Improved blockouts for concrete moulds

Abstract

The invention relates to an improved blockout for concrete voids around a fixing. The improved blockout for concrete voids includes a blockout body for forming a generally corresponding blockout shape when surrounded by concrete, and a conduit within the blockout body for receipt of a fixing. A grip portion is also 5 included, associated with the blockout body to enable readily gripping of the body and removal from the formed blockout. The invention also includes variations thereon and methods of use.

Description

[0001] IMPROVED BLOCKOUTS FOR CONCRETE MOULDS

[0002] FIELD OF THE INVENTION

[0003] The present invention relates to an improved blockout for concrete moulds, and in particular to an improved blockout for concrete moulds for more ready removal.

[0004] BACKGROUND OF THE INVENTION

[0005] On a construction site, previously polystyrene cylinders or tubes were used to surround an bolt when pouring a concrete slap to keep this accessible for use as anchor bolts. The time needed to remove the polystyrene, as well as the hazard to health and the mess created meant this was an unpopular, time consuming and costly part of the construction. Blockouts for concrete moulds are known, as subject of Australian patent number 201 1221365 by the same inventor, for the first form of blockout. The reusable blockout of the previous invention removed the need for the hazardous polystyrene and allowed numerous blockouts to be created, and then quickly removed to create the void around the bolt by pulling up on the blockout and neoprene sleeve. The invention has been a great success and much used in the industry. The subject invention is the result of long research and development to provide an improved blockout over the prior art, including his own original product.

[0006] The original product was well received but has now been improved, to include a grip portion to assist to remove the blockout, after the concrete has set, with new form of protective sleeve, and a tapered body. Each of these features may be inventive in their own right and in combination provide a significant new invention over the art. The new fully reusable blockout further improves the rapid formation of repeated blockouts around anchor bolts for use in construction, making what would be a labour intensive and time consuming job much easier, quicker and so saving time and money in the construction. The product is a significant improvement in the art and as such is likely to be very well received once known about. The following describes a non-limiting example of the invention being used with reference to creating blockouts for concrete moulds around bolts as used in construction, as a particularly useful application of the invention. This clever invention may be utilised anywhere the improved removal of the blockout may be required. It is not intended to limit the scope of the invention other than as defined in the claims.

[0007] The blockouts described are creation of the holes or spaces in concrete around the bolts and fixings during construction. Examples of use are given in the described embodiment to facilitate understanding. However, the blockouts may be any similar blockouts.

[0008] For clarity, any prior art referred to herein, does not constitute an admission that the prior art forms part of the common general knowledge, in Australia or elsewhere.

[0009] It is an object of the present invention to provide an improved blockout for concrete moulds that at least ameliorates one or more of the aforementioned problems of the prior art. It is a further and separate object of the present invention to provide a method of use of an improved blockout for concrete moulds that at least ameliorates one or more of the aforementioned problems of the prior art.

[0010] DISCLOSURE OF THE INVENTION

[0011] Accordingly, the present invention provides an improved blockout for concrete voids around a fixing: a blockout body for forming a generally corresponding blockout shape when surrounded by concrete; a conduit within the blockout body for receipt of a fixing; and a grip portion, associated with the blockout body to enable readily gripping of the body and removal from the formed blockout. Preferably, the blockout is used on a construction site for fixings and a concrete pour. The invention may be used anywhere it is of use to make the void, and it is envisaged that the concrete could be another similar material in other forms of the invention. The blockout may be any suitable blockout to create a void about something. The blockout may be a mould to create a suitable shape, the blockout is a void around an anchor bolt. Preferably, the blockout void is a void around a construction fixing. Other materials than concrete may be used to create the void.

[0012] The blockout void may be any suitable shape. The void may be made substantially cylindrical. Preferably, the cylinder is somewhat tapered. Preferably, the shaping of the blockout body and hence void to be created is somewhat tapered from one end to the other. Preferably, the body is substantially cylindrical and the taper is from a top of a slightly greater diameter to the bottom. The taper of just a few millimetres assists to break the natural hold on the cylinder of the concrete and allows a gap for release. Any suitable size of taper may be used instead. Preferably, the blockout body shape allows for readily release. The blockout shape may create a small gap through tapering along its length that allows a grip, move and pull manoeuvre to readily release the block mould for removal.

[0013] Preferably, the block is generally circular in cross section. Preferably, the body is generally cylindrical. Preferably the bottom and top are substantially cylinders, of a similar but slightly different size.

