Optionally, the embodiment comprises a step of void opening. The step of void opening comprises removing the void former cover or void former covers from the mold, for example by burning them or by mechanically ripping them from the void former walls. The step of void opening preferably follows the step of concrete pouring and / or the step of concrete leveling, and is applied after the concrete is set. Optionally, the embodiment comprises a step of void filling, wherein earth or another substrate, suitable for planting and growing grass or other ground covering plants, is inserted into the void former volume or void former volumes. The step of void filling preferably follows the step of concrete pouring, concrete leveling and / or void opening.

[0028] In a further embodiment of the invention, the method of using a mold for shaping cast-in-place concrete paving further comprises the step of concrete posttreatment. The step of concrete posttreatment comprises washing or polishing the concrete. Polishing the concrete comprises applying a concrete polishing machine during the concrete curing process and washing the concrete comprises removing the top layer of concrete during the concrete curing process. The step of concrete posttreatment preferably follows the step of concrete pouring and / or concrete leveling and preferably precedes the step of void opening and / or void filling.

[0029] The invention also discloses a method of making a mold for shaping cast-in-place concrete paving.

[0030] In an embodiment of the invention, a mold for shaping cast-in-place concrete paving is manufactured using an injection molding technique. Preferably, especially when a mold for shaping cast-in-place concrete paving with multiple void formers is made, the injection molding technique employs multiple hot runners that inject a plastic composite material into an injection molding mold suitable for making a mold for shaping cast-in-place concrete paving, the hot runners injecting material from the void former cover of each void former towards the base plane.Brief description of the drawings

[0031] The invention will be further elucidated by means of the following description and the appended figures. Figure 1 shows an isometric view of a mold for shaping cast-in-place concrete paving according to a first embodiment of the invention. Figure 2 shows both sides of a void former of the mold according to the first embodiment of the invention. Figure 3 shows multiple views of a reinforcing bar support structure of the mold according to a first embodiment of the invention. Figure 4 shows a top view of the mold according to the first embodiment of the invention. Figure 5 shows a side view of the mold according to the first embodiment of the invention on which a concrete-reinforcing mesh has been placed. Figure 6 shows an isometric view of a void former of the mold according to the first embodiment of the invention. Figure 7 shows an isometric view of a cast-in-place permeable combined concrete / grass paving according to a second embodiment of the invention. Figure 8 shows a flow chart of a method of using a mold for shaping cast-in-place permeable paving according to a third and a fourth embodiment of the invention. Modes for carrying out the invention

[0032] The present invention will be described with respect to particular embodiments and with reference to certain drawings but the invention is not limited thereto but only by the claims. The drawings described are only schematic and are non-limiting. In the drawings, the size of some of the elements may be exaggerated and not drawn on scale for illustrative purposes. The dimensions and the relative dimensions do not necessarily correspond to actual reductions to practice of the invention.

[0033] Furthermore, the terms first, second, third and the like in the description and in the claims, are used for distinguishing between similar elements and not necessarily for describing a sequential or chronological order. The terms are interchangeable under appropriate circumstances and the embodiments of the invention can operate in other sequences than described or illustrated herein.

[0034] Moreover, the terms top, bottom, over, under and the like in the description and the claims are used for descriptive purposes and not necessarily for describing relative positions. The terms so used are interchangeable under appropriate circumstances and the embodiments of the invention described herein can operate in other orientations than described or illustrated herein.

[0035] The term "comprising", used in the claims, should not be interpreted as being restricted to the means listed thereafter; it does not exclude other elements or steps. It needs to be interpreted as specifying the presence of the stated features, integers, steps or components as referred to, but does not preclude the presence or addition of one or more other features, integers, steps or components, or groups thereof. Thus, the scope of the expression "a device comprising means A and B" should not be limited to devices consisting only of components A and B. It means that with respect to the present invention, the only relevant components of the device are A and B.

[0036] Figures 1 to 6 show a mold 101 for shaping cast-in-place concrete paving 702 according to a first embodiment of the invention, or details thereof. For clarity, we will first describe the first embodiment of the invention and then shortly discuss what elements you see in which figure.

[0037] The first embodiment of the invention is a mold 101 for shaping cast-in-place concrete paving 702. The mold 101 comprises a base plane 105 and a rectangular array of void formers 112 with at least 3 rows and at least 3 columns, in particular 4 rows and 8 columns. The base plane 105 comprise a void former through hole for every void former 102 and every void former 102 comprises a void former wall 103 with a void former wall height h, and a void former cover 104. The respective void former walls 103 have substantially the same, preferably the same, void former wall height h. The void former wall height h is between 13 cm and 17 cm, preferably 15 cm, in particular 15 cm.

[0038] For each void former 102, the void former cover 104 lies transverse to the respective void former wall 103 at the void former wall height h, the void former wall 103 lies transverse to the base plane 105, the void former wall 103 connects the respective void former cover 104 to the base plane 105. The void former cover 104 is connected along a void former cover edge 106 delimiting the void former cover 104 and the base plane 105 is connected along a void former through hole edge 107 delimiting the void former through hole. The void formers protrude from the base plane 105 in a protruding direction p, forming hollow peaks that are substantially closed at the respective void former walls 103 and void former covers, and that are substantially open at the base plane 105. The hollow peaks determine void former volumes 201.

[0039] The void former cover 104 and the void former through hole are both circular. The void former cover 104 has a smaller diameter than the void former through hole. The void former 102 is shaped as a truncated cone. The void former cover 104 has a diameter between 8 cm and 11 cm, preferably 9.5 cm, in particular 9.5 cm and the void former through hole has a diameter between 10 cm and 14 cm, preferably 12 cm, in particular 12 cm. In alternative embodiments, the void former 102 is cylindrical. In alternative embodiments, the void former 102 is a prismoid. In alternative embodiments, the void former 102 is tapered in the protruding direction p. In alternative embodiments, the shape of the void former cover 104 and the void former through hole is that of a star, a cross, a triangle, a quadrangle, a hexagon, .... In alternative embodiments the shape of the void former cover 104 and the void former through hole are different from each other.

[0040] The mold 101 further comprises two opposing sides, in particular a concrete-facing side 202, being the side towards which the void former 102 protrudes from the base plane 105, and a subgrade-facing side 203. The concrete-facing side 202 and the subgrade-facing side 203 have a substantially complimentary shape so that two molds can be nested.

[0041] The base plane 105 thickness is the same or substantially the same as the void former wall 103 thickness and is larger than the void former cover 104 thickness. The void former cover 104 further comprises multiple void former cover sheets 601, wherein the void former cover sheet 601 thickness is smaller than the void former cover 104 thickness. In particular, the base plane 105 thickness is between 1 mm and 2 mm, preferably 1.5 mm, in particular 1.5 mm, the void former wall 103 thickness is between 1 mm and 2 mm, preferably 1.5 mm, in particular 1.5 mm, the void former cover 104 thickness is between 0.3 mm and 0.7 mm, preferably 0.5 mm, in particular 0.5 mm, and the void former cover sheet 601 thickness is between 0.1 mm and 0.5 mm, preferably 0.3 mm, in particular 0.3 mm. In alternative embodiments, the base plane 105 thickness is different from the void former wall 103 thickness. In alternative embodiments, the void former cover 104 thickness is the same as the void former wall 103 thickness.

[0042] The void former cover sheets 601 are adjacent to the void former cover edge 106, have a similar shape to each other and are spaced regularly along the full length of the void former cover edge 106. The ratio between the length of the void former cover edge 106 that is adjacent to a void former cover sheet 601 and the length of the void former cover edge 106 that is not adjacent to a void former cover sheet 601 is between 1.5 and 2.5, in particular 2.0. In alternative embodiments, the void former cover 104 comprises a single void former cover sheet 601 or any other area of weakness. In alternative embodiments, the void former cover sheet lies along substantially the full length of the void former cover edge 106.

[0043] Each void former cover 104 further comprises a void former cover 104 through hole configured for allowing the passage of air while preventing the passage of concrete aggregate. These are called suction holes 108 and have a diameter between 0.6 and 0.1 cm, preferably about 0.5 cm, in particular 0.5 cm.

[0044] The mold 101 further comprises mold spacers 110 for maintaining a distance between two molds when they are stacked. A mold spacer 110 comprises a planar protrusion from the concrete-facing side 202 of the mold 101, protruding between the base plane 105 and the void former wall 103, the mold spacer 110 being transverse to the base plane 105 and transverse to the void former wall 103. The mold spacer 110 thickness is between 1 mm and 5 mm, preferably about 3 mm, in particular 3 mm. In alternative embodiments, the mold spacer 110 protrudes from the subgrade-facing side 203 of the mold 101. In alternative embodiments, the mold spacer 110 protrudes from the void former 102. In alternative embodiments, another means is foreseen for maintaining a distance between two molds when they are stacked.

