A formwork frame and method

Abstract

A formwork frame (50, Fig. 23) for locating footings in concrete foundations during a concrete pour suitable for a structure to which solar panels can be mounted, the formwork frame including: lengthw

Description

FIELD OF INVENTION

[0001] The present invention relates to a formwork frame and a method of setting out and pouring foundations for footings of the structure for mounting solar panels. The structure may be mounted over any suitable terrain and may ideally be used in solar farms for generating electrical power. BACKGROUND

[0002] Solar panels for generating electrical power can be mounted in a range of situations including mounting solar panels to roofs of existing structures such domestic, industrial and semiindustrial installations. The structures used for mounting solar panels in these situations are purposely design and constructed to suit the type of roofing structure such as tiled roofs, or corrugated iron roofs, having many different pitches and slopes.

[0003] Solar farms have purpose built structures for solar panels and are constructed with the aim of generating significantly more power than most roof top installations. Solar farms maximise power generation by optimising the exposure of solar panels to the sunlight. Typically solar farms have rows of solar panels that are arranged at the same or a similar orientation to face at an angle toward the sun and are not impacted by architecture of existing buildings to which the solar panels are installed.

[0004] One of the constraints of arranging solar panels at an angle is that they cast a shadow and when the sun is lower in the sky during days of shorter daylight hours, the panels are oriented more upright due to sun angle which casts larger shadows. To reduce this impact, rows of the panels are typically spaced apart to reduce the extent and period in which panels are in the shadow cast by another row.

[0005] In addition, providing the layout and erection of footings for a solar panel structure can be a time-consuming and labor intensive activity. Generally speaking, footings are laid out on an individual post-by-post basis using a string line method. String lines are first arranged between profile boards which denote lines on which holes need to be excavated at spaced intervals. After the holes are excavated, an amount of concrete is poured into each hole to partially fill the hole and a footing can then be placed in the concrete. A person installing the footing then maneuvers the footing to achieve vertical plumb using a spirit level or a similar tool. This may require the base of the footing to be lifted and moved within the hole as needed in addition to moving the top of the footing. The person installing the footing also maneuvers the footing upward and downward in the concrete to achieve the correct height of the footing relative to the string line. Each footing is manually held during this procedure and requires the footing to have been immersed in the concrete in the hole to retain the footing in the correct orientation, location and height when the footing is released by the person installing the footing. Each hole can then either be filled with concrete or backfilled with excavated material, however, during the filling step care needs to be taken so as not to move the footing from the correct position. SUMMARY OF THE INVENTION

[0006] An embodiment relates to a formwork frame for locating footings in concrete foundations during a concrete pour for a structure to which solar panels can be mounted, the formwork frame including: lengthways members, widthways members attached laterally to the lengthways member, and multiple pre-set mountings being directly or indirectly connected to one or both of the lengthways member and / or the widthways member for releasably attaching footings to the formwork frame so the footings can extend downward from the formwork frame into foundation holes; wherein the pre-set mountings are arranged in a grid arrangement including: i) pairs of the pre-set mountings being arranged in a direction of the widthways members, and ii) lines of the pre-set mountings being arranged in the direction of the lengthways members; and legs that support the formwork frame above the ground, the legs having an adjustable effective length from the formwork frame to the ground, the being adjustable so that the formwork frame can be oriented in a desired planar arrangement which will locate footings attached to the formwork frame in a desired position while concrete is being poured into the foundation holes.

[0007] The structure that can be erected on the footings may have any architecture for mounting solar panels. By way of example, the structure may have a gable roof, a skillion roof, a saw tooth roof, an inverted gable roof also referred to as a butterfly roof, and so forth.

[0008] The pre-set mountings may be located on the formwork frame so that the footings attached to the pre-set mountings are in the desired layout corresponding to the required position of the posts of the structure to be assembled on the footings.

[0009] The pre-set mountings may be located at an intersection of the lengthways and the widthways members, and the lengthways members and the widthways members have a predetermined length so that the footings are located in the desire layout.

[0010] The footings can be located in a desired planar arrangement relative to each other by being fixed to the pre-set mountings, including a horizontal plane, or a plane substantially parallel to the topography of the ground on which the footings are arranged.

[0011] By adjusting the effective length of the legs on which the formwork frame is supported, the footings can be attached to the pre-set mountings to locate multiple footings, and suitably all of the footings attached to the formwork frame in the desired height.

[0012] The position of the footings can be attached to the formwork frame can be adjusted in a horizontal plane by moving the legs over the ground. At least one diagonal member that interconnects: i) two of the widthways members, ii) two of the lengthways members, or ill) one of the widthwise members and one of the lengthways members so as to brace the formwork structure in a squared rigid configuration or a squared grid configuration.

[0013] The lengthways members and the widthways members may define an outer perimeter and the adjustable legs are located inward of the outer perimeter.

[0014] The legs may be attached to the widthways members inward of the pre-set attachment points.

[0015] The legs may have a longitudinal slot that receives a threaded pin of the frame that can move along the slot to allow the effective length of the leg below the frame to be adjusted, and a threaded nut can be tightened on the threaded pin to secure the leg in an operative position in the slot.

[0016] The formwork frame may include a stabilizer piece to which the legs abuts when the leg is in an upright orientation.

[0017] The pre-set mountings may extend outward from the lengthways member.

[0018] The pre-set mountings may be located outward of lengthways members and the widthways members.

[0019] The formwork frame may include pairs of the pre-set mountings, one of the pairs being arranged in the direction of the widthways members, and a line of the pairs extending in a direction of the lengthways members.

[0020] The pre-set mountings have two fastener attachments for releasably attaching the footings.

[0021] The formwork frame may be disassembled and the lengthways members used as purlins of the structure to which the solar panels can be mounted. The purlins are attached to the widthways members using screw fasteners. The widthways members may be used as rafters or posts of the structure to which the solar panels can be mounted.

[0022] The pre-set mounting is connected to either one or both of the lengthways or widthways members so that the footings attached thereto are spaced outwardly of the lengthways members by a spacing ranging from 0.2 to 0.5m, and suitably from 0.3 to 0.5m.

[0023] Each of the pre-set mountings may include: i) two opposite limbs on opposite sides to which the lengthways members of the formwork can be connected, and ii) a third lateral limb to which the widthways members can be connected, wherein the lengthways members can be connected to at least one of the opposite limbs in two possible positions, thereby enabling the spacing between the footings connected to the pre-set mountings at opposite ends of the lengthways members to be set at different spacings by selecting the position at which the lengthways member is connected to the pre-set mountings.

[0024] The pre-set mounting may include a stiffening member extending between one of the opposite limbs to which to which the lengthways members can be connected and the third lateral limb to which the widthways member is attached.

[0025] One of the two opposite limbs extending outwardly in opposite directions from the pre-set mounting has at least two possible positions at which the lengthways members can be connected.

[0026] The pre-set mounting may include detachable extension pieces that are releasably connect to the pre-set mountings and extend outwardly therefrom so that footings for the structure can be attached to the pre-set mountings at a spacing outwardly from the formwork frame. The detachable extension piece may be substantially in plane with the formwork frame when attached thereto. The detachable extension piece can be detached from the formwork frame to allow access for excavation of the foundation holes.

[0027] The detachable extension piece may have a first end that can be releasably attached to the pre-set mountings, and a second end providing an outer pre-set mounting to which the footings can be attached.

[0028] The extension piece has a length so that the outer pre-set mounting is in the range 0.5 to 1.2m outward from the lengthways members, and suitably in the range of 0.7 to 1.0m from the lengthways members.

[0029] A method of setting out foundations for a structure to which solar panels can be mounted using the formwork frame of any one of the preceding claims.

[0030] A method of setting out foundations for a structure to which solar panels can be mounted, the method including the stepsof: locating a formwork frame on terrain where the structure is to be erected, in which the locating step includes assembling lengthways members, widthways members attached laterally to the lengthways member, multiple pre-set mountings being directly or indirectly connected to one or both of the lengthways member and / or the widthways member for releasably attaching footings to the formwork frame so the footings can extend downward from the formwork frame into foundation holes; wherein the pre-set mountings are arranged in grid including i) pairs of the pre-set mountings being arranged in a direction of the widthways members and ii) lines of the pre-set mountings being arranged in the direction of the lengthways members; and excavating foundation holes in the terrain beneath the pre-set mountings; releasably attaching footings of the structure to the formwork frame so as to suspend the footings in the foundation holes; adjusting the height of the formwork frame so that the formwork frame is oriented into a desired planar arrangement which will locate footings attached to the formwork frame in a desired position; and pouring concrete into the foundation holes to anchor the footings in the foundation holes.

[0031] The method may include a preliminary step of setting out string lines that mark the locate the foundation holes, and the step of locating the formwork template includes maneuvering the formwork template relative to setting out string lines.