[0014] Preferably, the conduit runs from a top to a bottom of the body. Preferably, the body of the block out is an echo of the desired void shape, sized to suit a particular fixing. The fixing may be an anchor bolt. The fixing may be part of a construction footing. The fixing may be any suitable fixing. Preferably, the fixing is surrounded by the conduit in use. Preferably, the conduit is open at the base to receive a fixing therewithin. Preferably, the sizing is to fit easily over the fixing in use. A larger conduit could be used instead, but the sizing provides a steady positioning of the blockout over the fixing. The receipt of the fixing may be in any suitable manner. The conduit may take any suitable shape to receive the fixing and could be more in the form of a recess or opening in other forms of the invention. Preferably, the conduit receives the fixing by being placed over the top and slides over the fixing in place.

[0015] Preferably, the grip portion enables ready holding in the hand and removal of the block from the set concrete. Preferably, an neck portion is included to allow grip. Preferably, an edge or lip to contact the hand is included assist to hold the block. The edge or lip may resist the hand sliding off. The edge or lip may take any suitable form. The edge may surround a top of a neck. The edge may surround an edge of the blockout body. The grip may enable very quick removal. Preferably, the quick removal is under 30 seconds per unit.

[0016] Preferably, a sleeve is used. Preferably, the sleeve surrounds the block out in use. Preferably, the sleeve assists to create a smooth surface of the void. Preferably, the sleeve is a plastic sleeve. Preferably, the sleeve is longer than the blockout. Preferably, the sleeve is sized to be generally larger than the blockout and fit thereabout. Preferably, the sleeve facilitates removal. The smooth sleeve and tapering both can assist removal. The sleeve, tapering and grip in particular can make for a quick and easy removal. Preferably, the sleeve is reusable. Preferably, the blockout body is reusuable.

[0017] Accordingly, the present invention provides in a variant an improved blockout for concrete voids around a fixing: a blockout body for forming a generally corresponding blockout shape when surrounded by concrete; a conduit within the blockout body for receipt of a fixing; a grip portion, associated with the blockout body to enable readily gripping of the body and removal from the formed blockout; and a sleeve for substantially surrounding the blockout body and assisting in ready removal.

[0018] Accordingly, the present invention provides in a further variant an improved blockout for concrete voids around a fixing: a generally cylindrical blockout body, tapered from the top to the bottom for forming a generally corresponding blockout shape when surrounded by concrete; a conduit within the blockout body for receipt of a fixing in the bottom of the cylindrical blockout body; a grip portion including an neck and lip, associated with the blockout body to enable readily gripping of the body and removal from the formed blockout; and a plastic sleeve for substantially surrounding the blockout body and assisting in ready removal.

[0019] Accordingly, the invention also provides a method of use of a blockout including a blockout body, with conduit and grip portion, and sleeve, to create a blockout void for a fixing in concrete, the method including the following steps: a) positioning the blockout over the fixing so that the fixing is within the conduit and fully surrounded by the blockout body; b) covering the body of the blockout with the sleeve to cover the parts to be contacted by the concrete (may occur before the positioning step); c) after the concrete has been applied and is suitably set, gripping the grip portion to pull up and release the apparatus and remove it to leave a void around the fixing.

[0020] The steps may be performed in any suitable order. The apparatus of the method may be the apparatus of the invention in any of its forms or variants. INDUSTRIAL APPLICABILITY

[0021] The blockout will be manufactured and applied industrially, for supply for construction sites or similar.

[0022] BRIEF DESCRIPTION OF THE DRAWINGS

[0023] The invention will now be described in connection with a non-limiting preferred embodiment with reference to the accompanying drawings, in which:

[0024] Figure 1 is a perspective view from above of blockout mould according to a preferred embodiment of the invention with the sleeve, fixing and concrete omitted for ease of reference;

[0025] Figure 2 is a front view of the blockout mould of Figure 1 ;

[0026] Figure 3 is plan view from above of the blockout mould of Figures 1 and 2;

[0027] Figure 4 is a schematic perspective cross-sectional view of the blockout mould of Figure 1 , illustrating the conduit for receipt of the anchor bolt;

[0028] Figure 5 is a perspective view from above of several of the blockouts of Figures 1 to 4, in experimental use with sleeve in position over anchor bolts before the concrete pour; and

[0029] Figure 6 is a perspective view from above of several of the blockouts of Figures 1 to 4, in experimental use with illustrating the method of removal by hand from above to reveal the void and anchor bolt in the poured concrete.

[0030] DETAILED DESCRIPTION OF THE INVENTION INCLUDING A BEST MODE

[0031] Referring to Figures 1 to 6, a preferred embodiment of the invention will be described, where blockout mould 1 , has body 10, which is shaped to echo the desired blockout void mould shape. In this case, body 10 is shaped to be a cylinder with a tapered body to be narrower at the base. The tapering is advantageous when removing the blockout to assist in release from the concrete. The shape could be other shapes but use of forming a general cylinder around the anchor bolts in the concrete pour (refer Figures 5 and 6 in particular) is most advantageous for ease of use. With tapering to ease the release once the concrete is set.

