Modular permanent formwork panel

Abstract

A modular permanent formwork panel 100 comprising a first formwork section 110 and a second formwork section 120, wherein each of the first and second formwork sections comprise a plurality of steel m

Description

TECHNICAL FIELD The present application generally relates to a modular permanent formwork panel for use in various applications, and more particularly to glass reinforced polymer, GRP, formwork panels that can be easily assembled and disassembled for efficient construction processes. BACKGROUND ART In the field of civil, structural, and construction engineering, the use of formwork has been a fundamental aspect of construction processes for centuries. Formwork is a temporary structure used to support freshly poured concrete or other materials until they harden sufficiently to maintain their shape without support. Traditional formwork systems involve the use of wood, metal, or composite materials that are assembled onsite to create the structure of a building or other construction project. After the concrete has gained sufficient strength, the formwork is removed and discarded. However, in recent years, a new approach known as "permanent formwork" has been increasingly adopted in civil engineering projects such as composite bridge construction, where concrete or steel beams are combined with a concrete deck. This approach involves using formwork that is not removed but left in place, contributing to the load carrying capacity of the structure or simply containing the concrete until it gains its initial strength. The current technology primarily involves the use of prefabricated formwork panels that are shipped to the construction site. These panels are designed to fit within standard shipping containers, such as standard 20 foot or 40 foot containers, to facilitate efficient transportation. The formwork is then assembled on-site to create the structure. In some cases, larger panel sizes may be required to accommodate the increased clear span of the structures, or to provide cantilever sections. This approach presents limitations. SUMMARY This application addresses the problem of constructing modular permanent formwork panels that are durable, easy to assemble, and can be more easily shipped than conventional formwork. This and other objects are solved by the subject matter of the independent claims. Further improvements are given by the dependent claims. The application provides solutions for encapsulating steel members in glass reinforced plastic (GRP) to enhance their longevity, aligning and fixing the steel members in the splice region to ensure structural integrity, and disassembling the splice region for convenient transportation. In addition, there is provided a modular permanent formwork panel comprising a first formwork section and a second formwork section, where each section includes steel members substantially encapsulated in glass reinforced plastic and connected to one another in the splice region. The connection may be effected through a bolting or other coupling arrangement. In further aspects additional formwork sections may also be coupled to one or more of the first or second formwork sections so as to expand the modular formwork panel to greater dimensions. There is also provided a modular permanent formwork panel with a planar first formwork section that is spliced through a mechanical coupling to a non-planar second formwork section such as one having an L-shaped or similar configuration. It will be appreciated that an L-shaped configuration is suited for certain applications which require vertical upstand arrangement but that not all upstands are necessarily provided at right angles. The non-planar second formwork will typically have a profile with a horizontal base portion and a vertical or non horizontal upright portion which is angularly offset from the plane of the horizontal base portion. In addition, there is provided a method of forming a modular permanent formwork panel where the steel members are encapsulated in glass reinforced plastic, aligned longitudinally, and connected to one another in the splice region. Embodiments of the invention are associated with various advantages and / or technical effects BRIEF DESCRIPTION OF DRAWINGS The present disclosure is illustrated by way of example and not limited in the accompanying figures in which like reference numerals indicate similar elements. Embodiments of the application will now be described with reference to the attached drawings: Figure 1 is a perspective view of components of a formwork panel in accordance with the present invention. Figure 2 is a plan view of assembled components of a formwork panel in accordance with the present invention. Figure 3 is a side view of assembled components of a formwork panel in accordance with the present invention. Figure 4 is an exemplary process flow for providing a modular formwork panel in accordance with the present invention. Figure 5 is a schematic showing connection of first and second formwork sections to one another in a splice region in accordance with one aspect of the present teaching. Figure 6 is a side view schematic showing connection of first and second formwork sections to one another in a splice region in accordance with one aspect of the present teaching. DETAILED DESCRIPTION OF THE DRAWINGS According to a first aspect and as shown in Figures 1 to 6 there is provided a modular permanent formwork panel 100 comprising a first formwork section 110 and a second formwork section 120. Each of the first 110 and second 120 formwork sections comprise a plurality of steel members 130. Each formwork section 110, 120 comprises a first encapsulated portion 115 wherein the plurality of steel members are encapsulated and a second splice portion 125. The sections are configured such that when the first and second formwork sections are coupled together through a fixing of the steel members of their respective splice portions to one another a splice region 140 is formed. In the example