[0032] The step of adjusting the height of the formwork may include changing the effective length of adjustable legs on which the formwork is supported.

[0033] The step of assembling the formwork frame may include connecting the pre-set mounting to either one or both of the lengthways or widthways members so that the footings attached thereto are located outwardly from the lengthways member at a spacing in a range from 0.2 to 0.5m, and suitably from 0.3 to 0.5m.

[0034] Each of the pre-set mountings includes: i) two opposite limbs on opposite sides to which the lengthways members of the formwork can be connected, and ii) a third lateral limb to which the widthways members can be connected, and wherein the method may include connecting the lengthways members to one of the opposite limbs in one of two possible positions, thereby enabling the spacing between the footings connected to the pre-set mountings at opposite ends of the lengthways members to be set at different spacings by selecting the position at which the lengthways member is connected to the pre-set mountings.

[0035] The method may include connecting detachable extension pieces to the formwork frame so that the extension pieces extend outwardly from the formwork frame to provide an outer pre-set mounting so footings can be attached to the outer pre-set mountings at an increased spacing from the formwork frame, and detaching the extension pieces during excavation of the foundation holes.

[0036] The detachable extension pieces may have a first end that can be releasably attached to the pre-set mountings, and a second end providing an outer pre-set mounting to which the footings can be attached.

[0037] The method may include disassembling the formwork frame and using the lengthways members as purlins of the structure to which the solar panels can be mounted.

[0038] The present invention relates to a structure for mounting solar panels, the structureincluding: a first frame that faces upwardly at an angle toward a first cardinal direction, and the first frame extends in a lengthways direction that is lateral to the first cardinal direction, such as in a north-south orientation; a second frame that faces upwardly at an angle toward a second cardinal direction, and the second frame extends in a lengthways direction that is lateral to the second cardinal direction, such as in a north-south orientation; wherein the first cardinal direction and the second cardinal direction are away from each other, and wherein the first and second frames are arranged side-by-side, with the first and second rafters being connected at a central ridge or a central trough of the structure, and the first and second posts are spaced from outer ends of the first and second rafters so that the first and second rafters form an overhang located outwardly of the first and second posts.

[0039] The first frame having a first plane that faces upwardly in the first cardinal direction, and the second frame having a second plane that faces upwardly in the second cardinal direction.

[0040] The first and second cardinal directions may be opposite. For example, the first cardinal direction may be in an easterly direction, the second cardinal direction may be in a westerly direction, and the lengthways direction may be in a north-south orientation. In other words, the first cardinal direction may be toward the sunrise, and the second cardinal direction may be toward the sunset.

[0041] Depending on the gradient of the terrain on which the structure is assembled, either one or both of the first and second planar faces may be curvilinear in at least the lengthways direction. It may also be possible for the first and second planar faces to be curvilinear in a width-ways direction.

[0042] The structure and formwork frame may be any suitable material, including wood, steel, engineered products including polymeric materials, and laminates of different materials. Ideally, the structure is coated with a corrosion inhibiting coating such as galvanised coated, or a zinc and aluminium coating such as zincalume™. In one example, any part of the structure that is positioned in the ground may have a galvanised coating, and any part of the structure above ground may be coated with a coating including zinc and aluminium.

[0043] The structure can be used for mounting solar panels having a frame made of any suitable material, including aluminium and alloys containing aluminium.

[0044] In the gable formation, the first and second planes face away from each other. In otherwords, an angle between the first and second planes is greater than 180 degrees. In one example, the planes may be arranged at an angle in the range of 200 to 240 degrees, and even more preferably, the planes may be arranged at an angle of approximately 196 to 200 degrees, and yet even more suitably, the planes may be arranged at angle of approximately 198 degrees.

[0045] In the valley formation, the first and second planes face toward each other. In other words, an angle between the first and second planes is less than 180 degrees. In one example,the planes may be arranged at an angle in the range of 170 to 120 degrees, and even more preferably, the planes may be arranged at an angle in the range of 150 to 160 degrees, and even more suitably in the range of approximately 154 degrees.

[0046] The shadow cast by solar panels mounted to either the first or second frames is dependent on number of factors, include the orbit of the sun over the sky. However, one of the benefits of the present invention is that when one of the first and second frames is directly radiated by sunlight, shadows from the first and second frame is minimised. For example, during sunrise, the first frame will receive direct sunlight, and the second frame position adjacent to the first frame will begin to be radiated directly as soon as the sun rises above the plane of the first frame. Similar, shadow from the second frame will extend over the first frame as soon as the sun falls below the plane of the second frame. One of the benefits of the present invention is that spacing between the first and second frames can be avoided all together, thereby maximising "land usage", minimising cabling, and reducing the foot print of other associated equipment.

[0047] An upper ridge formation may be located at a junction of the first and second frames of the gable formation.

[0048] A lower trough formation may be located at a junction of the first and second frames of the valley formation.

[0049] The structure is ideally ground mounted. For example, the structure may be directed anchored to the ground, and the structure includes posts that can be attached to foundations. The posts may be attached to footings that are embedded in the foundations. The footings may, for example, be screw pile footings, or footings that are embedded in concrete.

[0050] In a preferred embodiment, the posts and footings may each be discrete bodies that are assembled together.

[0051] In another embodiment, the posts and footings may be integrally formed, and may for example have different coatings for portions that can be embedded in a foundation, and portions that are above the foundation.

[0052] In an embodiment, the footings are separable from the posts. The footings may be galvanised.

[0053] The footings may have an elongate section of substantially uniform cross-section that extends into a foundation and above the ground. The footings and the posts are conFigured to fit one within the other. Ideally, axes of the post and the footings are co-axial when assembled. The posts may have a uniform cross-section that inter-fits within the cross-section of the footing. For example, the posts and footings may be sections, such as roll formed sections that inter-fit.

[0054] Either one or both of the footings and the posts may have a locator, such as a locating pin, that is operable to provide a stop when the posts and footings are interfitted in an assembled position. For example, the locating pin may be attached to the post, which engages the footing when inter-fitted, or the locating pin may be attached to the footing, which engages the post when inter-fitted. The posts and footings may be in the assembled position when pre-formed openings on the footings and the posts are aligned for receiving fasteners.

[0055] Ideally, the footings are multi-end so that one end of the footings that can extend to a foundation can also be used as an upper end of the footings above the foundation and vice versa.

[0056] The footings may have apertures through which concrete, including aggregate can flow when wet, the apertures are placed along the footings.

[0057] The footings may have any cross-section, including square tubular shapes, circular tubular shapes, H-shapes, L-shapes and C-shapes. The footings may have a central web. In one example, the central web may be outer wall of a rectangular or square shaped tubular section, or a wall of an L-shaped section.

[0058] In the situation in which the footings have a C-shaped cross-section, the C-shape has a central web and two side flanges extending from the web facing toward each other. The locating pin, such as a nut and bolt fastener, may extend between the flanges at a positioned above the ground, and engage a lower end of the posts to locate the posts in an operative position. Suitably, the lower end of the post engages an inside the two side flanges.

[0059] The posts and the footings may have preformed fastener openings that align when the posts are seated on the locating pin that allow fasteners, such as nut and bolt fasteners to connect the posts to the footings.

[0060] The preformed fastener openings may be provided at one end, but preferably at both ends of the footings.

[0061] Ideally, the posts can be received inside the footings.

[0062] The posts and the footings may each have first and second central webs, respectively, that are located against each other when the posts and footings are inter-fitted. The first and second central webs may be flat planar plates. The posts and footings may have at least one flange extending from the first and second central webs respectively.

[0063] The posts may also be made of any suitable section, including square tubular shapes, circular tubular shapes, H-shapes, L-shapes and preferably C-shapes. The posts may have a central web. In one example, the central web may be an outer wall of a rectangular or square shaped tubular section, or a wall of an L-shaped section.

[0064] The posts of the structure ideally extend upright and support the first and second frameworks in an operative position above the ground. The posts may be C-shaped which includes the first central web and side flanges extending from the first central web. The side flanges and first central web may form a channel along the length of the post. The channel is open along a majority of the length of the post. Suitably, the channel is open along the entire length of the post.

[0065] The first and second frames have opposite ends, such as north and south facing ends, and the structure may have end posts and a least one intermediate post between the end posts to form two lines of the posts. One line of posts support the first frame, and one of second posts supports the second frame. In addition, the first and second frames are connected.

[0066] The structure may include pairs of posts in which one of the posts (of each pair) supports either the first frame or the second frame respectively, and a pair of rafters span between the posts of each pair of posts. The pairs of post and the corresponding pairs of rafters joined to the posts spans from the first frame to the second frame to provide a standing sub-structure. Spaces between each standing sub-structure defined a bay. The structure may have any number of bays. For example, depending the particular application, the structure may have in the range of 3 to 25 bays, suitably from 5 to 15 bays, or even more suitably in the range of 6 to 12 bays.