[0045] The mold 101 comprises multiple reinforcing bar support structures 111, for supporting a concrete-reinforcing bar or concrete-reinforcing mesh 401. The reinforcing bar support structures 111 protrude from the base plane 105 in the protruding direction p.

[0046] A reinforcing bar support structure 111 comprises a first reinforcing bar support structure wall 301, a second reinforcing bar support structure wall 302 and a reinforcing bar support structure plane 303. The first reinforcing bar support structure wall 301 and the second reinforcing bar support structure wall 302 lie transversal to the base plane 105. The reinforcing bar support structure plane 303 lies transversal to the first reinforcing bar support structure wall 301 and the second reinforcing bar support structure wall 302. The reinforcing bar support structure plane 303 lies substantially along the direction of the base plane 105.

[0047] The reinforcing bar support structure plane 303 extends in a reinforcing bar support structure plane 303 lateral direction b between a first reinforcing bar support structure plane end 306 and a second reinforcing bar support structure plane end 307, and in a reinforcing bar support structure plane longitudinal direction I between a third reinforcing bar support structure plane end 308 and a fourth reinforcing bar support structure plane end 309. The first reinforcing bar support structure wall 301 connects the base plane 105 to the reinforcing bar support structure plane 303 at the first reinforcing bar support structure plane end 306, the second reinforcing bar support structure wall 302 connects the base plane 105 to the reinforcing bar support structure plane 303 at the second reinforcing bar support structure plane end 307.

[0048] A reinforcing bar support structure 111 pairwise connects void formers that are arranged adjacently in the rectangular array of void formers 112, either column-wise or row-wise, the connections made by the reinforcing bar support structures 111 respectively called column-wise connections and row-wise connections. In particular, it connects a first void former 304 to a second void former 305. The reinforcing bar support structure plane 303, the first reinforcing bar support structure wall 301 and the second reinforcing bar support structure wall 302 connect to the void former wall 103 of the first void former 304 near the third reinforcing bar support structure plane end 308 and connect to the void former wall 103 of the second void former 305 near the fourth reinforcing bar support structure end 309. The base plane 105, the first void former 304, the second void former 305 and the reinforcing bar support structure 111 are connected with substantially uninterrupted, in particular uninterrupted seams.

[0049] The reinforcing bar support structure 111 forms a hollow peak that is substantially closed, in particular closed at the reinforcing bar support structure plane 303, at the first reinforcing bar support structure wall 301 and at the second reinforcing bar support structure wall 302 and substantially open at the base plane 105, at the void former wall 103 of the first void former 304, and at the void former wall 103 of the second void former 305. In alternative embodiments, the seams are dashed, such that the holes are configured for allowing the passage of air while preventing the passage of concrete aggregate. In alternative embodiments, the reinforcing bar support structure 111 protrudes from the base plane 105 without connecting void formers. In alternative embodiments, the reinforcing bar support structures 111 do not form a hollow peak. In alternative embodiments the shape of the reinforcing bar support structure 111 is such that the reinforcing bar support structure 111 serves as a reinforcing bar support structure 111 while also serving as a mold spacer 110 described above, by only forming a partially hollow peak, or by having a mold spacer 110 connected to the inside of the hollow peak.

[0050] The reinforcing bar support structure plane 303 is arched along the longitudinal direction l, so that the midpoint of the reinforcing bar support structure plane 310 along the longitudinal direction l is closer to the base plane 105 than the first reinforcing bar support structure plane end 306 and the second reinforcing bar support structure plane end 307. The distance between the midpoint of the reinforcing bar support structure plane 310 along the longitudinal direction I and the base plane 105 is between 2 cm and 6 cm, preferably 4 cm, in particular 4 cm. In alternative embodiments, the reinforcing bar support structure 111 has a reinforcement bar centering means for ensuring that a concrete-reinforcing bar on its own or as part of a concrete-reinforcing mesh 401 is positioned in between the first void former 304 and the second void former 305 at substantially equal, preferably equal, distances from the first void former 304 and the second void former 305, such as a central clamping shape.

[0051] The mold 101 comprises outer void formers 402 and inner void formers 403. Outer void formers 402 are void formers on the edge of the array. They do not have row-wise and / or column-wise neighboring void formers on all sides. Inner void formers 403 have row-wise and column-wise neighbors on all sides. Each void former 102 is connected to at most two reinforcing bar support structures 111 and each inner void former 403 is connected to exactly two reinforcing bar support structures 111. If a void former 102 is connected to two reinforcing bar support structures 111, one reinforcing bar support structure 111 makes a column-wise connection and the other one makes a row-wise connection.

[0052] The mold 101 comprises at least two drainage holes 109, in particular two drainage holes 109, for each reinforcing bar support structure 111. A drainage hole 109 is a base plane through hole configured for the passage of water, having a diameter between 1 cm and 3 cm, preferably 2 cm, in particular 2 cm. The drainage holes 109 are lying on either side of the reinforcing bar support structure according to the reinforcing bar support structure plane 303 lateral direction b.

[0053] Some drainage holes 109, in particular all drainage holes 109, are configured for anchoring the mold 101 to the ground 703 using a ground anchor, for example a picket, when the mold 101 is placed subgrade-facing side 203 down on the ground 703 with the void formers protruding upwards. In alternative embodiments, the mold 101 is configured for anchoring to the ground 703 at the outer edges delimiting the base plane 105.

[0054] The mold 101 is made from a plastic composite material, by preference a thermoplastic composite material, by preference having a thermal expansion coefficient below 0.20 mm / m°C, by further preference below 0.17 mm / m°C. The mold 101 is made by preference from a plastic composite material comprising polypropylene, polypropylene preferably serving as a matrix material. The plastic composite material by preference further comprises talcum powder, talcum powder preferably serving as a structural component reinforcing the composite material. Preferably the talcum powder occupies 0.5 wt% to 20.0 wt% of the composite material, more preferably 1 wt% to 10 wt%, and most preferably 7 wt%. In particular, the plastic composite material is a thermoplastic composite material comprising recycled polypropylene and 7 wt% talcum powder. In alternative embodiments, the plastic composite material comprises non-recycled polypropylene, high-density polyethylene, low-density polyethylene or any other suitable matrix material for plastic composite materials known in the state of the art.

[0055] Figure 1 shows an isometric view of the mold 101 for shaping cast-in-place concrete paving 702 according to the first embodiment of the invention. It shows a rectangular array of void formers 112 protruding from a base plane 105 in a protruding direction p, each having a void former wall 103 that connects the base plane 105 and a void former cover 104, respectively at a void former through hole edge 107 and a void former cover edge 106. It also shows a void former cover 104 with a suction hole 108, it shows a drainage hole 109 in the base plane 105, a mold spacer 110 and a reinforcing bar support structure 111.

[0056] Figure 2 shows both sides of a void former 102 of the mold 101 according to the first embodiment of the invention. It shows a concrete-facing side 202 in Figure 2a and a void former volume 201 and a subgrade-facing side 203 in Figure 2b.

[0057] Figure 3 shows multiple views of a reinforcing bar support structure 111 of the mold 101 according to a first embodiment of the invention. Figure 3a shows a first reinforcing bar support structure wall 301, a second reinforcing bar support structure wall 302, a reinforcing bar support structure plane 303 between a first void former 304 and a second void former 305. Figure 3b shows a top view with a reinforcing bar support structure plane 303 lateral direction b, a first reinforcing bar support structure plane end 306, a second reinforcing bar support structure plane end 307, a reinforcing bar support structure plane 303 longitudinal direction l, a third reinforcing bar support structure plane end 308 and a fourth reinforcing bar support structure plane end 309. Figure 3c shows the midpoint of the reinforcing bar support structure plane 310 along its longitudinal direction l.

[0058] Figure 4 shows a top view of the mold 101 according to the first embodiment of the invention. Figure 4a shows outer void formers 402 and inner void formers 403 of the rectangular array of void formers 112, the reinforcing bar support structures 111 with row-wise and column-wise connections between void formers, and drainage holes 109 on either sides of the reinforcing bar support structures 111. Figure 4b shows a concrete-reinforcing mesh 401 that is placed on the mold 101.