of Figures 2 and 3, the panel 100 comprise two of the second 120 formwork sections that are coupled to a single one of the first 110 formwork sections at either end thereof. In this way the first 110 formwork section has first and second splice regions 140, each providing a connection to a respective one of the two second 120 formwork section. The first 110 formwork section has a planar form so as to provide a planar section, whereas each of the second 120 formwork sections have non-planar geometries so as to provide non-planar section. The inclusion of both planar and non-planar formwork sections within the panel design allows for the creation of complex geometries in concrete structures, expanding architectural possibilities. These examples demonstrate the use of an L-shaped profile at either end of the planar section. The ability to combine planar and non-planar sections in a single formwork system simplifies the construction process by reducing the need for multiple specialized formwork systems. The versatility provided by having different formwork section shapes within the same system can lead to a more efficient use of materials and a reduction in waste, as the same formwork can be adapted to various design specifications. The inclusion of a second formwork section with a non-planar, such as the exemplary L-shaped, profile enhances the structural integrity of the panel, providing increased stability and load-bearing capacity. The L-shaped profile allows for more efficient use of materials, as it can provide additional support without the need for extra components, leading to cost savings in material usage and transportation. As is evident from inspection of Figure 3, the L-shaped profile has a horizontal base portion 300 and a vertical upright portion 310. The L-shaped profile with a horizontal base and vertical upright portion offers a convenient means of alignment and connection with other structural elements, simplifying the construction process. As is evident again, the splice region 140 is formed in the base portion. The formation of a splice region 140 in the base portion of the L-shaped profile allows for a seamless connection between adjacent panels, resulting in a continuous and uniform structure. It will be appreciated that the L-shaped profile is an example of the type angular configuration that can be provided in accordance with the present teaching. As this section is configured to be connected, in use, to the other sections so as to form the ultimate panel, it will be appreciated that the shape and configuration of this panel can be designed for specific applications with great flexibility. Furthermore, the ability to detach this section from other sections during transportation advantages allows for a greater density in stacking these sections during the transportation process. The inclusion of different formwork section profiles, such as planar and non-planar sections, provides the advantage of versatility in construction applications. The modular design of the permanent formwork panel allows for easy transportation and assembly on-site, reducing construction time and labour costs. The ability to couple multiple formwork sections together in a splice region through the fixing of respective splice portions enhances the versatility of the panel, enabling the construction of various sizes and shapes of concrete structures. The modular permanent formwork panel provides the advantage of easy assembly and disassembly due to the coupling of the first and second formwork sections in the splice region. The combination of encapsulated steel members and the splice portion within each formwork section provides a balance of protection against environmental factors and structural integrity for concrete casting processes. The splice region is typically a skeleton region which may include exposed steel members. The splice portion of each formwork section desirably comprises a plurality of exposed steel members whereas the use of glass reinforced plastic / polymer (GRP) encapsulation in the first formwork section provides the advantage of increased durability and resistance to corrosion. Encapsulating the steel members in glass reinforced plastic, GRP, offers increased resistance to corrosion and chemical attack, extending the lifespan of the formwork panel. The use of GRP as an encapsulating material provides a lightweight yet robust alternative to traditional formwork materials, facilitating easier handling and positioning of the panels. The inherent properties of GRP, such as non-conductivity and thermal insulation, contribute to safer working conditions and may improve the energy efficiency of the completed concrete structure. The alignment of the steel members in the splice region provides the advantage of structural integrity and stability whilst also preventing any onsite clashes occurring with the concrete deck reinforcing steel mat. Onsite clashes may be present in the form of reinforcement clashes or clashes seen with the shear studs used when steel beams are part of the composite bridge construction. As can be seen from inspection of figure 3 for example that typically the splice region is provided over the top flange of the supporting girder. This is best positioned as there will be no clashes with site installations such as shear studs or reinforcement that is laid onto the panels and provides another advantage on site. As shown in Figure 5 and 6, the respective fixing may be effected by a coupling- such as that achieved for example using a series of nuts 500 and bolts 600 or other fixing members- together of the steel members 130 in the splice region 140. Other arrangements for effecting the fixing could involve a welding arrangement. The secure fixing, by welding or other fixing processes, provides the advantage of a secure and reliable connection between the first and second formwork sections. Bolting or otherwise securing the steel members of adjacent formwork sections together in the splice region provides a strong and reliable connection