[0067] In a preferred embodiment, the rafters that are connected to each post.

[0068] Ideally the rafters are located directly over the posts, and a haunch bracket interconnects the rafter to the respective post.

[0069] The rafters may have any suitable cross-section. The rafters may have a third central web and at least one flange extending from the third central web. In one example, the rafters may have a C-shaped cross-section in which the third central web is oriented upright, and top and bottom flanges extend from the central web.

[0070] The haunch bracket includes a main plate and at least first and second outer flanges extending outwardly from the same side of the main plate. The main plate may be located flush with the post and the rafter. Ideally, the rafter is located so that the first and third central webs of the post and the rafter are aligned, and the main plate of the haunch bracket can be located against the first central web of the post and third central web of the rafter. The first outer flanges of the haunch bracket extend about a side flanges of the post and the second outer flange extends about either one of the top or bottom flanges the rafter. Suitably, the second outer flange of the haunch plate extends about and engages the top flange of the rater. The side flanges of the post and the top and bottom flanges rafter may all extend in the same direction relative to the first and third central webs. Fasteners, such as self- drilling screws, tek screws, or nut and bolt fasteners can attach the haunch plate to the post and the rafter.

[0071] The structure may have a lengthwise beam extending between end posts of the first and second frames. The lengthwise beam may also extend between the end posts, or between the end posts and the, or each, intermediate post. The beam may also extend between multiple intermediate posts. The beam may be a fascia beam.

[0072] In a preferred embodiment, the first and second frames have parallel rafters extending widthways.

[0073] In this situation, the rafters may be parallel in plan view. The rafters may also be arranged at a first angle of inclination.

[0074] The rafters of the first frame and of the second frame may be connected at an apex of the gable formation or at the trough of the valley formation.

[0075] The structure may include a junction bracket that interconnects the rafters at the apex or at the trough.

[0076] The junction bracket may have i) a base web that can be located on the third central web of the rafters of the first and second frames and ii) a pair of flanges, in which each flange is arranged at an angle to the other and engages the top flanges of the rafters of the first and second frames. Ideally, the pairs of flanges are at an angle that corresponds to the angle between the rafters of the first and second frames. Fasteners can be used to fix the junction brackets to the rafters.

[0077] The junction bracket may also have a bottom flange that extends between the rafter of the first and second frames. Suitably, the bottom flange engages the rafters of the first and second frames.

[0078] The structure defines bays between each pair of post and each pair of rafters of the first and second frames connected to the posts.

[0079] The battens may extend over the rafters in a lengthways direction of the first and second frames. Ideally each batten comprises a plurality of purlins arranged in the line so that adjacent purlins overlap and are connected together so as to be able topivot about longitudinal axes of the purlins. The pivot connection may be provided by a single fastener interconnecting the purlins.

[0080] The purlins may be of any suitable cross-section, but ideally have a Z-shaped section, including a fourth central web, and top and bottom flanges. The top and bottom flanges extend outward from opposite sides of the plane of the fourth central web.

[0081] The top and bottom flanges of the purlins may have a lip and electrical cabling can be accommodated under the top flange or on top of the bottom flange and secured in position using tie downs, such as cable ties, ziplock ties, fabric tie downs and so forth.

[0082] At least one of the purlins may be arranged on the haunch plate. The purlins may be attached using fasteners. The fastener attaching the purlins on top of the haunch plate, can fasten the purlin to the haunch plate and to the rafter, and indirectly to the post to which the haunch plate is connected. In other words, locating the purlin on top of the rafter in this manner provides addition rigidity to the structure.

[0083] The first and second frames may have any number of the purlins. For example, the frames may have two purlins for each solar panel.

[0084] Solar panels may be attached to the purlins without cladding extending between the purlins. Ideally, the purlins have pre-installed holes for securing solar panels to the purlins. If required, isolation members may be located between the solar panels and the purlins to minimise galvanic reaction therebetween. In addition, isolation members may also be located between the purlins and the rafters. The isolation members may be any suitable polymeric membrane, including polypropylene sheets and polyethylene sheets.

[0085] The structure may also be characterized by having solar panels mounted thereon. The solar panels may be arranged in rows and ranks. For example, each bay may have 4 rows and 4 ranks of the solar panels. Specifically, each bay of the first frame may have 2 rows and 4 ranks of the solar panels, and each bay of the second frame may have 2 rows and 4 ranks of the solar panels.

[0086] The present invention also relates to a method including the stepsof: locating a formwork frame on the terrain where the structure is to be erected; excavating foundation holes in the terrain to be erected; attaching the footings of the structure to the formwork frame at the designated locations so as to suspend the footings in the foundation holes; adjusting the height of the formwork frame to position the footings at a desired height; and pouring concrete into the foundation holes to anchor the footings in the foundation holes.

[0087] The present invention also relates to a method of assembling the structure for mounting solar panels described herein, the method including the stepsof: locating a formwork frame on the terrain where the structure is to be erected; excavating foundation holes in the terrain to be erected; attaching the footings of the structure to the formwork frame at the designated locations so as to suspend the footings in the foundation holes; adjusting the height of the formwork frame to position the footings at a desired height; and pouring concrete into the foundation holes to anchor the footings in the foundation holes.

[0088] Locating the formwork frame may include manually maneuvering the formwork frame relative to setting out strings that have been installed in a preliminary step.

[0089] Excavating the foundation holes maybe are carried out manually or with the assistance of an auger. Identifying the location of the foundation holes may be performed using the setting out strings or via the formwork frame.

[0090] Ideally the footings are attached to the formwork frame using fasteners to prevent pivoting movement of the footings.

[0091] Adjusting the height of the formwork may include levelling the formwork frame by chocking the formwork frame.

[0092] Adjusting the height of the formwork may include changing the effective length of the legs on which the formwork is supported. The effective length of the legs may be operable for locating the formwork frame in a desired plane, such as a horizontal plane or in a plane substantially parallel to the slope of the terrain. In one example, the legs may be adjustable legs having a screw threaded rod that is adjusted up and down by rotating the rod. In another example, the adjustable legs may have an elongated slot and the formwork has a pin that moves along the slot to adjust the point of connection between the formwork frame and the point at which the formwork is attached to the leg.

[0093] The method may also include erecting the structure for mounting solar panels described herein.

[0094] The steps of the method of the present invention may be carried out concurrently, consecutively or disjunctively with one or more pauses between each step.

[0095] Once the concrete has set, the formwork frame can be removed from the footings and relocated for erecting the next set of footings.

[0096] An embodiment relates to a structure for mounting solar panels, the structureincluding: a first frame that faces upwardly and at an angle toward a first cardinal direction, and the first frame extends in a lengthways direction that is lateral to the first cardinal direction, and the first frame has at least two posts, in which each post supports a first rafter that extends widthways; a second frame that faces upwardly and at an angle toward a second cardinal direction, and the second frame extends in a lengthways direction that is lateral to the second cardinal direction, and the second frame has at least two posts, in which each post supports a second rafter that extends widthways; wherein the first cardinal direction and the second cardinal direction are away from each other, and wherein the first and second frames are arranged side-by-side and form either a gable formation or a valley formation.

[0097] An embodiment of the present invention relates to a formwork frame for locating footings in concrete foundations during a concrete pour, the formwork frame having: an outer perimeter frame that extends about the foot print of the structure, wherein the outer perimeter includes lengthways members, and widthways members, wherein the outer perimeter having pre-set attachment points for attaching footings to the outer perimeter; at least one diagonal member that interconnects spaced parts of the outer perimeter frame, and the diagonal members ideally interconnected adjacent widthways members; and the outer perimeter having pre-set attachment points for attaching footings to the outer perimeter.

[0098] An embodiment relates to a structure for mounting solar panels, the structure including: a first framework defining a first upward planar surface, (hereafter the first plane,) in which the first planar surface is also conFigured to face in a first co-ordinate direction, and the first framework being arranged to extend in a north-south orientation, a second framework defining a second upward planar surface, (hereafter the second plane,) in which the second plane is also conFigured to face in a second co-ordinate direction, the second framework being arranged to extend in a north-south orientation, wherein the first co-ordinate direction and the second co-ordinate direction are opposite, and wherein the first and second frameworks are arranged side-by-side and form either a gable formation or a valley formation.

[0099] The present invention relates to an installation having a plurality of the structures described herein that are arranged side-by-side, in which the first frames of one of the structures is located adjacent to the second frame of another of the structures, so that at least two of the first frames are separate by one of the second frames, and at least two of the second frames are separated by one of the first frames.

[0100] The structures may be arranged side-by-side, in which the structures are arranged adjacently in either an easterly or westerly direction relative to the other.

[0101] Suitably, solar panels are mounted to the first and second frames of the structures of the installation.

[0102] In one embodiment, a gap may be provided between the solar panels of the first and second frames of the structures arranged side-by-side. The gap may allow vehicle access or maintenance access between the structures.

