U.S. patent application number 12/096553 was filed with the patent office on 2009-04-23 for formwork.
This patent application is currently assigned to Bluescope Steel Limited. Invention is credited to Campbell John Seccombe.
Application Number | 20090100776 12/096553 |
Document ID | / |
Family ID | 38162496 |
Filed Date | 2009-04-23 |
United States Patent
Application |
20090100776 |
Kind Code |
A1 |
Seccombe; Campbell John |
April 23, 2009 |
FORMWORK
Abstract
An elongate formwork element for use in the construction of a
concrete floor is disclosed. The formwork element includes a base
wall (15) and a side wall (17) extending from one side edge of the
base wall so that the element is generally L-shaped in transverse
section.
Inventors: |
Seccombe; Campbell John;
(New South Wales, AU) |
Correspondence
Address: |
BARNES & THORNBURG LLP
11 SOUTH MERIDIAN
INDIANAPOLIS
IN
46204
US
|
Assignee: |
Bluescope Steel Limited
Melbourne, Victoria
AU
|
Family ID: |
38162496 |
Appl. No.: |
12/096553 |
Filed: |
December 11, 2006 |
PCT Filed: |
December 11, 2006 |
PCT NO: |
PCT/AU2006/001916 |
371 Date: |
July 28, 2008 |
Current U.S.
Class: |
52/414 ;
249/13 |
Current CPC
Class: |
E04C 2003/046 20130101;
E04G 11/46 20130101; E04G 11/365 20130101; E04B 5/40 20130101; E04B
2005/322 20130101; E04G 11/36 20130101 |
Class at
Publication: |
52/414 ;
249/13 |
International
Class: |
E04B 1/30 20060101
E04B001/30 |
Foreign Application Data
Date |
Code |
Application Number |
Dec 12, 2005 |
AU |
2005906982 |
Claims
1. An elongate formwork element comprising: a base wall and a side
wall extending from one side edge of the base wall so that the
element is generally L-shaped in transverse section, and the
formwork element is configured to interlock, in use, with a
horizontally disposed profiled decking sheet so that the side wall
extends upwardly from a side edge of the profiled decking
sheet.
2. The formwork element of claim 1 wherein the side wall of the
formwork element includes a strengthening member.
3. The formwork element of claim 2 wherein the strengthening member
is in the form of a plurality of ribs in the side wall of the
formwork element.
4. The formwork element of claim 3 wherein the ribs extend
transversely to a length direction of the formwork element.
5. The formwork element of claim 4 wherein the ribs extend at least
substantially between the base wall and a free end of the side
wall.
6. The formwork element of of claim 4 wherein the ribs are in the
form of deep embossments of at least about 2.0 mm that make it
possible for the side wall to act compositely with the concrete
layer.
7. The formwork element of claim 1 wherein the base wall is shaped
to interlock with the profiled decking sheet.
8. The formwork element of claim 1 wherein, in a situation in which
the profiled decking sheet includes at least one rib, the base wall
includes an upturned lip that is configured to extend into a rib of
the profiled decking sheet and the length of the base wall is
selected so that, in use, the formwork element can be positioned so
that the base wall is positioned against an undersurface of the
profiled decking sheet at one side of the sheet and the lip extends
into and engages the rib of the sheet.
9. The formwork element of claim 1 wherein an upper end of the side
wall includes an end formation that defines a platform on which one
or more than one profiled decking sheet can be located and
secured.
10. The formwork element of claim 9 wherein the end formation
includes a lip that is configured to contact edges of the ends of
profiled decking sheets positioned on the end formation.
11. An assembly comprising: a plurality of profiled decking sheets
and a plurality of formwork elements that form a formwork of a base
of a part of a beam and slab sections of a concrete floor.
12. The assembly of claim 11 wherein the formwork elements that
form sides of the beam formwork are interlocked with the profiled
decking sheets that form the base of the beam formwork, and wherein
each formwork element comprises a base wall, and a side wall
extending from a side edge of the base wall.
13. The assembly of claim 12 wherein upper ends of the formwork
elements that form the sides of the beam formwork define a support
platform that supports the profiled decking sheets that form the
base formwork of the slab sections.
14. The assembly of claim 13 further comprising safety rail.
15. A concrete floor that includes one or more than one concrete
beam and a concrete slab section extending outwardly from the beam
as a part of the floor, the floor comprising: (a) a base that
includes a formwork in the form of an assembly of a plurality of
profiled decking sheets and a plurality of formwork elements, and
(b) a layer of concrete on the base, and wherein each formwork
element comprises a base wall, and a side wall extending from a
side edge of the base wall.