that can withstand the forces exerted by wet concrete and live load. Bolted connections enable quick and easy adjustments or replacements of individual formwork sections, enhancing the adaptability of the formwork system to various project requirements. The splice region enhances the overall durability of the formwork system by distributing loads and stresses more evenly across the panel, thereby reducing the likelihood of failure at the joints. As can be seen from the Figures, the panel further comprises in the splice region the steel members of respective first and second formwork sections being aligned longitudinally. Aligning the steel members longitudinally in the splice region ensures a continuous load path across the formwork sections, improving the structural performance of the assembled panel. The longitudinal alignment of steel members facilitates precise and straightforward alignment, with a degree of flexibility and adjustment of the presentation of the sections to one another, during assembly, leading to a reduction in construction errors and a higher quality finished product. This configuration allows for a more efficient transfer of stresses between connected formwork sections, which is critical for maintaining the integrity of the formwork during concrete placement and curing. As is referenced in Figure 4, there is disclosed a method 400 of forming a modular permanent formwork panel comprising multiple parts including a first formwork section and a second formwork section, wherein each of the first and second formwork sections comprise a plurality of steel members, the method comprising: providing 410 each formwork section with a first encapsulated portion wherein the plurality of steel members are encapsulated and a second splice portion which operatively provides a coupling between respective formwork sections, and packing 420 the separate parts for shipping. The method of forming a modular permanent formwork panel with an encapsulated region and a splice region ensures that the critical connection points are robust and protected, while still allowing for easy assembly and disassembly. The method typically comprises using glass reinforced plastic, GRP to provide the first encapsulated portion. The splice portions can also be treated so as to form a protective barrier against environmental factors, such as moisture and corrosion. This treatment may include for example a galvanizing process, a painting process, or could include encapsulating the splice region withing a GRP. This can be done prior to packing the sections for transport. The use of glass reinforced plastic (GRP) for encapsulating the steel members offers high strength-to-weight ratio, ensuring that the formwork panels are both lightweight and capable of withstanding substantial loads. GRP encapsulation provides excellent resistance to a wide range of chemicals and environmental conditions, which is particularly beneficial in harsh construction environments and contributes to the longevity of the formwork panels. The ability to pack the formwork sections as separate parts significantly enhances the transportability and storage efficiency of the system, reducing logistics costs. The method may further comprise: unpacking 430 the separate parts at a construction site; aligning 440 the steel members of each of the splice portions to one another; fixing 450 the steel members of each of the splice portions to one another to form a splice region, thereby forming a formwork panel; pouring 460 concrete onto the formed formwork panel. Typically, the method will additionally include the placing of the assembled formwork panel onto supporting beams or other support members of the structure - this can be effected prior to fixing the splice portions to one another or in other configurations an assembled panel may be moved into position post fixing. In a development, the method further comprises in the splice region the steel members of respective first and second formwork sections being aligned longitudinally prior to fixing these one to the other. The longitudinal alignment of steel members in the splice region ensures a continuous and consistent load path across the formwork sections, which enhances the structural integrity of the assembled formwork system. By aligning the steel members longitudinally, the method facilitates a seamless connection between formwork sections, resulting in a uniform and smooth surface on the finished concrete structure. The precise alignment of steel members can reduce the time and labor required for assembly, as it simplifies the positioning and connection process during formwork construction. In a development, the method further comprises in the splice region the steel members of the respective first and second formwork sections being bolted to one another. It will be understood however that bolting is an example of a fixing arrangement whereby the steel members are secured to one another. Bolting, or otherwise fixing, the steel members of adjacent formwork sections together in the splice region provides a robust and secure connection that can withstand the high loads and pressures associated with concrete pouring and curing processes. It will be appreciated however that the use of bolts for connecting steel members allows for easy disassembly and reassembly of formwork sections, which enhances the reusability of the formwork and reduces material waste. The bolting method enables quick and efficient on-site adjustments and repairs, as bolts can be readily tightened or replaced if necessary, ensuring minimal downtime and maintaining construction schedules. It will be appreciated that by providing a modular construction that flexibility in design of the ultimately provided formwork is enhanced. In an initial design process, the desired use of the formwork can be used in creating bespoke sections that can be coupled together to form a continuous formwork within which concrete can be supported during a setting process. Typical dimensions for the individual sections