[0032] All parts are formed of a suitable plastics material such as PVC. Other materials can be used. The sleeve is a clear plastic sleeve.

[0033] The particular dimensions of the blockout will depend on the fixing size and shape, and particular requirements of the user of the space (blockout) to be created around these particular fixings. A range of sizes of popular blockout sizes can be provided or a particular construction site can order a particular size. The principle used is the same with different dimensions. It is envisaged that the and these are provided in a range of sizes to suit the needs of the user. As shown the dimensions are a diameter of 100 millimetres by 300 millimetres as is convenient but this can be varied.

[0034] Important to this form of the invention is the gripping portion that creates a fingerhold to grab and pull the blockout from the concrete and includes neck 12, with upper lip 14 about edge 16, around opening 18. Upper body 20, between surface 22 and base 24 define a tapered cylinder, to create the tapered shape, beneficial is use. Edge 16 is useful as it enables a person to put their fingers under edge 16 to hold neck 12 but also get upward grip. The blockouts will be firmly held in place once the concrete has set about them and so a certain amount of strength and force is required to pull them up and out to create the void. However, use of the novel neck with shaped lip edge, gives a grip hold significantly increasing the upward pull and ease with which the blockout can be removed. No tools are required for any part of the blockout installation or removal so it can be a quick and easy process, with reusable blockouts meaning this is a most economic invention when compared to the polystyrene moulds used in the past. Referring to Figures 5 and 6 in particular showing the invention used in an experimental use for anchor bolts 26, such as to replicate use on a construction site for tie in anchor bolts or the like. Sleeve 28 is used with blockout mould 1 , to surround, protect and facilitate removal. Sleeve 28 is a plastic sleeve sized to fit the configuration of the particular blockout mould. In the given example, if blockout mould is 300 millimetres long and 100 millimetre diameter, sleeve . Clearly this can be adapted to comfortably cover any sized blockout by being a 5 millimetres overall diameter bigger than the blockout itself, and longer than the blockout body so the sleeve can be gathered comfortably around the top in use. Sleeve 28 could be much bigger it that is convenient.

[0035] As shown in Figures 5 and 6, steel footings 30 and planks 32 are used in the usual way before the concrete pour about anchor bolts 28 with inventive blockouts 1 and sleeves 28 installed. In the usual way construction planks are used to surround the concrete pour and footings tied in as required. Any suitable construction task where it is desired to create a void such as around fixings in concrete could replace the illustrated steel 30 and planks 32.

[0036] Blockout voids 34 can be seen in Figure 6, as three of blockout moulds 1 and sleeves 28 have been removed after the concrete pour. These voids or spaces around the fixings once formed remain within the set concrete and the next steps of construction can take place.

[0037] Referring to Figure 4 in particular, a cross-sectional schematic drawing assists to show the core blockout mould 1 , with conduit 36 and aperture 38. Aperture 38 and conduit 36 are sized for the particular fixing the void is to be blocked out and created around, when concrete 40 is poured. Aperture 38 allows blockout mould 1 to be slipped over fixing in place, to surround and cover, and the sizing of the body creates a space or void that around the fixing. In this way anchor bolt 26 (refer Figures 5 and 6) is fully surrounded with a quick hand action of slipping over. Neck 12 and grip 16 are most useful for removal but can also provide a convenient hand hold when installing with sleeve 28 the outside. The tapering shapes of the body and (optional) conduit 36 do not interfere with installation but do significantly improve the ease and time needed for removal.

[0038] The void created as shown for a 100 millimetres diameter is approximately 30 millimetres all around but again this can be varied as needed for a particular fixing or need for the particular use.

[0039] To use the apparatus once anchor bolts 26 are in place sleeve 28 is put over blockout mould 1 . Sleeve 28 acts both to assist to provide a smooth plastic surface for removal, and to create the smooth outer surface of the void created but also to protect blockout mould 1 . As a reusable item it is more economic to replace plastic sleeve 28 than the whole of block out mould, should for some reason it become damage or after length use starts to wear out. Once plastic sleeve 28 is over blockout mould 1 , all the parts can still be seen as sleeve 28 is advantageously clear. Gripping the top part of sleeve 28 and blockout mould 1 , seeing through the plastic sleeve the apparatus can be positioned over anchor bolt 26.