[0103] In another embodiment, little or no gap may be provided between the solar panels on the first and second frames of the structures arranged side-by-side. That is to say, little or no gap is provided between the solar panels of the first and second frames of adjacent structures. For example, the gap may be less than the length of one solar panel. Suitably, the gap may be less than 50cm. BRIEF DESCRIPTION OF THE FIGURES

[0104] A preferred embodiment of the present invention will now be described with reference to the accompany Figures. A summary of the Figures is as follows.

[0105] Figure 1 is a perspective view of an assembled structure to which solar panels can be mounted, the structure comprising first and second frames defining first and second planes facing in easterly and westerly directions respectively, and the first and second frames extending in a north-south orientation.

[0106] Figure 2 is a side view of the assembled structure shown in Figure 1.

[0107] Figure 3A is a side view of one of the footings and part of one of the posts identified in circle A in Figure 2.

[0108] Figure 3B is an enlarged perspective view of part of the footings shown in Figure 3A.

[0109] Figure 4A is a side view of part of the portion of the structure identified by circle B in Figure 2, comprising of an upper end of a post, on which a rafter is seated and a purlin are shown in cross-section, in which the rafter is interconnected to the post via a haunch plate.

[0110] Figure 4B is a perspective view of the portion of the structure identified by circle J in Figure 1.

[0111] Figure 4C is an enlarged view of the rafter and purlin identified by circle C in Figure 2.

[0112] Figure 5A is a perspective view of the portion of the structure shown in circle G in Figure 1, comprising rafters of the first and second frames being interconnected by a junction plate.

[0113] Figure 5B is an enlarged side view of the rafters of the first and second frames being interconnected by the junction plate as shown in circle D of Figure 2.

[0114] Figure 6 is an enlarged view of the corner of the structure shown in circle E of Figure 1, comprising a purlin supported on a rafter and a diagonal bracing member.

[0115] Figure 7 is an enlarged view of the rafter and a purlins shown in circle F of Figure 1.

[0116] Figure 8 is a perspective view of a formwork frame for locating and supporting the footings within foundation holes during concrete pouring, the formwork frame having positioned for four pairs of footing and corresponding posts.

[0117] Figure 9 is a plan view of the formwork frame shown in Figure 8.

[0118] Figure 10 is a block diagram of method steps for assembling a structure, such as the structure shown and described with reference to Figures 1 to 7, using the formwork frame shown in Figures 8 and 9.

[0119] Figure 11 is a side view of two of the structures shown in Figure 1 interconnected end-to-end in a lengthwise direction of the first and second frames.

[0120] Figure 12 is a plan view of the structure shown in Figure 11.

[0121] Figures 13 and 14 are perspective views of posts and screw pile footings.

[0122] Figures 15 and 16 are enlarged views of the posts and screw footings identified by circles H and I in Figures 13 and 14 respectively.

[0123] Figure 17 is a perspective view of a formwork frame for locating and supporting the footings within foundation holes during concrete pouring, the formwork frame having positioned for five pairs of footing and corresponding posts.

[0124] Figures 18 and 19 are enlarged perspective and side views respectively of the portion of the formwork frame shown in the circle J in Figure 17.

[0125] Figure 20 is top view of the adjustable leg shown in Figures 18 and 19.

[0126] Figure 21 is an isometric view of a formwork frame according to a first preferred embodiment in which the formwork frame is supporting footings of a solar panel structure within foundation holes for concrete pour.

[0127] Figure 22 is a close up view of part of the formwork frame showing a pair of pre-set mountings shown in Figure 21 having footings located in foundations holes.

[0128] Figure 23 is an isometric view of another formwork frame according to a second preferred embodiment in which the formwork frame is supporting footings of a solar panel structure within foundation holes for concrete pour.

[0129] Figures 24 is a closeup view and Figure 25 is a plan view of one pair of pre-set mountings of the formwork frame shown in Figure 23 in which footings are attached to the formwork frame and located in foundations holes.

[0130] Figure 26 is an isometric view of one of the pre-set mountings shown in Figure 24, no footing is attached to the pre-set mounting.

[0131] Figure 27 is an isometric view of one of the pre-set mountings shown in Figure 24, in which an extension piece of the pre-set mounting and the footing have been removed.

[0132] Figure 28 is an isometric view of another the pre-set mountings located in inner left corner of the formwork frame shown in Figure 24. DETAILED DESCRIPTION

[0133] A preferred embodiment of the present invention will now be described with reference to the accompanying Figures. Specifically, the following text includes reference numerals to help identify the corresponding features in the company Figures. To maintain the clarity of the Figures however, not all reference numerals are included in each Figure.

[0134] With reference to the Figures, the structure 10 is ground mounted and has first and second frames 11, 12 arranged side-by-side and interconnected in a gable formation that forms a central ridge extending in the north-south orientation lengthways of the structure 10. Although not shown in the Figures, it is possible that the first and second fames 11 and 12, may be connected in a valley formation.

[0135] The first and second frames 11, 12 including rafters 13 arranged widthways and battens 14 arranged lengthways. The structure 10 includes pairs of posts 15, in which one of the posts 15 (of each pair) supports either the first 11 frame or the second 12 frame respectively, and the rafters 13 span between the posts 15 and are interconnected at the ridge by a junction plate 17, best seen in Figures 5A and 5B. The structure 10 includes multiple pairs of posts 15, in which each pair of posts are interconnected by the rafters 13. In particular, the structure 10 shown in Figure 1 has five pairs of posts 15, totaling ten posts 15, and the posts 15 are arranged in a line under the first and second frames 11 and 12 and define four bays between the posts 15. In addition, the rafters 13 extend outwardly beyond the posts 15 to define an eave or overhang at the side of the structure extending lengthways, see Figures 1 and 2. Figures 1, 2, 11 and 12 also illustrate the battens 14 terminating flush with the sides of the rafters 13. However, it will be appreciated that the battens 14 may extend outwardly of the end rafters 13 at the gable ends if desired.

[0136] As can be seen in Figures 1 and 2, the first and second frames 11 and 12 are arranged at a reflex angle in the range of 200 to 240° and ideally approximately 198° apart. The first frame 11 is arranged to face upwardly and toward a first cardinal direction, namely in an easterly direction. The second frame 12 is arranged to face upwardly and toward an opposite second cardinal direction, namely in a westerly direction.

[0137] The battens 14 are provided in the form of a line of overlapping purlins 18. Solar panels, such as photovoltaic panels housed within aluminium frames can be mounted to the purlins 18 without any cladding between the solar panels and the purlins 18. Ideally the purlins 18 and the other parts of the structure 10 above the ground are made of a carbon steel that is coated with anticorrosion zincalume™ so as to minimise galvanic reaction between the outer solar panels and the structure 10. However, if desired an inert material, such as a polymeric membrane can be located between the solar panels and the purlins 18. Similarly, an inert material can also be located between the purlins 18 and the rafters 13.

[0138] One of the benefits of the structure 10 is that the solar panels on the first and second frames 11, 12 can be positioned closely adjacent to each other, for instance with minimal or no spacing between the solar panels mounted to the first and second frames 11, 12. This reduces the amount of terrain required compared to other mounting systems in which the frames for mounting solar panels are arranged in one direction. In addition, arranging the first and second frames 11,12 in a gable formation or the valley formation allows theshadow of the first frame 11 on the second frame 12 to be minimised while the sun is rising. Similarly when the sun is setting, the shadow of the second frame 12 on the first frame 11 is also avoided as much as possible.

[0139] This benefit can be further utilised when the structure 10 is duplicated in one or more of the north-south directions, as shown in Figures 10 and 11, or in the east-west direction.

[0140] As can be seen in Figures 3A and 3B, the posts 15 and footings 16 are C-shaped sections having first central webs 19 and second central webs 20 respectively, and two side flanges 21, 23 extending outwardly and facing toward each other to form a cavity. As can be seen the cavity of the C-shape of the footings 16, can be sized to receive the posts 15.

[0141] The footings 16 have a set of symmetrical openings along the length of the section so that the footings 16 are a multi-directional in the sense that the top can be used as the bottom and vice versa. Specifically, the footings 16 include fastening holes 26 in the second central web 20 and holes in the side flanges 23 that align with corresponding holes in the first central web 19 andside flanges 21 of the posts 15 that receive nut and bolt fasteners 24 that clamp the footings 16 and posts 15 together.

[0142] The second central web 20 of the footings 16 also includes larger openings 25 for allowing penetration of concrete mortar for securing the footing 16 in position. As can be seen in Figure 3B, a pin 22 in the form of a nut and bolt can be located between the opposite side flanges 23 of the footings 16 which provides a stop member on which a bottom end of the posts 15 can be seated for aligning the fastening holes 26 of the footings 16 and the posts 15.