are 5m and 1.5m however, these sections could be made to larger or smaller sizes, project dependent. The sections are designed to be bolted together in a splice region using high-strength bolts. Once in situ, the sections are bolted together using the high-strength bolts, which are tightened to an engineered specification torque, typically of the order of 90NM. This creates a continuous formwork structure. It will be appreciated from the above that at least some of the sections are encapsulated in a Glass Reinforced Plastic (GRP). The GRP is applied at a thickness of minimum 3 millimeters and is allowed to cure for 24 hours at a typical temperature range of 20-35 degrees Celsius. After the GRP has cured, the formwork is disassembled into its individual sections. The sections are then packaged separately for shipping. The formwork sections are transported to the construction site and reassembled using the high-strength bolts. As part of the fixing 450, and if the fixing is effected using a set of bolts (such as shown in Figure 5 and 6), the bolts 500 are tightened to a sufficient torque to ensure a secure and stable connection. The splice region is typically orientated relative to a bearing plate / flange 320, that provides a support surface that at least partially overlaps with the encapsulated regions 115. A seal may be provided between the two so as to ensure that concrete that is poured from above will not leak out along the sides of the bearing plate / flange 320. Upstanding lugs or reinforced bars 330 may extend up from the bearing plate 320. These can be coupled to the steel members of the splice region and project above an upper surface 340 of the planar formwork sections. Once the seal is formed, then the formwork is filled with concrete. The concrete is poured into the formwork in layers, with each layer being compacted using a concrete vibrator. The curing of the concrete will be done in accordance with industry standards, for example the concrete may be allowed to cure for 28 days at a temperature of 20 degrees Celsius. After the concrete has gained its initial strength, the formwork is left in place and contributes to the load carrying capacity of the structure. It will be appreciated from Figure 3 that the lugs or bars 330 project into the concrete and provide further reinforcement. This embodiment provides a method for constructing a structure using modular formwork that is easy to transport and assemble and contributes to the load carrying capacity of the structure thereby speeding up construction and reducing waste and cost. It will be appreciated that a formwork per the present teaching addresses problems, challenges and limitations associated with the current technology. One of the main issues is the constraint on the dimensions of the formwork that can be shipped due to the size of the shipping containers. This limitation can make it difficult or impossible to transport and assemble large formwork panels, particularly for structures with increased clear spans or cantilever sections. This is addressed in accordance with the present teaching by providing a modular construction that facilitates disassembly for transportation purposes and a secure mechanism for subsequent reassembly at the point of use. It will be understood that exemplary arrangements of formwork designed in multiple sections, each having steel members that can be bolted together in a splice region to connect a first section to a second section have been described. This modular design allows for easier transportation and assembly on-site, overcoming the constraints of shipping container sizes. After the sections are fixed together, they may be encapsulated in a Glass Reinforced Plastic (GRP). This encapsulation not only protects the formwork during transportation but also adds structural integrity to the formwork, enhancing its load-carrying capacity. The modular design allows the sections to travel separately before assembly on-site. This enables them to be packaged more densely in shipping containers, reducing transportation costs and time. The use of bolts or other fixing members for connecting the formwork sections simplifies the assembly and disassembly process, reducing the time and labor required compared to the current technology. The invention of modular formwork with steel members that can be bolted together and encapsulated in GRP has significant application prospects in the field of civil, structural, and construction engineering. It addresses the challenges associated with the current technology, such as the constraint on the dimensions of the formwork that can be shipped, the time-consuming and labor-intensive process of assembling and disassembling the formwork, and the unsuitability of the formwork for all types of structures or building designs. In the field of civil engineering, this technology can be used in the construction of roads, bridges, dams, and other large-scale infrastructure projects. It can facilitate the construction of larger and more complex structures that were previously not possible due to the constraints of traditional formwork systems. In the field of structural engineering, this technology can be used in the design and construction of 5 bridges, buildings and other structures with increased clear spans or cantilever sections. It can also be used in the construction of high-rise buildings, where the load-bearing capacity of the structure is a critical factor. In the field of construction technology, this technology can significantly speed up the construction process by reducing the need for extensive formwork and falsework. It can also reduce the overall cost and duration of a 10 construction project by simplifying the process of assembling the formwork. Given the increasing demand for efficient and cost-effective construction methods, this invention has significant market potential. It can meet the needs of both contractors and developers by providing a more flexible, efficient, and cost-effective solution for formwork construction. 15