16. The concrete floor of claim 15 wherein the profiled decking
sheets are pre-cambered along a length of the sheets.
17. The concrete floor of claim 15 wherein the profiled decking
sheets are pre-cambered along the length of the sheets so that pans
of the sheets form flat, horizontal surfaces when wet concrete is
poured to form the concrete floor.
18. The concrete floor of claim 15 wherein the concrete floor
further includes a reinforcement, embedded in the concrete.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is the U.S. national phase of
PCT/AU2006/001916 filed Dec. 11, 2006. PCT/AU2006/001916 claims the
benefit under the Convention of Australian patent application
AU2005906982 filed Dec. 12, 2005. The complete disclosures of
Australian patent application 2005906982 and PCT/AU2006/001916 are
hereby incorporated herein by reference.
FIELD OF THE INVENTION
[0002] The present invention relates generally to cast in situ
concrete beams for use in the building industry.
BACKGROUND OF THE INVENTION
[0003] The present invention relates particularly, although by no
means exclusively, to concrete beams that form part of cast in situ
concrete floors, hereinafter referred to as "concrete floors", such
as for example and without limitation mezzanine floors and floors
for multi-storey buildings, including multi-storey carparks.
[0004] The present invention relates particularly, although by no
means exclusively, to concrete floors that include concrete
beams.
[0005] The present invention also relates more particularly,
although by no means exclusively, to formwork elements for
constructing concrete floors, particularly formwork elements for
constructing beams of concrete floors, and to concrete floors made
using the formwork elements.
[0006] In the context of the construction of floors, the term
"concrete floor" is understood herein to include (a) one or more
than one concrete beam and (b) one or more than one concrete slab
section extending outwardly from the beam or beams as a part of the
floor.
[0007] In the context of the construction of floors, the term
"concrete floor" is understood herein to further include: [0008]
(c) a base of the floor that includes a formwork in the form of a
plurality of profiled decking sheets positioned in side-by-side
and/or end-to-end relationship as required and other formwork
elements as required to form the base; and [0009] (d) a layer of
concrete on the base.
[0010] Typically, in the context of the construction of floors, the
term "concrete floor" is understood herein to include reinforcement
embedded in the concrete layer. Such reinforcement may be in the
concrete of the beam or beams and/or in the concrete of the slab
section or sections.
[0011] The profiled decking sheets and other formwork elements of
the concrete floor may contribute to the mechanical performance of
the concrete floor. Specifically, the profiled decking sheets and
other formwork elements may act compositely with the concrete via
mechanical bonding and therefore contribute to the reinforcement of
the concrete floor.
[0012] Notwithstanding the above, the present invention extends to
arrangements in which the profiled decking sheets and other
formwork elements do not make a contribution to the mechanical
performance of the concrete floor and the profiled decking sheets
and other formwork elements act as lost formwork only.
[0013] Typically, a concrete floor is formed in situ by: [0014] (e)
positioning a plurality of profiled decking sheets and other
formwork elements onto a permanent support structure and forming a
continuous base of the floor, [0015] (f) positioning formwork that
defines the outer side wall perimeter of the concrete floor, [0016]
(g) placing reinforcement, typically in the form of flat sheets of
steel mesh or bars, or both mesh and bars, on or in relation to the
profiled decking sheets and other formwork elements, and [0017] (h)
finally pouring concrete onto the assembly of the decking sheets
and other formwork elements and reinforcement within the perimeter
of the formwork and forming a layer of concrete.
[0018] Depending on a number of factors, including the shapes of
the profiled decking sheets and other formwork elements, the weight
of concrete required to form a concrete floor, the span between
adjacent permanent support members, deflection limits, the concrete
pour sequence, the number of spans, the means of fixing to the
permanent support structure, and construction loads (other than wet
concrete), the profiled decking sheets and other formwork elements
may need to be propped temporarily between the permanent support
members.
[0019] The term "profiled decking sheet" is understood herein to
mean roll-formed sheets or brake pressed sheets that, typically
(although by no means exclusively), include at least one pan and
side edge formations that enable adjacent sheets to be positioned
together in side-by-side relationship.
[0020] In situations in which a profiled decking sheet includes two
or more than two pans, typically (although by no means
exclusively), the term "profiled decking sheet" is understood
herein to include one or more than one upstanding rib separating
adjacent pans.
SUMMARY OF THE INVENTION
[0021] The present invention may comprise one or more of the
following features, including features set forth in the claims
appended hereto, and combinations thereof.