[0143] The footings 16 are coated with a galvanised coating and can be embedded in concrete foundations of an appropriate size. The structure 10 above the footings 16 are ideally coated with a zincalume™ which is galvanically compatible with the aluminium frames of the solar panels.

[0144] As can best be seen in Figures 4A and 4B, the rafters 13 are in the form of C-shaped sections having an upright third central web 31 and upper and lower flanges 32, 33. The lower flange 33 of the rafter 13 is directly seated on the top end of the post 15, with the upright third central web 31 of the rafter 13 aligns with the first central web 19 of the post 15.

[0145] The posts 15 and footings 16 are arranged so that first and second webs 19 and 20 of the footings 16 and of the posts 15 in each consecutive pairing lengthways of the structure are arranged in opposite directions. For instance, if the first web 19 and the side flanges 21 of the first pair of posts 15 face in a first direction, then the first web 19 and the side flanges 21 of the second pair of posts 15 face in a second direction, which is opposite to the first direction. Similarly, as the third webs 31 of the rafters 13 align with the first webs 19 of the posts 15 on which the rafters 13 are seated, the third webs 31 of consecutive rafters in a lengthways direction also face in opposite directions. By alternating the positioning of the first and second webs 19 and 20 of the posts 15, rafters 13 and footings 16 in this way, the rigidity of the structure is improved.

[0146] In addition, the posts 15 and footings 16 define an elongate open channel along the length of the posts 15 and the footing 16 that are located above the ground. The elongate channel does not require a cover to provide structural rigidity. If electrical cabling is located in the channels, a cover may be provided over the channels to protect the cabling. However, the cover is not required to provide structural rigidity. Similarly, the rafters 13 define an open channel along their length that can be accommodate electrical cabling.

[0147] A haunch plate 27 is used to securely interconnect an upper end of the post 15 and the rafter 13 on top of the posts 15. The haunch plate 27 includes a main plate 34 having a triangular section, best seen in Figure 4A, and first and second locking flanges 29, 28 extending from adjacent sides of the main plate 34. The haunch plate 27 is installed so that the main plate 34 sits flush against the first central web 19 of the post 15 and the upright third web 31 of the rafter 13. The first and second locking flanges 29, 28 extend about the top flanged 32 of the rafter 13 and an outer flanged of post 15. Nut and bolt fasteners 35 can be used to secure the haunch plate 27 to the third central web 31 of the rafter 13 and to the first central web 19 of the post 15. Fasteners 35 can also be used to fix the first locking flange 29 to the top flanged 32 of the rafter 13 and fix the second locking flange 28 to an outer flanged of the post 15.

[0148] A spacing is provided between the first and second locking flanges 29, 28 which accommodates the rafter 13 as it extends outwardly of the post 15. As can best be seen in Figures 1 and 2, the rafters 13 overhang outwardly of the posts 15 to form an eave.

[0149] The rafters 13 of the first and second frames 11, 12 extend inwardly of the posts 15 and interconnect at a central ridge that extends in a north-south direction. The ends of the rafters 13 are square cut and are interconnected by a junction bracket 17 including a base web 36 that is located flush against the third central webs 31 of the rafters 13 and an upper angled flanged 37 having first and second portions that extend over the top flange 32 of the rafter 13. The first and second portions of the upper angled flange 37 are ideally angled to correspond to the angle of inclination of the rafters 13 to the central ridge.

[0150] Although not shown in the Figures, it will be appreciated that the first and second locking flanges 29, 28 could be arranged to engage either one or both of the lower flange 33 of the rafter 13 and / or an inner flange 23 of the post 15 that faces the main plate 34 of the haunch plate 27.

[0151] The junction bracket 17 may also include a bottom flange 38 that extends from a lower edge of the base web 36 that engages the lower flange 33 of the rafter 13. Nut and bolt fasteners 39 can be used to clamp the base web 36 with the third central web 31 of the rafter 13 and to secure the first and second portions of the angled flange to the upper flanges 37 of the adjacent rafters 13.

[0152] As can be seen in Figures 4C, 5A and 6, the purlins 18 are Z-shaped purlins having top and bottom flanges 40, 42 and an upright fourth central web 41. The lower flange 42 can be fastened to an upper flange 32 for the rafters 13 and the individual lengths of the purlins 18 can be overlapped. A single fastener 43 can be used through the upright fourth webs 41 of the purlins 18 to allow the purlins 18 to articulate, thereby accommodating difference gradients in the terrain along the length of the first and second frames 11,12.

[0153] As can be seen in Figure 4A, one of the purlins 18 is seated on the haunch plate 27, namely the haunch plate purlin. The haunch plate purlin sits on top of the upper flange 32 of the haunch plate 27 and is directly attach to the haunch plate 27 and the rafter 31 by a fastener. The haunch plate T1 therefore directly interconnects the haunch plate purlin to the respective post.

[0154] As can be seen in Figures 4B and 5A, 6 and 7, the top flange 40 of the Z-shaped purlins 18 include pairs of holes 44 for fixing the solar panels to the purlins 18. The structure has pairs of spaced purlins 18 for each solar panel. Specifically, the preferred embodiment has four purlins 18 on the first frame 11 and four purlins 18 on the second frame 12. In other words, the first frame 11 has two rows of solar panels, in which each solar panel is supported on the a pair of spaced apart purlins 18. Similarly, the second frame 12 has two rows of solar panels, in which each solar panel is supported on a pair of spaced apart purlins 18.

[0155] Additional benefits of the Z-shaped purlins 18 include, the lower flange 42 of the purlins 18 can be readily access by power tools for fitting the nut and bolt fasteners, and the top flange 40 can be used to accommodate and protect electrical cabling of solar panels. For example, although not shown in the Figures, cable ties can be used to fix electrical cabling beneath the top flange 40, or to the lower flange 42. The electrical cabling can be fixed to upper and lower faces of the lower flange 42.

[0156] In the event that the structure 10 is installed on uneven terrain, the length of the posts 15 can be modified and / or the length of the footings 16 above the ground can be controlled. If desired, the orientation of the first and second frames 11, 12 can follow the slope of the terrain.

[0157] Figures 1, 5A and 6, show the structure 10 with bracing members in the form of strip 46 or sections that have been installed diagonally between adjacent rafters 13, or adjacent posts 15 to provide triangulation stiffening.

[0158] The structure 10 according to the preferred embodiment is made up of essentially 5 main components, namely the footings 15, the posts 15, the rafters 13, the purlins 18, and connectors. The connectors include the haunch plate 27, the junction bracket 17 and bracing members 45, 46. The structure 10 has relatively few components and has a maximum height in the range of 1.5 to 2.0 metres which allows the structure 10 to be readily assembled by installers standing on the ground without scaffolding or height equipment.

[0159] Figures 8, 9 and 17 illustrate formwork frame 50 for setting out the foundations and more particularly, for supporting the footingsl6 in the foundations during a concrete pour. The formwork frame 50 of Figures 8 and 9 set out four pairs of footings 16 so that the structure 10 made with this frame has three bays. The formwork frame 50 of Figure 17 sets out five pairs of footings 16 so that the structure made with the formwork frame 50 has four bays. Multiple formwork frame 50 can of course be used end-to-end to allow the length to be structure to changed.

[0160] The frames 50 of Figures 8 and 17 have an outer perimeter with two parallel side members that include two longitudinal sections 51 connected end-to-end, two end members 52 extending widthways across the formwork frame 50, and two intermediate members 53 extending across the formwork frame 50. The formwork frame 50 also includes diagonal members 54 that stiffen the formwork frame 50 and maintain the formwork frame 50 in a square configuration.

[0161] Figure 9 is a plan view of the formwork frame 50 which includes circles representing the foundations for the footingsl6. Extension members 55 extend outward from the perimeter of the formwork frame 50, and footingsl6 not shown, can be temporarily connected to the extension members 55 via the faster holes (see Figures 18 and 19) to suspend the footings 16 in the hole of the foundation.

[0162] The formwork frame 50 can include adjustable legs 62 that are operable to level the frame 50, for example in a horizontal plane or in a plane parallel to the terrain. Figures 18 to 20 illustrate an example of an adjustable leg 62 having an elongate section 56 with a slot 61 and base plate 57, best seen in Figure 20. The base plate 57 can be fixed to the ground by a ground peg passing through the hole 63. The formwork fame 50 has a pin 60 that can be moved along the slot 61 and a tightening nut (not shown in the Figures) to fix the elevation of the formwork frame 50 on the leg 62, and hence the elevation of the formwork frame 50 from the ground. The formwork frame 50 also includes a stabilizing piece 58 that engages the legs 62, which helps prevent the leg 62 from pivoting about the pin 60. The stabilizing piece 58 helps to stabililize the leg 62 in an upright orientation.