[0059] Figure 5 shows a side view of the mold 101 according to the first embodiment of the invention on which a concrete-reinforcing mesh 401 has been placed. It shows a void former wall height h and an arched reinforcing bar support structure plane 303 on which a concrete-reinforcing mesh 401 is placed.

[0060] Figure 6 shows an isometric view of a void former 102 of the mold 101 according to the first embodiment of the invention. It shows a void former cover sheet 601 and indicates by dots the thickness of the different elements of the mold 101.

[0061] Figure 7 shows a cast-in-place permeable combined concrete / grass paving according to a second embodiment of the invention. The cast-in-place concrete paving 702 according to the second embodiment of the invention comprises a mold 101 for shaping cast-in-place concrete paving 702 according to the invention, concrete, and a concrete-reinforcing mesh 401. The mold 101 is lying subgrade-facing side 203 down on the ground 703 and the concrete is lying on the concrete-facing side 202 of the mold 101, with a height substantially equal to, in particular equal to, the void former wall height h. The concrete is for example a concrete with a high water / concrete ratio, for example a C30 / 37 grade concrete of environmental class EE3, with concrete slump class S4 or S5. The void former 102 covers have been removed and the void former volumes 201 have been filled with earth 704.

[0062] In alternative embodiments, multiple concrete-reinforcing bars are used instead of a concrete-reinforcing mesh 401. In alternative embodiments, the height of the concrete paving 702 is greater than the void former wall height h. In alternative embodiments, the void former covers 104 are not removed. In alternative embodiments, the concrete paving 702 is washed or polished. In alternative embodiments, the void former volumes 201 are filled with another substrate suitable for planting and growing grass or other ground covering plants. In alternative embodiments, the void former 102 volumes are filled with loose aggregate, such as pebbles or sand.

[0063] Figure 7a shows an isometric view of the paving, showing a mold 101, concrete, for example concrete paving 702, a ground 703 and an earth-filled void former volume 201. Figure 7b shows a detail of a side view of the paving, showing in addition to Figure 7a a concrete-reinforcing mesh 401 and a void former wall height h.

[0064] Figure 8 shows a flow chart of a method of using a mold 101 for shaping cast-in-place permeable paving 701 according to a third and a fourth embodiment of the invention.

[0065] Figure 8a shows the third embodiment of the invention, that comprises a method of using a mold 101 for shaping cast-in-place concrete paving 702, comprising the following steps. A mold placing 802 step, wherein a mold 101 is placed subgrade-facing side 203 down on the ground 703. A mold anchoring 803 step, wherein the mold 101 is anchored to the ground 703, the subbase or the subgrade, using a ground anchor, for example a picket. The ground anchor is by preference applied through a drainage hole 109 in the base plane 105. A concrete-reinforcement application 804 step, wherein a concrete-reinforcing mesh 401 is placed between void formers, preferably at substantially equal distances, in particular equal distances, from the void formers and supported by the reinforcing bar support structure 111. A concrete pouring 805 step wherein unset concrete is poured onto the mold 101 that is placed on the ground 703. The concrete is for example a concrete with a high water / concrete ratio, for example a C30 / 37 grade concrete of environmental class EE3, with concrete slump class S4 or S5. The concrete is poured with a height substantially equal or equal to the void former wall height h. A concrete leveling 806 step, wherein the concrete is leveled at a height substantially equal, in particular equal, to the void former wall height h. This step is executed before the concrete is set. A concrete posttreatment 807 step, wherein the concrete is polished by applying a concrete polishing machine during the concrete curing process. This step is executed before the concrete is set. A void opening 808 step, wherein a void former cover 104 is removed from the mold 101 by burning it off with a blowtorch. This step is executed after the concrete is set. A void filling 809 step, wherein earth 704 is inserted into a void former volume 201.

[0066] In alternative embodiments, the steps are executed in another order. In alternative embodiments, the mold placing 802 and concrete pouring 805 steps are executed. Some or all of the other, optional steps, are not executed. In alternative embodiments, the step of void opening 808 is executed with another known technique from the state of the art to remove a void former cover 104, such as removing it mechanically by ripping it out of the void former 102 or by using high pressure water. In alternative embodiments the concrete is poured to a height that is larger than the void former wall height h. In alternative embodiments, other posttreatment processes applied during or after the curing process to change the appearance of the paving or to ensure its longevity known from the state of the art are applied, such as stamping the concrete with a particular pattern or applying a color. In alternative embodiments, the step of void filling 809 inserts another material into a void former volume 201, such as another substrate suitable for planting and growing grass or other ground covering plants, aggregates, for example pebbles or sand.

[0067] Figure 8b shows the fourth embodiment of the invention, that comprises a method of using a mold 101 for shaping cast-in-place concrete paving 702, comprising the following steps: a mold placing 802 step, a concrete pouring 805 step, a concrete leveling 806 step, and a void opening 808 step.

[0068] In a fifth embodiment of the invention, a mold 101 for shaping cast-in-place concrete paving 702 is manufactured using an injection molding technique. Preferably, especially when a mold 101 for shaping cast-in-place concrete paving 702 with multiple void formers is made, the injection molding technique employs multiple hot runners that inject a plastic composite material into an injection molding mold suitable for making a mold 101 for shaping cast-in-place concrete paving 702, the hot runners injecting material from the void former cover 104 of each void former 102 towards the base plane 105.

[0069] In alternative embodiments, other measures known from the state of the art for injection molding are employed for manufacturing the mold 101 for shaping cast-in-place concrete paving 702. In alternative embodiments, the runners inject material form the base plane 105 towards the void former 102 covers.

Examples

first embodiment

[0037]the invention is a mold 101 for shaping cast-in-place concrete paving 702. The mold 101 comprises a base plane 105 and a rectangular array of void formers 112 with at least 3 rows and at least 3 columns, in particular 4 rows and 8 columns. The base plane 105 comprise a void former through hole for every void former 102 and every void former 102 comprises a void former wall 103 with a void former wall height h, and a void former cover 104. The respective void former walls 103 have substantially the same, preferably the same, void former wall height h. The void former wall height h is between 13 cm and 17 cm, preferably 15 cm, in particular 15 cm.

[0038]For each void former 102, the void former cover 104 lies transverse to the respective void former wall 103 at the void former wall height h, the void former wall 103 lies transverse to the base plane 105, the void former wall 103 connects the respective void former cover 104 to the base plane 105. The void former cover 104 is conn...

fourth embodiment

[0064]Figure 8 shows a flow chart of a method of using a mold 101 for shaping cast-in-place permeable paving 701 according to a third and the invention.

third embodiment

[0065]Figure 8a shows the invention, that comprises a method of using a mold 101 for shaping cast-in-place concrete paving 702, comprising the following steps. A mold placing 802 step, wherein a mold 101 is placed subgrade-facing side 203 down on the ground 703. A mold anchoring 803 step, wherein the mold 101 is anchored to the ground 703, the subbase or the subgrade, using a ground anchor, for example a picket. The ground anchor is by preference applied through a drainage hole 109 in the base plane 105. A concrete-reinforcement application 804 step, wherein a concrete-reinforcing mesh 401 is placed between void formers, preferably at substantially equal distances, in particular equal distances, from the void formers and supported by the reinforcing bar support structure 111. A concrete pouring 805 step wherein unset concrete is poured onto the mold 101 that is placed on the ground 703. The concrete is for example a concrete with a high water / concrete ratio, for example a C30 / 37 gra...

Technical field

[0001] The present invention relates to a mold for shaping cast-in-place concrete paving, a cast-in-place concrete paving, a method of using a mold for shaping cast-in-place concrete paving, a method of making a mold for shaping cast-in-place concrete paving.Background art

[0002] Permeable paving is a type of pavement that allows water to penetrate through its surface and infiltrate the underlying soil. By allowing the water to infiltrate in the underlying soil, it contributes to environmental sustainability by preserving natural water systems and soil ecosystems. It further aids with flood and draught alleviation, by avoiding stormwater runoff.

[0003] One type of permeable paving is a combined concrete / grass paving. It combines a concrete mesh filled with soil in which grass or other ground covering plants can grow. It combines the load-bearing functionality of concrete pavement with the aesthetics of greenery. It can manage heavy traffic, while maintaining green space and reducing heat island effects in heavily paved environments, such as cities.