Claims

1. A modular permanent formwork panel comprising:a first formwork section and a second formwork section,wherein each of the first and second formwork sections comprise a plurality of steel members, each formwork section comprising a first encapsulated portion wherein the plurality of steel members are encapsulated and a second splice portion configured such that when the first and second formwork section are coupled together through a fixing of the steel members of their respective splice portions, a splice region is defined.

2. The formwork panel of claim 1 wherein the first encapsulated portion comprises the plurality of steel members encapsulated in glass reinforced plastic, GRP.

3. The formwork panel of claim 1 or 2 wherein, on fixing the steel members of the respective splice portions to one another in the splice region the steel members of respective first and second formwork sections are aligned longitudinally.

4. The formwork panel of claim 3 wherein in the splice region the steel members of the respective first and second formwork sections are bolted to one another.

5. The formwork panel of any preceding claim wherein the first formwork section is a planar section, and the second formwork section is a non-planar section.

6. The formwork panel of claim 5 wherein the second formwork section has a non-vertical, such as L-shaped, upstand profile.

7. The formwork panel of claim 6 wherein the non-vertical profile has a horizontal base portion and a non-horizontal upright portion.

8. The formwork panel of claim 7 wherein the splice region is formed in the base portion.

9. The formwork panel of any preceding claim wherein the splice portions define a skeletal structure.

10. The formwork panel of any preceding claim further comprising at least a third formwork section coupled to at least one of the first or second formwork sections.

11. A method of forming a modular permanent formwork panel comprising a first formwork section and a second formwork section, wherein each of the first and second formwork sections comprise a plurality of steel members, the method comprising:Providing each formwork section with a first encapsulated portion wherein the plurality of steel members are encapsulated and a second splice portion wherein the plurality of steel members are exposed;packing the separate parts for shipping.

12. The method of claim 11 further comprising, at a construction site:unpacking the separate parts;aligning the steel members of each of the second exposed portions to one another;fixing the steel members of each of the second exposed portions to one another to form a splice region;pouring concrete onto the formwork panel.

13. The method of claim 12 further comprising placing components of the formwork panel onto a supporting member prior pouring the concrete.

14. The method of any one of claims 11 to 13 wherein the first encapsulated portion comprises the plurality of steel members encapsulated in glass reinforced plastic, GRP.

15. The method of claim 12 wherein in the splice region the steel members of respective first and second formwork sections are aligned longitudinally.5 16. The method of any one of claims 12 to 15 wherein in the splice region the steel members of the respective first and second formwork sections are bolted to one another.Application No: GB2410162.8Examiner:Mrs Judith PeakeClaims searched: 1-16Date of search: 10 January 2025Patents Act 1977: Search Report under Section 17Documents considered to be relevant:Category Relevant to claims Identity of document and passage or figure of particular relevance A EMJ Plastics LTD, 2024. 'PERMADEC- GRP PERMANENT FORMWORK' showing steel members encapsulated in GRP to form deck panel. Available from https: / / www.emiplastics.com / wp-content / uploads / 2019 / 08 / permadec-tech-doc-brochure.pdf Accessed via the Wayback Machine Internet archive. Dated 17th Feb 2024. A - US2002 / 088194 Al (RAY T FORMS INC) plastic form constructed from form sections with spliced edges A - US2005 / 210793 Al (HALDANE- WILSONE et al) Encapsulated steel straps 16 protruding at edges, but these are for attachment to the first and second support beams and not for splicing to another channel section, Fig 1. A - CN118600848 A (SHANDONG HIGHWAY &BRIDGE CONSTRUCTION GROUP) Stay in place formwork panel (Fig 1) with connections 5 to the support beams 7 A Construction and Building Materials, April 2009. Hanus J.P et al, Combined loading of a bridge deck reinforced with a structural FRP stay-in-place form'. Elsevier Science B.V Netherlands. ISSN 0950-0618. Published electronically 2008-01-14. Institute of Engineering and Technology 2009. A Construction and Building Materials, January 2018. Zuo Yize, Liu Yuqing, He Jun 'Experimental Investigation on Hybrid GFRP-concrete decks with T shaped perforated ribs subjected to negative moment' Elsevier Science B.V Netherlands. Published electronically 2018-04-13. Institute of Engineering and Technology 2009. ISSN 0950-0618Categories:X Document indicating lack of novelty or inventive step A Document indicating technological background and / or state of the art. Y Document indicating lack of inventive step if combined with one or more other documents of same category'. P Document published on or after the declared priority date but before the filing date of this invention. & Member of the same patent family E Patent document published on or after, but with priority' date earlier than, the filing date of this application.Field of Search:International Classification:Subclass Subgroup Valid From E04G 0009 / 05 01 / 01 / 2006 E01D 0019 / 00 01 / 01 / 2006 E01D 0019 / 12 01 / 01 / 2006 E04G 0009 / 00 01 / 01 / 2006 E04G 0009 / 10 01 / 01 / 2006 E04G 0017 / 04 01 / 01 / 2006

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