[0040] There would usually be a great many anchor bolts 26 in place and so a worker can take an equal number of block out moulds 1 and sleeves 28 and put each over the anchor bolts 26 in turn in a single quick action. No tools or special training is needed and so a person can quickly be shown what needs to be done and achieve it for a large area or large number of anchor bolts. As no tools or training are needed and the apparatus is convenient to hold and use the set up is quick and convenient.

[0041] To remove after concrete 40 is poured and sufficiently set to do so (perhaps before fully cured) a hold on neck 12 and finger hold on grip 16 allows a good hold to pull straight up. The hand is on sleeve 28 but has fully visual and contact access with blockout mould 1 below. A strong grip and pull up and each void is created in just a few seconds, a great time and costs saving of the invention. The action can be repeated as the tapered shape facilitates ready removal and with minimal force so the person can repeat the task a great many times before becoming fatigued. Once concrete 40 has cured for 4 to 6 hours, the initial set period, the blockouts can be stripped out quickly and the voids have been created around anchor bolts 26.

[0042] As both the sleeve and blockout are reusable, repeated actions can be continued for efficient work on a site.

[0043] It is one of the many advantages of the invention that it can be used over and over again, in a quick, tool free action without waste. The removal is so quick, around 25 seconds per blockout removal when installed correctly with sleeve. The easy grip by hand on neck 12 and grip section 16 enables that the job can be achieved very quickly and easily, a significant step over the prior art.

[0044] Overall it can be seen that this is a significant advance over the prior art and an important step forward for blockout moulds and void creation.

[0045] It will be apparent to a person skilled in the art that changes may be made to the embodiment disclosed herein without departing from the spirit and scope of the invention in its various aspects.

[0046] REFERENCE SIGNS LIST:

Claims

AMENDED CLAIMS received by the International Bureau on 03 March 2025 (03.03.2025)THE CLAIMS:

1. An improved blockout for concrete voids around a fixing: a blockout body tapered from the top to the bottom for forming a generally corresponding tapered blockout shape when surrounded by concrete; a smooth sleeve surrounding the blockout body, and extending longer than the block out body, to form a substantially smooth surface to the concrete void, and the sleeve facilitates removal; a conduit within the blockout body for receipt of a fixing; and a neck and grip portion, associated with the blockout body to enable ready gripping of the neck and grip portion and smooth removal of the blockout body from the formed blockout concrete void.

2. The improved blockout of claim 1 , wherein the blockout is a void around an anchor bolt.

3. The improved blockout of claim 1 or 2, wherein the taper is of just a few millimetres to assist to break the natural hold on the cylinder of the concrete and allows a gap for release.

4. The improved blockout according to any one of claims 1 to 3, wherein the blockout body shape allows for readily release by creating a small gap through tapering along its length that allows a grip, move and pull manoeuvre to readily release the block mould for removal.

5. The improved blockout according to any one of claims 1 to 4, wherein the block is generally circular in cross section, and the body is generally cylindrical.

6. The improved blockout according to any one of claims 1 to 5, wherein the bottom and top are substantially cylinders, of a similar but slightly different size.

7. The improved blockout according to any one of claims 1 to 6, wherein the conduit is open at the base to receive a fixing therewithin.

8. The improved blockout according to any one of claims 1 to 7, wherein an edge or lip to contact the hand is included to assist to hold the block9. The improved blockout according to any one of claims 1 to 8, wherein the grip of the grip portion enables very quick removal.

10. The improved blockout according to any one of claims 1 to 9, wherein the quick removal is under 30 seconds per unit.

11. The improved blockout according to any one of claims 1 to 10, wherein the sleeve is a plastic sleeve.

12. The improved blockout according to any one of claims 1 to 1 1 , wherein the sleeve is reusable.

13. The improved blockout according to any one of claims 1 to 12, wherein the blockout body is reusuable.

14. An improved blockout for concrete voids around a fixing: a generally cylindrical blockout body, tapered from the top to the bottom for forming a generally corresponding blockout shape when surrounded by concrete; a conduit within the blockout body for receipt of a fixing in the bottom of the cylindrical blockout body; a grip portion including an neck and lip, associated with the blockout body to enable readily gripping of the body and removal from the formed blockout; and a plastic sleeve for substantially surrounding the blockout body and assisting in ready removal.

15. A method of use of the blockout of claim 1 , including a blockout body, with conduit and grip portion, and sleeve, to create a blockout void for a fixing in concrete, the method including the following steps: a) positioning the blockout over the fixing so that the fixing is within the conduit and fully surrounded by the blockout body; b) covering the body of the blockout with the sleeve to cover the parts to be contacted by the concrete (may occur before the positioning step); c) after the concrete has been applied and is suitably set, gripping the grip portion to pull up and release the apparatus and remove it to leave a void around the fixing.

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