[0004] Patent FR2960568 describes a water-degradable formwork mold for producing alveolate concrete paving. It has a void former, comprising a void former wall with a void former wall height and a void former cover, and it has a base plane, comprising a void former through hole. The void former cover lies transverse to the void former wall at the void former wall height. The void former wall lies transverse to the base plane and connects the void former cover to the base plane, respectively along a void former cover edge delimiting the void former cover and a void former through hole edge delimiting the void former through hole. The void former protrudes from the base plane in a protruding direction, forming a hollow peak that is substantially closed at the void former wall and void former cover and substantially open at the base plane, the hollow peak determining a void former volume.

[0005] This formwork mold known from the state of the art is made from a biodegradable material that degrades when in contact with water. This has the disadvantage that this mold is not suitable for creating washed concrete or polished concrete paving, as these concrete treatment processes require the use of water or wet concrete. The mold known from the state of the art will not be able to retain its shape under these conditions. An additional drawback is that polishing the concrete is done with a heavy machine before the concrete will have set. This exacerbates the problem of the mold known from the state of the art not retaining its shape. This degradation might lead to a paving that collapses in places, destroying the cavities for grass or other ground covering plants. In addition, the edges of the cavities for grass or other ground covering plants are be less regular, and will withstand less the impact of traffic, leading to unnecessary damage and reducing the lifetime of the paving. Lastly, the paving might not be level or smooth due to the degradation of the mold during the concrete curing and treatment process, reducing the comfort of driving on it.Disclosure of the invention

[0006] It is an aim of the present invention to provide a solution for at least part of the abovementioned problem that exists in the state of the art. It aims to provide a mold that is suitable for creating a combined washed-or-polished-concrete / grass paving.

[0007] This aim is achieved according to the invention with a mold for shaping cast-in-place concrete paving according to claim 1.

[0008] In particular, the invention discloses a mold for shaping cast-in-place concrete paving that comprises a void former and a base plane. The void former comprises a void former wall with a void former wall height and a void former cover. The base plane comprises a void former through hole. The void former cover lies transverse to the void former wall at the void former wall height and the void former wall lies transverse to the base plane. The void former wall connects the void former cover to the base plane, respectively along a void former cover edge delimiting the void former cover and a void former through hole edge delimiting the void former through hole. The void former protrudes from the base plane in a protruding direction, forming a hollow peak that is substantially closed at the void former wall and void former cover and substantially open at the base plane, the hollow peak determining a void former volume. The mold is made from a plastic composite material.

[0009] This has the advantage that the application of water in the process of washing the concrete or the use of a concrete with a high water / concrete ratio and / or with additives or films to retain more water in the concrete to allow the polishing process, does less or even not degrade the former. The mold hence allows the creation of concrete paving with a particular appearance. An additional advantage is that the mold has a load-bearing capacity sufficient to support a human or a machine, for example a concrete-polishing machine, even when the mold is not filled with concrete. Its load-bearing capacity ensures that operators can freely walk over it during the construction of the paving, and that a concrete polishing machine can be applied before the concrete has set. Therefore the speed of the process of making the pavement is increased and additional treatment steps, such as polishing the concrete, are enabled. Additionally, the load-bearing capacity of the mold ensures that the molds can be placed in any orientation with a reduced risk of breaking under their own weight during transportation or storage, especially when stacked. This reduces the amount of unintended scrap.

[0010] In an embodiment of the invention, the plastic composite material is a thermoplastic composite material, preferably with a thermal expansion coefficient below 0.20 mm / m°C and more preferably below 0.17 mm / m°C. It has the advantage that it can be processed using methods such as extrusion, injection molding, thermoforming and blow molding, which ensure an accurate control of product quality when doing large production runs. Moreover a low thermal expansion coefficient ensures that the size variability of an injection molding process can be controlled better and that large structures with areas of thin thickness can be made up to strict quality standards.

[0011] In an embodiment of the invention, the plastic composite material comprises polypropylene. The polypropylene can serve as a matrix material. This has the advantage is that the mold is impact-resistant, while retaining properties that enable its manufacturing with an injection molding process. The impact-resistance ensures that handling during installation leads to less inadvertent damaging of part of the mold or of the whole mold, leading to less unintended scrap.

[0012] In a further embodiment of the invention, the plastic composite material comprises talcum powder. The talcum powder can serve as a structural component and as a reinforcement agent. Preferably the talcum powder occupies 0.5 wt% to 20.0 wt% of the composite material, more preferably 1 wt% to 10 wt%, and most preferably 7 wt%. This has the advantage that the impact-resistance and the stiffness of the mold is increased, while retaining properties that enable manufacturing with an injection molding process. An additional advantage is that it facilitates the injection molding process, by facilitating taking out the mold for shaping cast-in-place concrete paving from an injection molding mold suitable for making a mold for shaping cast-in-place concrete paving.

[0013] In an embodiment of the invention, the base plane thickness is the same or substantially the same as the void former wall thickness, and it is larger than the void former cover thickness. This has the advantage that the load-bearing capacity of the mold is increased, while facilitating the removal of the void former cover in the process of creating permeable combined concrete / grass paving.

[0014] In an embodiment of the invention, the void former cover comprises an area of weakness, for example a void former cover sheet adjacent to the void former cover edge wherein the void former cover sheet thickness is smaller than the void former cover thickness. This facilitates the removal of the void former cover in the process of creating permeable combined concrete / grass paving, while avoiding that holes appear in the void cover when operators walk over the mold in the process of creating permeable combined concrete / grass paving. Through these holes concrete might pour into the void former volume in the process of creating permeable combined concrete / grass paving, decreasing the quality of the resulting permeable paving.

[0015] In an embodiment of the invention, the void former cover further comprises multiple void former cover sheets, wherein the void former cover sheet thickness is smaller than the void former cover thickness. The void former cover sheets are adjacent to the void former cover edge, have a similar shape to each other and are spaced regularly along the full length of the void former cover edge. The ratio between the length of the void former cover edge that is adjacent to a void former cover sheet and the length of the void former cover edge that is not adjacent to a void former cover sheet is smaller than 2.5, preferably between 1.5 and 2.5, preferably 2.0. This has the advantage that an area of weakness is created in the void former cover, facilitating the removal of the void former cover, while improving the material flow during the injection molding process used to create the mold.

[0016] In an embodiment of the invention, the void former cover comprises a void former cover through hole configured for allowing the passage of air while preventing the passage of concrete aggregate, called a suction hole. This has the advantage that, when two molds that were nested and / or stacked during transport or storage have to be separated, they will stick less to each other due to the appearance of a (partial) vacuum between their respective stacked or nested void formers, while preventing concrete from seeping into the void former volume in the process of creating permeable combined concrete / grass paving. This effect is increased when the suction hole is combined with a mold spacer described below. As a result, the quality of the resulting permeable paving can be ensured, while avoiding installation difficulties due to sticky stacked molds.

[0017] In an embodiment of the invention, the mold comprises a mold spacer for maintaining a distance between two molds when they are stacked. By preference, the mold spacer comprises a protrusion, by preference a planar protrusion, for example on the concrete-facing side of the mold. Preferably, it protrudes between the base plane and the void former wall, the mold spacer being transverse to the base plane and transverse to the void former wall. This ensures that when two molds are nested and / or stacked during transport or storage, a gap filled with air remains between the two molds. When they have to be separated, they will stick less or even not stick to each other due to the appearance of a (partial) vacuum between them. This avoids installation difficulties due to sticky stacked molds. This effect is increased when combined with a suction hole described above. Preferably, the mold spacer has sufficient strength, for example from its thickness, to hold the weight of multiple stacked molds. This has the advantage that when multiple molds are stacked, the less-sticky effect is maintained between all pairs of stacked molds.

[0018] In an embodiment of the invention, the mold comprises a reinforcing bar support structure for supporting a concrete-reinforcing bar or concrete-reinforcing mesh. Preferably, the reinforcing bar support structure has a height that will position the concrete-reinforcing bar or concrete-reinforcing mesh at a location in the concrete where the tensile forces are greatest when loading the paving, for example with heavy traffic. This will increase the tensile strength of the paving and extend the paving's lifetime.

[0019] In an embodiment of the invention, the shape of the reinforcing bar support structure is such that the reinforcing bar support structure serves as a reinforcing bar support structure while also serving as a mold spacer described above. This has the advantage that the mold contains less protrusions, which increases the ease of installation, and increases the quality of the molds created by an injection molding process.

[0020] In an embodiment of the invention, the mold comprises a first void former and a second void former, wherein their respective void former walls substantially have the same void former wall height, and the first void former and the second void former protrude from the base plane in a single protruding direction. The mold also comprises a reinforcing bar support structure, that protrudes in the protruding direction. The reinforcing bar support structure has a reinforcement bar centering means for ensuring that a concrete-reinforcing bar on its own or as part of a concrete-reinforcing mesh is positioned in between the first void former and the second void former at substantially equal, preferably equal, distances from the first void former and the second void former. This had the advantage that the concrete-reinforcing bar or concrete-reinforcing mesh is placed such that the strength of the concrete paving is increased.