[0163] Figure 10 is a block diagram illustrating the steps for setting out the foundations and pouring the foundations with footings 16. Steps include setting out string lines defining the corners and orientation of the structure on the site. The formwork frame 50 can then be located in position relative to the string lines. If desired, the formwork frame 50 can take the place of the string lines and surveying applied directly to the frame to locate the frame in position with the use of the string lines. In any event, the foundation holes can be excavated, for example using an auger under the extension members, as denoted by the circles in Figure 9. The formwork frame 50 is levelled and supported in a level orientation using chocks or adjustable legs and the footings temporarily attached to the frame. Concrete can then be poured into the foundations and allowed to set. Once the concrete is set the frame can be disconnected from the footings and moved to the site of the next structure.

[0164] Figures 11 and 12 illustrate an installation in which the structure 10 has been repeated in an end-to-end manner in a north-south direction, thereby aligning the first frames 11 and second frames 12 in longitudinal flanks with a continuous central ridge between theflanks. The installation comprises two of the structures 10 arranged end-to-end to provide a total of eight bays.

[0165] Installation can also include the structure 10 being repeated in a side-to-side manner in an east-west direction, whereby a lowermost aspect of the first frame 11 is located adjacent to the lowermost aspect of the second frame 12 of an adjacent structure, thereby creating a wave profile of the gable formations, heading in an east-west direction. In this arrangement, the first frame of one of the structures is connected to the second frame of the same structure and is adjacent to the second frame of another adjacent structure. Similarly, the second frame of one of the structures is connected to the first frame of the same structure and is adjacent to the first frame of another adjacent structure.

[0166] Figures 11 and 12 also illustrate banks of solar panels 56 arranged in two rows and four columns on the first frames 11, and similarly two rows and four columns on the second frame 12 between consecutive posts. In other words, each bay has of the first frame has eight solar panels, and the second frame has eight solar panels.

[0167] Figures 13 and 14 illustrate an example of an alternative footing 16 in the form of a screw pile footing 62 that is rotatably driven into the ground. Figures 15 and 16 are enlarged views of the footing in circles H and I of Figures 13 and 14. The screw pile footing 16 has a shaft with a screw threaded along a lower portion of the shaft, and top plate having a set of slots extending radially on the top plate. A separate bracket is used to connect the screw pile footing 16 to the post 15. The bracket has a base plate 63 and a wall including flanges66 and 67 that are arranged at right angles to provide a corner to which a post 15 is attached. The base plate 63 has parallel slots 68 that can be align with two or more of the slots of the top plate to allow fasteners, preferably in the form of nut and bolts 65, to attach the bracket to the top plate of the screw pile 16. The flanges 66 and 67 also have holes that align with holes in the lower end of the posts 15 to allow fasteners, suitably in the form of nut and bolts 64 to attach the postsl5 to the corner of the bracket, and in turn, anchor the posts 15 to the ground via the bracket and the footing 16.

[0168] The screw pile footings 16 do not require concrete foundations and can be used instead of, or in combination with, the footings 16 of Figures 3A and 3B.

[0169] Figures 20 to T1 relate to two further formwork frames 50 for locating footings 16 in concrete foundations during a concrete pour. The footingsl6 are for a structure 10 that mounts solar panels in a operative position as described herein. The formwork frame 50 includes lengthways members 51, widthways members 52 attached laterally to the lengthways members 51, and pre-set mountings 59 that are directly or indirectly connected to one or both of the lengthways members 51 and / or the widthways member 52. The pre-set mountings 59 are configured to releasably attach the footings 16 to the formwork frame 50 so the footings 16 can extend downward from the formwork frame 50 into foundation holes 64. As can be seen, the pre-set mountings 59 are arranged in a grid arrangement including: i) pairs of the pre-set mountings 59 being arranged in a direction of the widthways members 52, and ii) lines of the pre-set mountings 59 being arranged in the direction of the lengthways members 51. The formwork frame 50 also includes adjustable legs 62 that support the formwork frame 50 above the ground, the legs 62 having an adjustable effective length so that the formwork frame 50 can be oriented in a desired planar arrangement which will locate the footings 16 attached to the formwork frame 50 in a desired position while concrete is being poured into the foundation holes 64. The pre-set mountings 59 may be located on the formwork frame 50 so that the footings 16 attached to the pre-set mountings 59 are set out in the desired layout corresponding to the required position of the posts 15 of the structure 10 to be assembled on the footings 16. That is to say, the footings 16 can be located in a desired planar arrangement relative to each other, including a horizontal plane, or a plane substantially parallel to the topography of the ground on which the footings are arranged. That is to say, the planar arrangement may have more than one orientation. Moreover, by adjusting the effective length of the legs 62 on which the formwork frame 50 is supported, all of the footings 16 attached to the pre-set mountings 50 can be set to a desired height. One of the benefits this provides is that by positioning the formwork frame 50 relative to the preassembled site string lines, all footings 16 attached to the formwork frame 50 will be located in the desired height.

[0170] The pre-set mountings 59 are connected to either one or both of the lengthways or widthways members 51 and 52 so that the footings 16 attached thereto are spaced outwardly of the lengthways members 51 by a spacing ranging from 0.2 to 0.5m, and suitably from 0.3 to 0.5m.

[0171] In Figures 20 to 27, the lengthways members 51 and the widthways members 52 can define an outer perimeter and the adjustable legs 62 are located inward, or in the case of Figures 20 and 21 outwardly of the outer perimeter. As can be seen, the legs 62 have a longitudinal slot 61 that receives a threaded pin 60 that can move along the slot 61 to allow the effective length of the leg 62 below the formwork frame 50 to be adjusted, and a threaded nut can be tightened on the threaded pin 60 to secure the leg 62 in an operative position in the slot 61.

[0172] Figures 20 and 21 relate to an example in which the pre-set mountings 59 are defined by an intersection of the lengthways members 51 and the widthways members 52, and a portion of the widthways members 52 extending outwardly of the lengthways members 51. The widthways members 52 and the lengthways members 51 may be continuous sections and / or may include plates that join sections of the members 51, 52 together as to effectively form continuous sections. The lengthways and widthways members 51 and 52 may have predetermined lengths and have preformed markings denoting the intersection where the lengthways and widthways members 51 and 52 crossover. Moreover, the lengthways and widthways members 51 and 52 may have openings for receiving fasteners, such as nut and bolt fasteners. The portion of the widthways members 52 extending outward of the lengthways members 51 provide the pre-set mountings 59 for the footings 19. The pre-set mountings 59 include openings in the ends of the widthways members 52 to which the footings 16 can be attached. Any suitable fastener, including nut and bolt fasteners, pivots or self-taping screws can be used for temporarily attaching the footings 19 to the pre-set mounting 59. Ideally, the pre-set mountings 59 include two attachment points for releasably attaching the footings 16. The two attachment points can assist in providing perpendicular alignment of the footings 16 relative to the formwork frame 50 when the fastener attachments are tightened. However, it will be appreciated that in some instances, for example, when the site topography is not a flat horizontally landscape, it may be preferred that the footings 16 be attached at an angle to the formwork frame 50, in which case the fastener attachments may not be completely tightened, or only one of the fasteners may be used so that the footings 16 can be suspended downwardly into the foundation holes 64 at an angle to the formwork frame 50.

[0173] One of the benefits of the example shown in Figures 20 and 21 is that the formwork frame 50 can be disassembled and the lengthways members 51 may be used as purlins 18 of the structure 10 to which the solar panels can be mounted. This is possible without requiring additional steps to cut the lengthways members 51 to another length. In addition, the widthways members 52 can be used as the rafters 13 or posts 15 of the structure 10 to which the solar panels can be mounted. However, using the widthways members 52 in this manner may require the widthways members 53 to be cut to length.

[0174] Although not shown in Figures 20 or 21, one or more diagonal member 54 may be used to interconnect: i) two of the widthways members 52, ii) two of the lengthways members 51, or ill) one of the widthways members 52 and one of the lengthways members 51 so as to brace the formwork structure 50 in a squared rigid configuration or a rigid rectangular configuration. It is also possible that the formwork frame 50 may not include diagonal members 54, for example, when the pre-set mounting 59 provides sufficient rigidity by having multiple fastenings between the lengthways and widthways members 52, 53 where these members crossover.

[0175] With reference to Figures 22 to 26, the lengthways and widthways members 51 and 52 do not crossover, but rather the pre-set mountings 59 has a body that connects to the lengthways and widthways members 51 and 52. In this instance, the pre-set mountings 50 include: i) two opposite limbs 65 on opposite sides to which the lengthways members 51 of the formwork frame 59 can be connected, and ii) a third lateral limb 66 to which the widthways members 52 can be connected. The lengthways members 51 can be connected to at least one of the opposite limbs 65 in two possible positions provided by multiple adjustment holes 67 that co-operate with a corresponding hole on the ends the lengthways members 52. By selecting and aligning the hole of the lengthways members 52 and the adjustment holes 67, the spacing between the footings 16 connected to the pre-set mountings 59 at opposite ends of the lengthways members 52 can be set at different spacings corresponding to the spacings of the posts 15 of the structure 10. Generally speaking, the posts 15 and therefore the footings 16 of are arranged at a spacing that is approximately equal to the width of either three or four solar panels wide. In any event, the adjustability of the spacing between the footings 16 allows for solar panels of different sized widths. The pre-set mounting 59 acts a joiner between the lengthways members 51 and the lengthways members 52. In one example, the pre-set mounting 59 may be T-shaped or Cross-shaped body.