[0022] The present invention provides an elongate formwork element
that is particularly well suited for use as part of the formwork
for concrete beams of a concrete floor.
[0023] According to the present invention there is provided an
illustrative elongate formwork element for use in the construction
of a concrete floor, which formwork element includes a base wall
and a side wall extending from one side edge of the base wall so
that the element is generally L-shaped in transverse section.
[0024] In one illustrative embodiment the formwork element is
configured to interlock, in use, with a horizontally disposed
profiled decking sheet so that the side wall extends upwardly from
a side edge of the profiled decking sheet.
[0025] The illustrative formwork element is suitable for use as
part of the formwork of a concrete beam of a concrete floor. In
this application, the beam formwork illustratively is defined by:
[0026] (c) a profiled decking sheet that forms a base of the beam
formwork, and [0027] (d) the formwork element positioned on
opposite sides of the profiled decking sheet and interlocked with
the profiled decking sheet and forming the sides of the beam
formwork.
[0028] The illustrative formwork element is also suitable for use
as other parts of the formwork of a concrete floor.
[0029] In a number of illustrative applications it is not necessary
that the side wall of the formwork element illustratively be a load
bearing element. Therefore, the formwork element can be made, by
way of example, form small gauge steel. The term "small" gauge
steel is understood herein to mean steel that is less than about
1.0 mm thickness.
[0030] Illustratively the side wall of the formwork element may
include a strengthening member. The strengthening member reduces
lateral deflection (bulging) of the side wall when wet concrete is
poured and bears against the side wall. The strengthening member
also makes it possible to use lighter gauge steel to make the side
wall than would otherwise be the case.
[0031] Illustratively the strengthening member is in the form of a
plurality of ribs in the side wall of the formwork element.
[0032] Illustratively the ribs extend transversely to the length
direction of the formwork element.
[0033] Illustratively the ribs may extend at least substantially
between the base wall and a free end of the side wall. In a
situation in which the formwork element is interlocked with a
horizontally disposed profiled decking sheet so that the side wall
extends upwardly from a side edge of the profiled decking sheet,
the ribs extend upwardly at least substantially between the base
wall and the free, i.e. upper, end of the side wall.
[0034] Illustratively the ribs are in the form of deep embossments
that make it possible for the side wall to act compositely with the
concrete layer.
[0035] The term "deep" as used herein in the context of the
embossments means that the depth of the embossments is at least
about 2.0 mm and illustratively at least about 3 mm. It will be
appreciated that the depth may exceed 3.0 mm.
[0036] Illustratively the base wall is shaped to interlock with the
profiled decking sheet.
[0037] Illustratively the base wall is shaped to interlock with the
profiled decking sheet without the use of mechanical fasteners.
[0038] In a situation in which the profiled decking sheet includes
at least one rib, illustratively the base wall includes an upturned
lip that is adapted to extend into a rib of the profiled decking
sheet and the length of the base wall is selected so that, in use,
the formwork element can be positioned so that the base wall is
positioned against an undersurface of the profiled decking sheet at
one side of the sheet and the lip extends into and engages the rib
of the sheet.
[0039] Illustratively an upper end of the side wall includes an end
formation that defines a platform on which one or more than one
profiled decking sheet can be located and secured, preferably by
fasteners.
[0040] With the arrangement described in the preceding paragraph,
it is possible to assemble together the formwork for an elongate
concrete beam and sections of a concrete slab extending outwardly
from one or both sides of the beam.
[0041] For example and without limitation, with this arrangement,
it is possible to pre-assemble sections of the formwork for a
concrete floor on the ground and thereafter lift the sections into
a required location on a building under construction.
[0042] Illustratively the end formation includes a lip that is
adapted to contact edges, which are typically sharp edges, of the
ends of profiled decking sheets positioned on the end formation.
The lip forms an end cap that prevents flow (and thereby loss) of
concrete through deck voids, such as the ribs of profiled decking
sheets. In addition, the lip covers sharp edges that may result in
injury to workers assembling and/or installing the formwork.
[0043] According to the present invention there is also provided an
illustrative assembly of a plurality of profiled decking sheets and
a plurality of the above-described formwork element that form a
formwork of a base of a part of a beam and slab sections of a
concrete floor.
[0044] The above-described illustrative assembly may be put
together on the ground and then lifted into a required position on
a building under construction.
[0045] Illustratively the assembly includes the formwork elements
that form the sides of the beam formwork being interlocked with the
profiled decking sheets that form the base of the beam
formwork.