[0021] In an embodiment of the invention, the mold comprises a rectangular array of void formers, wherein the respective void former walls have substantially the same, preferably the same, respective void former wall height and all void formers protrude from the base plane in the protruding direction. This is an array that consists of rows and columns of void formers, preferably with at least 3 rows and at least 3 columns. The rectangular array comprises outer void formers, void formers on the edge of the array, not having row-wise and / or column-wise neighboring void formers on all sides, and optionally inner void formers, that have row-wise and column-wise neighbors on all sides. The mold further comprises multiple reinforcing bar support structures, wherein each reinforcing bar support structure protrudes from the base plane in the protruding direction and connects a pair of void formers that are arranged adjacently in the rectangular array of void formers, either column-wise or row-wise, the connections made by the reinforcing bar support structures respectively called a column-wise connection and a row-wise connection. Each void former is connected to at most two reinforcing bar support structures, each inner void former is connected to exactly two reinforcing bar support structures, and if a void former is connected to two reinforcing bar support structures, one reinforcing bar support structure makes a column-wise connection and the other reinforcing bar support structure makes a row-wise connection. This has the advantage that the reinforcing bar support structures and the void formers protruding from the base plane do not jointly enclose an area on the base plane. If the base plane is placed on the ground, with the protrusions protruding upwards, and it rains before the concrete is poured, the water can run of the mold and infiltrate in the ground between the molds. Therefore, the composition of the concrete is not inadvertently changed, and hence the quality of the poured concrete can be controlled.

[0022] In a further embodiment of the invention, the mold comprising a rectangular array of void formers, connected by reinforcing bar support structures as explained above, further comprises at least two through holes in the base plane for each reinforcing bar support structure, called drainage holes. The drainage holes lie on either side of the reinforcing bar support structure wall. This has the advantage that water that might run-off against a reinforcing bar support structure will have the opportunity to infiltrate in the ground through a drainage hole.

[0023] The invention also discloses a cast-in-place paving comprising a mold for shaping cast-in-place concrete paving and concrete, for example a concrete with a high water / concrete ratio, for example a C30 / 37 grade concrete of environmental class EE3, with concrete slump class S4 or S5.

[0024] In an embodiment of the invention, the paving comprises a cast-in-place permeable paving, that comprises a mold for shaping cast-in-place concrete permeable paving in which the void former covers have been removed and in which the void former volumes have been filled with earth, suitable for planting and growing grass or other ground covering plants.

[0025] In an embodiment of the invention, the paving is washed or polished.

[0026] The invention also discloses a method of using a mold for shaping cast-in-place concrete paving.

[0027] In an embodiment, the method of using a mold for shaping cast-in-place concrete paving comprises the steps of mold placing and concrete pouring. The step of mold placing comprising placing a mold, that comprises a subgrade-facing side, in particular the side from which the void formers do not protrude, subgrade-facing side down on a ground. The ground is preferably prepared for receiving paving, for example by leveling the subgrade, by applying a foundation and / or by applying, compacting and leveling a subbase or other road layers, prior to the step of mold placing. The step of concrete pouring comprises pouring unset concrete onto the mold that is placed on the ground. The concrete is for example a concrete with a high water / concrete ratio, for example a C30 / 37 grade concrete of environmental class EE3, with concrete slump class S4 or S5. Preferably, the concrete is poured with a height substantially equal or equal to the void former wall height. Preferably, expansion joints are foreseen when large areas of paving are cast. This step preferably follows the step of mold placing. Optionally, the embodiment comprises a step of mold anchoring, wherein the mold is anchored to the ground, the subbase or the subgrade, using a ground anchor, for example a picket. The ground anchor can be applied through a drainage hole in the base plane, if present. The step of mold anchoring preferably follows the step of mold placing and preferably precedes the step of concrete pouring. Optionally, the embodiment comprises a step of concrete-reinforcement application. The step of concrete-reinforcement application preferably comprises applying a concrete-reinforcing bar or a concrete-reinforcing mesh between the void formers, preferably at equal distances or substantially equal distances from the void formers and supported by the reinforcing bar support structure if present on the mold. The step of concrete-reinforcement application preferably follows the step of mold placing and / or the step of mold anchoring and preferably precedes the step of concrete pouring. Optionally, the embodiment comprises a step of concrete leveling, in which the concrete is leveled, preferably at a height substantially equal or equal to the void former wall height. Preferably, the step of concrete leveling is executed after the step of concrete pouring. Optionally, the embodiment comprises a step of void opening. The step of void opening comprises removing the void former cover or void former covers from the mold, for example by burning them or by mechanically ripping them from the void former walls. The step of void opening preferably follows the step of concrete pouring and / or the step of concrete leveling, and is applied after the concrete is set. Optionally, the embodiment comprises a step of void filling, wherein earth or another substrate, suitable for planting and growing grass or other ground covering plants, is inserted into the void former volume or void former volumes. The step of void filling preferably follows the step of concrete pouring, concrete leveling and / or void opening.

[0028] In a further embodiment of the invention, the method of using a mold for shaping cast-in-place concrete paving further comprises the step of concrete posttreatment. The step of concrete posttreatment comprises washing or polishing the concrete. Polishing the concrete comprises applying a concrete polishing machine during the concrete curing process and washing the concrete comprises removing the top layer of concrete during the concrete curing process. The step of concrete posttreatment preferably follows the step of concrete pouring and / or concrete leveling and preferably precedes the step of void opening and / or void filling.

[0029] The invention also discloses a method of making a mold for shaping cast-in-place concrete paving.

[0030] In an embodiment of the invention, a mold for shaping cast-in-place concrete paving is manufactured using an injection molding technique. Preferably, especially when a mold for shaping cast-in-place concrete paving with multiple void formers is made, the injection molding technique employs multiple hot runners that inject a plastic composite material into an injection molding mold suitable for making a mold for shaping cast-in-place concrete paving, the hot runners injecting material from the void former cover of each void former towards the base plane.Brief description of the drawings

[0031] The invention will be further elucidated by means of the following description and the appended figures. Figure 1 shows an isometric view of a mold for shaping cast-in-place concrete paving according to a first embodiment of the invention. Figure 2 shows both sides of a void former of the mold according to the first embodiment of the invention. Figure 3 shows multiple views of a reinforcing bar support structure of the mold according to a first embodiment of the invention. Figure 4 shows a top view of the mold according to the first embodiment of the invention. Figure 5 shows a side view of the mold according to the first embodiment of the invention on which a concrete-reinforcing mesh has been placed. Figure 6 shows an isometric view of a void former of the mold according to the first embodiment of the invention. Figure 7 shows an isometric view of a cast-in-place permeable combined concrete / grass paving according to a second embodiment of the invention. Figure 8 shows a flow chart of a method of using a mold for shaping cast-in-place permeable paving according to a third and a fourth embodiment of the invention. Modes for carrying out the invention

[0032] The present invention will be described with respect to particular embodiments and with reference to certain drawings but the invention is not limited thereto but only by the claims. The drawings described are only schematic and are non-limiting. In the drawings, the size of some of the elements may be exaggerated and not drawn on scale for illustrative purposes. The dimensions and the relative dimensions do not necessarily correspond to actual reductions to practice of the invention.

[0033] Furthermore, the terms first, second, third and the like in the description and in the claims, are used for distinguishing between similar elements and not necessarily for describing a sequential or chronological order. The terms are interchangeable under appropriate circumstances and the embodiments of the invention can operate in other sequences than described or illustrated herein.

[0034] Moreover, the terms top, bottom, over, under and the like in the description and the claims are used for descriptive purposes and not necessarily for describing relative positions. The terms so used are interchangeable under appropriate circumstances and the embodiments of the invention described herein can operate in other orientations than described or illustrated herein.

[0035] The term "comprising", used in the claims, should not be interpreted as being restricted to the means listed thereafter; it does not exclude other elements or steps. It needs to be interpreted as specifying the presence of the stated features, integers, steps or components as referred to, but does not preclude the presence or addition of one or more other features, integers, steps or components, or groups thereof. Thus, the scope of the expression "a device comprising means A and B" should not be limited to devices consisting only of components A and B. It means that with respect to the present invention, the only relevant components of the device are A and B.