[0176] The pre-set mounting 59 may include a stiffening member 68 extending between one of the opposite limbs 65 and the lateral limb 66. In the example shown, best seen in Figures 24 to 26, the stiffening member 68 may be a web such that the pre-set mounting 59 has a triangular portion that can provide rigidity to the formwork frame 59, including the lengthways 52 and the widthways members 53.

[0177] As can be seen in Figure 23, the formwork frame 50 of Figures 23 to 27 can also include diagonal members 54 to brace the formwork frame 50 in a squared rigid configuration or a rigid rectangular configuration. The diagonal members 54 may interconnect: i) two of the widthways members 52, such as opposite widthways members 52, ii) two of the lengthways members 53, such as opposite lengthways members 52, or ill) adjacent widthways and lengthways members 52 and 53. The diagonal member 54 may be omitted from the formwork frame 50 when the formwork frame 50 has sufficient inherent rigidity. This will depend on factors such as the stability and slope of the ground on which the formwork frame 50 is assembled, and whether the pre-set mountings 59 include an optional stiffening member 68 as described above.

[0178] In the case of the embodiment in Figures 22 to 26, the pre-set mounting 59 may include a detachable extension piece 69 that are releasably connect to the formwork frame 50 and extend outwardly therefrom so that footings 16 for the structure 10 can be attached to the pre-set mountings 59 at a spacing outwardly from the lengthways members 52. The detachable extension piece 69 is ideally substantially planar with the formwork frame 50 when attached thereto, and is releasably connected to the pre-set mounting 59 using fasteners 70, such as a pair of nut and bolt fasters as shown in Figures 24 and 26. The detachable extension piece 69 also includes a stabilizing piece 58 against which the footing 16 can abut to reduce pivoting of the footing 16 and help orient the footing 16 in an upright orientation when fitted to pre-set mounting 59. The stabilizing piece 58 may also be removed to allow the footings 16 to be suspended at an angle to the formwork frame 50, in which case only one of the fasteners may be used or the fasteners may be contained within a slot.

[0179] Figure 26 illustrates the pre-set mounting 59 without the footing 16 being attached. Figure 27 illustrates the situation in which the detachable extension piece 69 has been detached from the formwork frame 50, and therefore the footing 16 also removed, to allow access for excavation of the foundation holes 64. Likewise, the detachable extension piece 69 can be detached to allow for further excavation of the foundation holes 64 in the event that the footing 16 is not centrally located in the foundation hole 64 or the footing 16 is too close to the side wall of the hole and the hole needs to be widened.

[0180] One of the benefits of the formwork frame 50 is that by checking and confirming that a sub-set of the footings 16 are in the correct position with reference to preset layout strings, the formwork frame 50 will locate the remaining footings 16 are in the correct position. For example, the subset of the footings 16 may be the corner footings 16, and by checking that the corner footings 16 are in the correct position relative to the string lines, the formwork frame 50 will ensure that the footings 16 between the corner footings 16 are also in the correct position.

[0181] The preferred embodiment may also include a method of setting out foundations for a structure 10 made of pre-cut sections as described herein can be assembled for mounting solar panels in an operative position. The method may include the stepsof locating a formwork frame 50 on ground where the structure 10 is to be erected including assembling lengthways members 51, widthways members 52 attached laterally to the lengthways members 51, and multiple preset mountings 59 being connected to, or form part of, one or both of the lengthways members 51 and / or the widthways member 52 for releasably attaching footings 16 to the formwork frame 50 so the footings 16 can extend downward from the formwork frame 50 into foundation holes 64. The pre-set mountings 59 are arranged in a grid formation including i) pairs of the pre-set mountings 59 being arranged in a direction of the widthways members 53, and ii) lines of the pre-set mountings 59 being arranged in the direction of the lengthways members 51.

[0182] The method may also include excavating foundation holes 64 in the ground beneath the pre-set mountings 59 and thereafter attaching footings 16 of the structure 10 to the formwork frame 50 so as to suspend the footings 16 in the foundation holes 64. The method may also include adjusting the height of the formwork frame 50 so that the formwork frame 50 is oriented into a desired planar arrangement which will locate the footings 16 attached to the formwork frame 50 in a desired position and height relative to each other, so the structure 10 made from precut sections can be assembled on the footings 16. Concrete or some other foundation material can then be loaded or poured into the foundation holes 64 to anchor the footings 16 in the foundation holes.

[0183] The formwork frame 50 can be arranged into any desired planar arrangement, for example with reference to leveling devices including laser levels or water levels. The method may also include a preliminary step of setting out string lines that mark the location of the foundation holes and the desired planar orientation of the formwork frame 50. The step of locating the formwork frame 50 may then include maneuvering the formwork frame 50 relative to setting out string lines and adjusting the effective length of the adjustable legs 62 on which the formwork frame 50 is supported.

[0184] In the case of the embodiment show in Figures 23 to 27, the pre-set mountings 59 include: i) two opposite limbs 65 on opposite sides to which the lengthways members 51 of the formwork frame 50 can be connected, and ii) a third lateral limb 66 to which the widthways members 52 can be connected. The method may also include connecting the lengthways members 51 to one of the opposite limbs 65 in one of multiple possible positions, thereby enabling the spacing between the footings 16 connected to the pre-set mountings at opposite ends of the lengthways members 51 to be set at different spacings by selecting the position at which the lengthways members 51 are connected to the pre-set mountings 59. That is to say, adjusting the position at which the lengthways member 51 is connected to the pre-set mountings 59 adjusts that the spacing between the pre-set mountings 59 and, in turn, the spacing between the footings 16 and the posts 15 of the structure 10.

[0185] The method may include connecting detachable extension pieces 69 to the formwork frame 50 so that the detachable extension pieces 69 extend outwardly from the formwork frame 50. The detachable extension pieces 69 may have a first end that can be releasably attached to the pre-set mountings 59, and a second end providing an outer pre-set mounting 50 to which the footings 16 can be attached. The footings 16 can be attached to the pre-set mountings 59 at an increased spacing from the formwork frame 50, and detaching the extension pieces 69 during excavation of the foundation holes 64. The footings 16 attached to the formwork frame 50 can be located outwardly from the lengthways member 51 at a spacing in a range from 0.2 to 1.0m, and suitably in a from 0.3 to 0.5m.

[0186] Figure 28 is an isometric view of another the pre-set mounting 59 located at inner left corner of the formwork frame shown in Figure 24. The pre-set mounting 59 has a body that includes one limb 65 for connected to the lengthways members 51 of the formwork frame 50 and a lateral limb 66 for connection to the widthways member 52. A stiffening web 68 interconnects the limbs 65 and 66. The pre-set mounting 59 also includes a detachable extension piece 69 connected to the body of the pre-set mounting via fasteners 70 at one end and having the footing 16 connected to the other end. The pre-set mounting 59 also includes a stabilizing piece 58 that can abut against the footing 16. The adjustable leg 62 is fitted to the widthways member 52 by a pin 60 that can slide along slot 61 to allow adjustment of the height of the formwork frame and the footing 16 in the foundation hole 64.

[0187] In the case of the embodiment shown in Figures 20 and 21, the formwork frame 50 can be disassembled and the lengthways members 51 can be used as purlins of the structure 10 to which the solar panels can be mounted.