[0036] Figures 1 to 6 show a mold 101 for shaping cast-in-place concrete paving 702 according to a first embodiment of the invention, or details thereof. For clarity, we will first describe the first embodiment of the invention and then shortly discuss what elements you see in which figure.

[0037] The first embodiment of the invention is a mold 101 for shaping cast-in-place concrete paving 702. The mold 101 comprises a base plane 105 and a rectangular array of void formers 112 with at least 3 rows and at least 3 columns, in particular 4 rows and 8 columns. The base plane 105 comprise a void former through hole for every void former 102 and every void former 102 comprises a void former wall 103 with a void former wall height h, and a void former cover 104. The respective void former walls 103 have substantially the same, preferably the same, void former wall height h. The void former wall height h is between 13 cm and 17 cm, preferably 15 cm, in particular 15 cm.

[0038] For each void former 102, the void former cover 104 lies transverse to the respective void former wall 103 at the void former wall height h, the void former wall 103 lies transverse to the base plane 105, the void former wall 103 connects the respective void former cover 104 to the base plane 105. The void former cover 104 is connected along a void former cover edge 106 delimiting the void former cover 104 and the base plane 105 is connected along a void former through hole edge 107 delimiting the void former through hole. The void formers protrude from the base plane 105 in a protruding direction p, forming hollow peaks that are substantially closed at the respective void former walls 103 and void former covers, and that are substantially open at the base plane 105. The hollow peaks determine void former volumes 201.

[0039] The void former cover 104 and the void former through hole are both circular. The void former cover 104 has a smaller diameter than the void former through hole. The void former 102 is shaped as a truncated cone. The void former cover 104 has a diameter between 8 cm and 11 cm, preferably 9.5 cm, in particular 9.5 cm and the void former through hole has a diameter between 10 cm and 14 cm, preferably 12 cm, in particular 12 cm. In alternative embodiments, the void former 102 is cylindrical. In alternative embodiments, the void former 102 is a prismoid. In alternative embodiments, the void former 102 is tapered in the protruding direction p. In alternative embodiments, the shape of the void former cover 104 and the void former through hole is that of a star, a cross, a triangle, a quadrangle, a hexagon, .... In alternative embodiments the shape of the void former cover 104 and the void former through hole are different from each other.

[0040] The mold 101 further comprises two opposing sides, in particular a concrete-facing side 202, being the side towards which the void former 102 protrudes from the base plane 105, and a subgrade-facing side 203. The concrete-facing side 202 and the subgrade-facing side 203 have a substantially complimentary shape so that two molds can be nested.

[0041] The base plane 105 thickness is the same or substantially the same as the void former wall 103 thickness and is larger than the void former cover 104 thickness. The void former cover 104 further comprises multiple void former cover sheets 601, wherein the void former cover sheet 601 thickness is smaller than the void former cover 104 thickness. In particular, the base plane 105 thickness is between 1 mm and 2 mm, preferably 1.5 mm, in particular 1.5 mm, the void former wall 103 thickness is between 1 mm and 2 mm, preferably 1.5 mm, in particular 1.5 mm, the void former cover 104 thickness is between 0.3 mm and 0.7 mm, preferably 0.5 mm, in particular 0.5 mm, and the void former cover sheet 601 thickness is between 0.1 mm and 0.5 mm, preferably 0.3 mm, in particular 0.3 mm. In alternative embodiments, the base plane 105 thickness is different from the void former wall 103 thickness. In alternative embodiments, the void former cover 104 thickness is the same as the void former wall 103 thickness.

[0042] The void former cover sheets 601 are adjacent to the void former cover edge 106, have a similar shape to each other and are spaced regularly along the full length of the void former cover edge 106. The ratio between the length of the void former cover edge 106 that is adjacent to a void former cover sheet 601 and the length of the void former cover edge 106 that is not adjacent to a void former cover sheet 601 is between 1.5 and 2.5, in particular 2.0. In alternative embodiments, the void former cover 104 comprises a single void former cover sheet 601 or any other area of weakness. In alternative embodiments, the void former cover sheet lies along substantially the full length of the void former cover edge 106.

[0043] Each void former cover 104 further comprises a void former cover 104 through hole configured for allowing the passage of air while preventing the passage of concrete aggregate. These are called suction holes 108 and have a diameter between 0.6 and 0.1 cm, preferably about 0.5 cm, in particular 0.5 cm.

[0044] The mold 101 further comprises mold spacers 110 for maintaining a distance between two molds when they are stacked. A mold spacer 110 comprises a planar protrusion from the concrete-facing side 202 of the mold 101, protruding between the base plane 105 and the void former wall 103, the mold spacer 110 being transverse to the base plane 105 and transverse to the void former wall 103. The mold spacer 110 thickness is between 1 mm and 5 mm, preferably about 3 mm, in particular 3 mm. In alternative embodiments, the mold spacer 110 protrudes from the subgrade-facing side 203 of the mold 101. In alternative embodiments, the mold spacer 110 protrudes from the void former 102. In alternative embodiments, another means is foreseen for maintaining a distance between two molds when they are stacked.

[0045] The mold 101 comprises multiple reinforcing bar support structures 111, for supporting a concrete-reinforcing bar or concrete-reinforcing mesh 401. The reinforcing bar support structures 111 protrude from the base plane 105 in the protruding direction p.

[0046] A reinforcing bar support structure 111 comprises a first reinforcing bar support structure wall 301, a second reinforcing bar support structure wall 302 and a reinforcing bar support structure plane 303. The first reinforcing bar support structure wall 301 and the second reinforcing bar support structure wall 302 lie transversal to the base plane 105. The reinforcing bar support structure plane 303 lies transversal to the first reinforcing bar support structure wall 301 and the second reinforcing bar support structure wall 302. The reinforcing bar support structure plane 303 lies substantially along the direction of the base plane 105.

[0047] The reinforcing bar support structure plane 303 extends in a reinforcing bar support structure plane 303 lateral direction b between a first reinforcing bar support structure plane end 306 and a second reinforcing bar support structure plane end 307, and in a reinforcing bar support structure plane longitudinal direction I between a third reinforcing bar support structure plane end 308 and a fourth reinforcing bar support structure plane end 309. The first reinforcing bar support structure wall 301 connects the base plane 105 to the reinforcing bar support structure plane 303 at the first reinforcing bar support structure plane end 306, the second reinforcing bar support structure wall 302 connects the base plane 105 to the reinforcing bar support structure plane 303 at the second reinforcing bar support structure plane end 307.

[0048] A reinforcing bar support structure 111 pairwise connects void formers that are arranged adjacently in the rectangular array of void formers 112, either column-wise or row-wise, the connections made by the reinforcing bar support structures 111 respectively called column-wise connections and row-wise connections. In particular, it connects a first void former 304 to a second void former 305. The reinforcing bar support structure plane 303, the first reinforcing bar support structure wall 301 and the second reinforcing bar support structure wall 302 connect to the void former wall 103 of the first void former 304 near the third reinforcing bar support structure plane end 308 and connect to the void former wall 103 of the second void former 305 near the fourth reinforcing bar support structure end 309. The base plane 105, the first void former 304, the second void former 305 and the reinforcing bar support structure 111 are connected with substantially uninterrupted, in particular uninterrupted seams.

[0049] The reinforcing bar support structure 111 forms a hollow peak that is substantially closed, in particular closed at the reinforcing bar support structure plane 303, at the first reinforcing bar support structure wall 301 and at the second reinforcing bar support structure wall 302 and substantially open at the base plane 105, at the void former wall 103 of the first void former 304, and at the void former wall 103 of the second void former 305. In alternative embodiments, the seams are dashed, such that the holes are configured for allowing the passage of air while preventing the passage of concrete aggregate. In alternative embodiments, the reinforcing bar support structure 111 protrudes from the base plane 105 without connecting void formers. In alternative embodiments, the reinforcing bar support structures 111 do not form a hollow peak. In alternative embodiments the shape of the reinforcing bar support structure 111 is such that the reinforcing bar support structure 111 serves as a reinforcing bar support structure 111 while also serving as a mold spacer 110 described above, by only forming a partially hollow peak, or by having a mold spacer 110 connected to the inside of the hollow peak.