[0188] A person skilled in the art will appreciate that many variations and modifications may be made to the preferred embodiment described herein without departing from the spirit and scope of the present invention. Reference numeral table structure 10 formwork frame 50 first frame 11 longitudinal sections / lengthways members 51 second frame 12 widthways members 52 rafters 13 intermediate members 53 battens 14 diagonal member 54 posts 15 extension member 55 footing(s) 16 elongated section 56 junction plate 17 base plate 57 purlins 18 stabilizing piece 58 first central web 19 pre-set mountings 59 second central web 20 pin 60 two side flanges 21, 23 slot 61 bolt fastener 24 elongated slot 61 openings 25 adjustable legs 62 fastening holes 26 hole 63 haunch plate 27 foundation hole 64 second locking flange 28 opposite limbs 65 first locking flange 29 lateral limb 66 central web 31 adjustment holes 67 upper flange 32 stiffening member 68 lower flange 33 detachable extension piece 69 main plate 34 fasteners (nut and bolt) 70 nut and bolt fastener 35 top flange 40 lower flange 42 bracing members 45, 46

Claims

1. A formwork frame for locating footings in concrete foundations during a concrete pour for a structure to which solar panels can be mounted, the formwork frame including:lengthways members, widthways members attached laterally to the lengthways member, and multiple pre-set mountings being directly or indirectly connected to one or both of the lengthways member and / or the widthways member for releasably attaching footings to the formwork frame so the footings can extend downward from the formwork frame into foundation holes; wherein the pre-set mountings are arranged in a grid arrangement including: i) pairs of the pre-set mountings being arranged in a direction of the widthways members, and ii) lines of the pre-set mountings being arranged in the direction of the lengthways members;legs that support the formwork frame above the ground, the legs having an adjustable effective length from the formwork frame to the ground, the being adjustable so that the formwork frame can be oriented in a desired planar arrangement which will locate footings attached to the formwork frame in a desired position while concrete is being poured into the foundation holes;wherein each of the pre-set mountings includes: i) two opposite limbs on opposite sides to which the lengthways members of the formwork can be connected, and ii) a third lateral limb to which the widthways members can be connected, wherein the lengthways members can be connected to at least one of the opposite limbs in at least two possible positions, thereby enabling the spacing between the footings connected to the pre-set mountings at opposite ends of the lengthways members to be set at different spacings by selecting the position at which the lengthways member is connected to the pre-set mountings.

2. The formwork frame of claim 1, wherein the pre-set mountings are located on the formwork frame so that the footings attached to the pre-set mountings are in the desired layout corresponding to the required position of the posts of the structure to be assembled on the footings.3.The formwork frame of any one of the preceding claims, wherein the pre-set mountings arelocated at an intersection of the lengthways and the widthways members, and the lengthways members and the widthways members have a predetermined length so that the footings are located in the desired layout.

4. The formwork frame of any one of the preceding claims, wherein the footings can be located in a desired planar arrangement relative to each other by being fixed to the pre-set mountings, including a horizontal plane, or a plane substantially parallel to the topography of the ground on which the footings are arranged.

5. The formwork frame of any one of the preceding claims, wherein by adjusting the effective length of the legs on which the formwork frame is supported, the footings can be attached to the pre-set mountings to locate multiple footings, and suitably all of the footings attached to the formwork frame in the desired height.

6. The formwork frame of any one of the preceding claims, wherein the position of the footings attached to the formwork frame can be adjusted in a horizontal plane by moving the legs over the ground.

7. The formwork frame of any one of the preceding claims, wherein at least one diagonalmember that interconnects: i) two of the widthways members, ii) two of the lengthways members, or ill) one of the widthwise members and one of the lengthways members8. The formwork frame of claim 8, wherein the diagonal member braces the formwork structure in a squared configuration or a squared grid configuration.

9. The formwork frame of any one of the preceding claims, wherein the lengthways members and the widthways members define an outer perimeter and the adjustable legs are located inward of the outer perimeter.

10. The formwork frame of any one of the preceding claims, wherein the legs are attached to the widthways members inward of the pre-set attachment points.

11. The formwork frame of any one of the preceding claims, wherein the legs have a longitudinal slot that receives a threaded pin of the frame that can move along the slot to allow the effective length of the leg below the frame to be adjusted, and a threaded nut can be tightened on the threaded pin to secure the leg in an operative position in the slot.

12. The formwork frame of any one of the preceding claims, wherein the formwork frame includes a stabilizer piece to which the legs abuts when the leg is in an upright orientation.

13. The formwork frame of any one of the preceding claims, wherein the pre-set mountings extend outward from the lengthways member.

14. The formwork frame of any one of the preceding claims, wherein the pre-set mountings are located outward of lengthways members and the widthways members.

15. The formwork frame of any one of the preceding claims, wherein the formwork includes pairs of the pre-set mountings, one of the pairs being arranged in the direction of the widthways members, and a line of the pairs extending in a direction of the lengthways members.

16. The formwork frame of any one of the preceding claims, wherein the pre-set mountings have two fastener attachments for releasably attaching the footings.

17. The formwork frame of any one of the preceding claims, wherein the formwork frame can be disassembled and the lengthways members used as purlins of the structure to which the solar panels can be mounted.

18. The formwork frame of claim 17 or 18, wherein the widthways members can be used as rafters or posts of the structure to which the solar panels can be mounted.

19. The formwork frame of any one of the preceding claims, wherein the pre-set mounting is connected to either one or both of the lengthways or widthways members so that the footings attached thereto are spaced outwardly of the lengthways members by a spacing ranging from 0.2 to 1.0m, and suitably from 0.3 to 0.5m.

20. The formwork frame of any one of the preceding claims, wherein the pre-set mounting includes a stiffening member extending between one of the opposite limbs to which to which the lengthways members can be connected and the lateral limb.

21. The formwork frame of any one of the preceding claims, wherein one of the two opposite limbs extending outwardly in opposite directions from the joiner has at least two possible positions at which the lengthways members can be connected.

22. The formwork frame of any one of the preceding claims, wherein the pre-set mountings include detachable extension pieces that are releasably connected to the formwork frame andextend outwardly therefrom so that the footings for the structure can be attached to the detachable extension pieces at a spacing outwardly from the formwork frame.

23. The formwork frame of claim 22, wherein the detachable extension piece is substantially in plane with the formwork frame when attached thereto.

24. The formwork frame of claim 22 or 23, wherein the detachable extension piece can be detached from the formwork frame to allow access for excavation of the foundation holes.

25. The formwork frame of any one of claims 22 to 24, wherein the detachable extension pieces have a first end that can be releasably attached to the pre-set mountings, and a second end providing an outer pre-set mounting to which the footings can be attached.

26. The formwork frame of any one of claims 22 to 25, wherein the detachable extension piece has a length so that the outer pre-set mounting is in the range 0.5 to 1.2m outward from the lengthways members, and suitably in the range of 0.7 to 1.0m from the lengthways members.

27. A method of setting out foundations for a structure to which solar panels can be mounted using the formwork frame of any one of the preceding claims.

28. A method of setting out foundations for a structure to be assembled from precut sections to which solar panels can be mounted, the method including the stepsof:locating a formwork frame on terrain where the structure is to be erected, in which the locating step includes assemblinglengthways members,widthways members attached laterally to the lengthways member,multiple pre-set mountings being directly or indirectly connected to one or both of the lengthways member and / or the widthways member for releasably attaching footings to the formwork frame so the footings can extend downward from the formwork frame into foundation holes; wherein the pre-set mountings are arranged in grid including i) pairs of the pre-set mountings being arranged in a direction of the widthways members and ii) lines of the pre-set mountings being arranged in the direction of the lengthways members; andexcavating foundation holes in the terrain beneath the pre-set mountings;releasably attaching footings of the structure to the formwork frame so as to suspend the footings in the foundation holes;adjusting the height of the formwork frame so that the formwork frame is oriented into a desired planar arrangement which will locate footings attached to the formwork frame in a desired position;pouring concrete into the foundation holes to anchor the footings in the foundation holes; andwherein each of the pre-set mountings includes: i) two opposite limbs on opposite sides to which the lengthways members of the formwork can be connected, and ii) a third lateral limb to which the widthways members can be connected, and the method includes connecting the lengthways members to one of the opposite limbs in one of two possible positions, thereby enabling the spacing between the footings connected to the pre-set mountings at opposite ends of the lengthways members to be set at different spacings by selecting the position at which the lengthways member is connected to the pre-set mountings.

29. The method of claim 28, wherein the method includes a preliminary step of setting out string lines that mark the locate the foundation holes, and optionally the planar orientation of the formwork frame, and the step of locating the formwork frame includes maneuvering the formwork frame relative to setting out string lines.

30. The method of claim 28 or 29, wherein the step of adjusting the height of the formwork includes changing the effective length of adjustable legs on which the formwork frame is supported.

31. The method of any one of claims 28 to 30, wherein the step of assembling the formwork frame includes connecting the pre-set mounting to either one or both of the lengthways or widthways members so that the footings attached thereto are located outwardly from the lengthways member at a spacing in a range from 0.2 to 0.5m, and suitably from 0.3 to 0.5m.

32. The method of any one of claims 30 to 31, wherein the method includes connecting detachable extension pieces to the formwork frame so that the extension pieces extend outwardly from the formwork frame to provide an outer pre-set mounting so footings can be attached to the outer pre-set mountings at an increased spacing from the formwork frame, and detaching the extension pieces during excavation of the foundation holes.

33. The method of claim 32, wherein the detachable extension pieces have a first end that canbe releasably attached to the pre-set mountings, and a second end providing an outer pre-set mounting to which the footings can be attached.

34. The method of any one of claims 28 to 31, wherein the method includes disassembling the formwork frame and using the lengthways members as purlins of the structure to which the solar panels can be mounted.

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