[0050] The reinforcing bar support structure plane 303 is arched along the longitudinal direction l, so that the midpoint of the reinforcing bar support structure plane 310 along the longitudinal direction l is closer to the base plane 105 than the first reinforcing bar support structure plane end 306 and the second reinforcing bar support structure plane end 307. The distance between the midpoint of the reinforcing bar support structure plane 310 along the longitudinal direction I and the base plane 105 is between 2 cm and 6 cm, preferably 4 cm, in particular 4 cm. In alternative embodiments, the reinforcing bar support structure 111 has a reinforcement bar centering means for ensuring that a concrete-reinforcing bar on its own or as part of a concrete-reinforcing mesh 401 is positioned in between the first void former 304 and the second void former 305 at substantially equal, preferably equal, distances from the first void former 304 and the second void former 305, such as a central clamping shape.

[0051] The mold 101 comprises outer void formers 402 and inner void formers 403. Outer void formers 402 are void formers on the edge of the array. They do not have row-wise and / or column-wise neighboring void formers on all sides. Inner void formers 403 have row-wise and column-wise neighbors on all sides. Each void former 102 is connected to at most two reinforcing bar support structures 111 and each inner void former 403 is connected to exactly two reinforcing bar support structures 111. If a void former 102 is connected to two reinforcing bar support structures 111, one reinforcing bar support structure 111 makes a column-wise connection and the other one makes a row-wise connection.

[0052] The mold 101 comprises at least two drainage holes 109, in particular two drainage holes 109, for each reinforcing bar support structure 111. A drainage hole 109 is a base plane through hole configured for the passage of water, having a diameter between 1 cm and 3 cm, preferably 2 cm, in particular 2 cm. The drainage holes 109 are lying on either side of the reinforcing bar support structure according to the reinforcing bar support structure plane 303 lateral direction b.

[0053] Some drainage holes 109, in particular all drainage holes 109, are configured for anchoring the mold 101 to the ground 703 using a ground anchor, for example a picket, when the mold 101 is placed subgrade-facing side 203 down on the ground 703 with the void formers protruding upwards. In alternative embodiments, the mold 101 is configured for anchoring to the ground 703 at the outer edges delimiting the base plane 105.

[0054] The mold 101 is made from a plastic composite material, by preference a thermoplastic composite material, by preference having a thermal expansion coefficient below 0.20 mm / m°C, by further preference below 0.17 mm / m°C. The mold 101 is made by preference from a plastic composite material comprising polypropylene, polypropylene preferably serving as a matrix material. The plastic composite material by preference further comprises talcum powder, talcum powder preferably serving as a structural component reinforcing the composite material. Preferably the talcum powder occupies 0.5 wt% to 20.0 wt% of the composite material, more preferably 1 wt% to 10 wt%, and most preferably 7 wt%. In particular, the plastic composite material is a thermoplastic composite material comprising recycled polypropylene and 7 wt% talcum powder. In alternative embodiments, the plastic composite material comprises non-recycled polypropylene, high-density polyethylene, low-density polyethylene or any other suitable matrix material for plastic composite materials known in the state of the art.

[0055] Figure 1 shows an isometric view of the mold 101 for shaping cast-in-place concrete paving 702 according to the first embodiment of the invention. It shows a rectangular array of void formers 112 protruding from a base plane 105 in a protruding direction p, each having a void former wall 103 that connects the base plane 105 and a void former cover 104, respectively at a void former through hole edge 107 and a void former cover edge 106. It also shows a void former cover 104 with a suction hole 108, it shows a drainage hole 109 in the base plane 105, a mold spacer 110 and a reinforcing bar support structure 111.

[0056] Figure 2 shows both sides of a void former 102 of the mold 101 according to the first embodiment of the invention. It shows a concrete-facing side 202 in Figure 2a and a void former volume 201 and a subgrade-facing side 203 in Figure 2b.

[0057] Figure 3 shows multiple views of a reinforcing bar support structure 111 of the mold 101 according to a first embodiment of the invention. Figure 3a shows a first reinforcing bar support structure wall 301, a second reinforcing bar support structure wall 302, a reinforcing bar support structure plane 303 between a first void former 304 and a second void former 305. Figure 3b shows a top view with a reinforcing bar support structure plane 303 lateral direction b, a first reinforcing bar support structure plane end 306, a second reinforcing bar support structure plane end 307, a reinforcing bar support structure plane 303 longitudinal direction l, a third reinforcing bar support structure plane end 308 and a fourth reinforcing bar support structure plane end 309. Figure 3c shows the midpoint of the reinforcing bar support structure plane 310 along its longitudinal direction l.

[0058] Figure 4 shows a top view of the mold 101 according to the first embodiment of the invention. Figure 4a shows outer void formers 402 and inner void formers 403 of the rectangular array of void formers 112, the reinforcing bar support structures 111 with row-wise and column-wise connections between void formers, and drainage holes 109 on either sides of the reinforcing bar support structures 111. Figure 4b shows a concrete-reinforcing mesh 401 that is placed on the mold 101.

[0059] Figure 5 shows a side view of the mold 101 according to the first embodiment of the invention on which a concrete-reinforcing mesh 401 has been placed. It shows a void former wall height h and an arched reinforcing bar support structure plane 303 on which a concrete-reinforcing mesh 401 is placed.

[0060] Figure 6 shows an isometric view of a void former 102 of the mold 101 according to the first embodiment of the invention. It shows a void former cover sheet 601 and indicates by dots the thickness of the different elements of the mold 101.

[0061] Figure 7 shows a cast-in-place permeable combined concrete / grass paving according to a second embodiment of the invention. The cast-in-place concrete paving 702 according to the second embodiment of the invention comprises a mold 101 for shaping cast-in-place concrete paving 702 according to the invention, concrete, and a concrete-reinforcing mesh 401. The mold 101 is lying subgrade-facing side 203 down on the ground 703 and the concrete is lying on the concrete-facing side 202 of the mold 101, with a height substantially equal to, in particular equal to, the void former wall height h. The concrete is for example a concrete with a high water / concrete ratio, for example a C30 / 37 grade concrete of environmental class EE3, with concrete slump class S4 or S5. The void former 102 covers have been removed and the void former volumes 201 have been filled with earth 704.

[0062] In alternative embodiments, multiple concrete-reinforcing bars are used instead of a concrete-reinforcing mesh 401. In alternative embodiments, the height of the concrete paving 702 is greater than the void former wall height h. In alternative embodiments, the void former covers 104 are not removed. In alternative embodiments, the concrete paving 702 is washed or polished. In alternative embodiments, the void former volumes 201 are filled with another substrate suitable for planting and growing grass or other ground covering plants. In alternative embodiments, the void former 102 volumes are filled with loose aggregate, such as pebbles or sand.

[0063] Figure 7a shows an isometric view of the paving, showing a mold 101, concrete, for example concrete paving 702, a ground 703 and an earth-filled void former volume 201. Figure 7b shows a detail of a side view of the paving, showing in addition to Figure 7a a concrete-reinforcing mesh 401 and a void former wall height h.

[0064] Figure 8 shows a flow chart of a method of using a mold 101 for shaping cast-in-place permeable paving 701 according to a third and a fourth embodiment of the invention.

[0065] Figure 8a shows the third embodiment of the invention, that comprises a method of using a mold 101 for shaping cast-in-place concrete paving 702, comprising the following steps. A mold placing 802 step, wherein a mold 101 is placed subgrade-facing side 203 down on the ground 703. A mold anchoring 803 step, wherein the mold 101 is anchored to the ground 703, the subbase or the subgrade, using a ground anchor, for example a picket. The ground anchor is by preference applied through a drainage hole 109 in the base plane 105. A concrete-reinforcement application 804 step, wherein a concrete-reinforcing mesh 401 is placed between void formers, preferably at substantially equal distances, in particular equal distances, from the void formers and supported by the reinforcing bar support structure 111. A concrete pouring 805 step wherein unset concrete is poured onto the mold 101 that is placed on the ground 703. The concrete is for example a concrete with a high water / concrete ratio, for example a C30 / 37 grade concrete of environmental class EE3, with concrete slump class S4 or S5. The concrete is poured with a height substantially equal or equal to the void former wall height h. A concrete leveling 806 step, wherein the concrete is leveled at a height substantially equal, in particular equal, to the void former wall height h. This step is executed before the concrete is set. A concrete posttreatment 807 step, wherein the concrete is polished by applying a concrete polishing machine during the concrete curing process. This step is executed before the concrete is set. A void opening 808 step, wherein a void former cover 104 is removed from the mold 101 by burning it off with a blowtorch. This step is executed after the concrete is set. A void filling 809 step, wherein earth 704 is inserted into a void former volume 201.

[0066] In alternative embodiments, the steps are executed in another order. In alternative embodiments, the mold placing 802 and concrete pouring 805 steps are executed. Some or all of the other, optional steps, are not executed. In alternative embodiments, the step of void opening 808 is executed with another known technique from the state of the art to remove a void former cover 104, such as removing it mechanically by ripping it out of the void former 102 or by using high pressure water. In alternative embodiments the concrete is poured to a height that is larger than the void former wall height h. In alternative embodiments, other posttreatment processes applied during or after the curing process to change the appearance of the paving or to ensure its longevity known from the state of the art are applied, such as stamping the concrete with a particular pattern or applying a color. In alternative embodiments, the step of void filling 809 inserts another material into a void former volume 201, such as another substrate suitable for planting and growing grass or other ground covering plants, aggregates, for example pebbles or sand.

[0067] Figure 8b shows the fourth embodiment of the invention, that comprises a method of using a mold 101 for shaping cast-in-place concrete paving 702, comprising the following steps: a mold placing 802 step, a concrete pouring 805 step, a concrete leveling 806 step, and a void opening 808 step.

[0068] In a fifth embodiment of the invention, a mold 101 for shaping cast-in-place concrete paving 702 is manufactured using an injection molding technique. Preferably, especially when a mold 101 for shaping cast-in-place concrete paving 702 with multiple void formers is made, the injection molding technique employs multiple hot runners that inject a plastic composite material into an injection molding mold suitable for making a mold 101 for shaping cast-in-place concrete paving 702, the hot runners injecting material from the void former cover 104 of each void former 102 towards the base plane 105.

[0069] In alternative embodiments, other measures known from the state of the art for injection molding are employed for manufacturing the mold 101 for shaping cast-in-place concrete paving 702. In alternative embodiments, the runners inject material form the base plane 105 towards the void former 102 covers.

Examples

first embodiment

[0037]the invention is a mold 101 for shaping cast-in-place concrete paving 702. The mold 101 comprises a base plane 105 and a rectangular array of void formers 112 with at least 3 rows and at least 3 columns, in particular 4 rows and 8 columns. The base plane 105 comprise a void former through hole for every void former 102 and every void former 102 comprises a void former wall 103 with a void former wall height h, and a void former cover 104. The respective void former walls 103 have substantially the same, preferably the same, void former wall height h. The void former wall height h is between 13 cm and 17 cm, preferably 15 cm, in particular 15 cm.

[0038]For each void former 102, the void former cover 104 lies transverse to the respective void former wall 103 at the void former wall height h, the void former wall 103 lies transverse to the base plane 105, the void former wall 103 connects the respective void former cover 104 to the base plane 105. The void former cover 104 is conn...

fourth embodiment

[0064]Figure 8 shows a flow chart of a method of using a mold 101 for shaping cast-in-place permeable paving 701 according to a third and the invention.

third embodiment

[0065]Figure 8a shows the invention, that comprises a method of using a mold 101 for shaping cast-in-place concrete paving 702, comprising the following steps. A mold placing 802 step, wherein a mold 101 is placed subgrade-facing side 203 down on the ground 703. A mold anchoring 803 step, wherein the mold 101 is anchored to the ground 703, the subbase or the subgrade, using a ground anchor, for example a picket. The ground anchor is by preference applied through a drainage hole 109 in the base plane 105. A concrete-reinforcement application 804 step, wherein a concrete-reinforcing mesh 401 is placed between void formers, preferably at substantially equal distances, in particular equal distances, from the void formers and supported by the reinforcing bar support structure 111. A concrete pouring 805 step wherein unset concrete is poured onto the mold 101 that is placed on the ground 703. The concrete is for example a concrete with a high water / concrete ratio, for example a C30 / 37 gra...

Claims

1. A mold (101) for shaping cast-in-place concrete paving (702), comprising: - a void former (102), comprising a void former wall (103) with a void former wall height (h) and a void former cover (104), - a base plane (105), comprising a void former through hole, wherein - the void former cover lies transverse to the void former wall at the void former wall height, - the void former wall lies transverse to the base plane, - the void former wall connects the void former cover to the base plane, respectively along a void former cover edge (106) delimiting the void former cover and a void former through hole edge (107) delimiting the void former through hole, - the void former protrudes from the base plane in a protruding direction (p), forming a hollow peak that is substantially closed at the void former wall and void former cover and substantially open at the base plane, the hollow peak determining a void former volume (201), characterized in that, - the mold is made from a plastic composite material.

2. A mold according to the previous claim, wherein the plastic composite material is a thermoplastic composite material comprising polypropylene and talcum powder.

3. A mold according to any of the previous claims, wherein the base plane thickness is the same or substantially the same as the void former wall thickness and is larger than the void former cover thickness.

4. A mold according to any of the previous claims, wherein the void former cover further comprises a void former cover sheet (601) adjacent to the void former cover edge, wherein the void former cover sheet thickness is smaller than the void former cover thickness.

5. A mold according to any of the previous claims, wherein the void former cover further comprising a void former cover through hole configured for allowing the passage of air while preventing the passage of concrete aggregate, called a suction hole (108).

6. A mold according to any of the previous claims, further comprising a mold spacer (110) for maintaining a distance between two molds when they are stacked.

7. A mold according to the previous claim, further comprising a reinforcing bar support structure (111) for supporting a concrete-reinforcing bar or concrete-reinforcing mesh (401), a first void former (304) and a second void former (305), wherein - the void former walls (103) of the first void former and of the second void former substantially have the same void former wall height, - the first void former and the second void former protrude from the base plane in the protruding direction, - the reinforcing bar support structure protrudes from the base plane in the protruding direction, - the reinforcing bar support structure comprises a reinforcing bar support structure plane (303), - the reinforcing bar support structure plane lies substantially along the direction of the base plane, - the reinforcing bar support structure plane extends in a reinforcing bar support structure plane lateral direction (b) between a first reinforcing bar support structure plane end (306) and a second reinforcing bar support structure plane end (307), and in a reinforcing bar support structure plane longitudinal direction (l) between a third reinforcing bar support structure plane end (308) and a fourth reinforcing bar support structure plane end (309), - the reinforcing bar support structure plane connects to the void former wall of the first void former near the third reinforcing bar support structure plane end and connects to the void former wall of the second void former near the fourth reinforcing bar support structure end.

8. A mold according to the previous claim, wherein the reinforcing bar support structure plane is arched along the longitudinal direction, so that the midpoint of the reinforcing bar support structure plane (310) along the longitudinal direction is closer to the base plane than the first reinforcing bar support structure plane end and the second reinforcing bar support structure plane end.

9. A mold according to any of the claims 7 to 8, wherein the mold further comprises - a rectangular array of void formers (112) with at least 3 rows and at least 3 columns, comprising outer void formers (402) and inner void formers (403), wherein the respective void former walls have the substantially same respective void former wall height and all void formers protrude from the base plane in the protruding direction, - multiple reinforcing bar support structures (111), wherein each reinforcing bar support structure protrudes from the base plane in the protruding direction and connects in its longitudinal direction a pair of void formers that are arranged adjacently in the rectangular array of void formers, either column-wise or row-wise, the connections made by the reinforcing bar support structures respectively called a column-wise connection and a row-wise connection, wherein - each void former is connected to at most two reinforcing bar support structures, - each inner void former (403) is connected to exactly two reinforcing bar support structures, - if a void former is connected to two reinforcing bar support structures, one reinforcing bar support structure makes a column-wise connection and the other one makes a row-wise connection,10. A mold according to any of the claims 7 to 9, wherein the base plane further comprises for each reinforcing bar support structure at least two base plane through holes configured for the passage of water, called drainage holes (109), the drainage holes lying on either side of the respective reinforcing bar support structure according to the respective reinforcing bar support structure plane lateral direction.

11. A mold according to any of the previous claims, further comprising two opposing sides, in particular a concrete-facing side (202), being the side towards which the void former protrudes from the base plane, and a subgrade-facing side (203), wherein the concrete-facing side and the subgrade-facing side have a substantially complimentary shape so that two molds can be nested.

12. A cast-in-place concrete paving comprising a mold according to any of the previous claims and concrete.

13. A method of using a mold for shaping cast-in-place concrete paving according to any of the claims 1 to 11, comprising: - a mold placing (802), wherein the mold is placed on the ground (703), and - a concrete pouring (805), wherein concrete is poured onto the mold.

14. A method according to the previous claim, further comprising a concrete posttreatment (807), wherein the concrete is washed or polished during the curing process.

15. A method of making a mold for shaping cast-in-place concrete paving according to any of the claims 1 to 11, wherein the mold is manufactured using an injection molding technique.

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