[0046] Illustratively the upper ends of the formwork elements that
form the sides of the beam formwork defining a support platform
that supports the profiled decking sheets that form the base
formwork of the slab sections.
[0047] Illustratively the assembly may include a safety rail.
[0048] The safety rail provides safety feature for persons
constructing a concrete floor when the assembly is lifted into
position.
[0049] In addition, the safety rail illustratively stiffens the
assembly and contributes to maintaining the integrity of the
assembly as it is lifted from the ground into a required
position.
[0050] According to the present invention there is also provided an
illustrative_concrete floor that includes one or more than one
concrete beam and a concrete slab section extending outwardly from
the beam as a part of the floor and may further include: [0051] (c)
a base that includes a formwork in the form of an assembly of a
plurality of profiled decking sheets and a plurality of the
above-described formwork element, and [0052] (d) a layer of
concrete on the base.
[0053] Illustratively, the profiled decking sheets may be
pre-cambered along the length of the sheets.
[0054] Illustratively, the profiled decking sheets may be
pre-cambered along the length of the sheets so that the pans of the
sheets form flat, horizontal surfaces when wet concrete is poured
to form the concrete floor.
[0055] Illustratively the concrete floor further includes
reinforcement, such as for example and without limitation steel
mesh, embedded in the concrete.
[0056] Illustratively, the reinforcement may be pre- or
post-tensioned.
[0057] Illustratively, the reinforcement may be welded or otherwise
connected to the side edge formations and/or the ribs of the
profiled decking sheets to increase the resistance to lateral
deflection under load.
[0058] These and other objects of the present invention will become
more apparent from the following description of the illustrative
embodiment.
BRIEF DESCRIPTION OF THE DRAWINGS
[0059] The present invention is described further by way of example
with reference to the accompanying Figures, of which:
[0060] FIG. 1 is a vertical cross-section through a part of one
illustrative embodiment of a concrete floor in accordance with the
present invention; and
[0061] FIG. 2 is a perspective view of one illustrative embodiment
of a formwork element in accordance with the present invention that
forms a part of the concrete floor shown in FIG. 1.
DESCRIPTION OF THE ILLUSTRATIVE EMBODIMENTS
[0062] For the purposes of promoting an understanding of the
principles of the invention, reference will now be made to a number
of illustrative embodiments illustrated in the drawings and
specific language will be used to describe the same.
[0063] The part of the concrete floor shown in FIG. 1 includes an
elongate concrete beam 3 (extending into the page) and a horizontal
concrete slab section 5 extending outwardly from each side of the
beam 3, as shown in the Figure.
[0064] The part of the concrete floor shown in FIG. 1 is formed
from: [0065] (d) a continuous base in the form of a formwork that
includes an assembly of a plurality of horizontal steel profiled
decking sheets 7 and generally vertical steel formwork elements 9,
[0066] (e) a layer of concrete 11 on the base; and [0067] (f)
reinforcement in the form of a steel mesh 13 embedded in the
concrete layer 11.
[0068] The base is supported by a plurality of permanent support
members (not shown). By way of example, and without limitation the
permanent support members may be in the form of columns.
[0069] Illustratively, the profiled decking sheets 7 may be of any
suitable configuration. Moreover, it is not necessary that the same
profiled decking sheets 7 be used to form the base of the beam 3
and the base of each slab section 5
[0070] FIG. 1 shows that the base of the beam 3 illustratively
includes two profiled decking sheets 7 positioned side-by-side in
overlapping relationship. Each profiled decking sheet 7
illustratively includes three pans 31 separated by parallel open
ribs 33 and side edge formations 35.
[0071] FIG. 1 shows two formwork elements 9 that form opposite
sides of the beam 3. Each formwork element 9 illustratively is made
form small gauge steel having a thickness of about 0.75 mm and
includes a base wall 15 and a non-load bearing side wall 17
extending upwardly (as viewed in FIG. 1) from one side edge of the
base wall 15 so that the element 9 is generally L-shaped in
transverse section.
[0072] Illustratively, each formwork element 9 is formed so that it
can interlock with an adjacent horizontal profiled decking sheet 7
of the base of the beam 3, without the use of mechanical fasteners,
so that the side wall 17 of the element 9 extends upwardly from a
side edge of the sheet 7 and is held in that position. The
interlocking of the formwork elements 9 and the profiled decking
sheets 7 is advantageous because it assembles the components
together and this simplifies construction of the concrete slab and
allows the components and the concrete to act compositely.
[0073] The side wall 17 of each formwork element 9 illustratively
includes a strengthening member in the form of a series of parallel
ribs 21 of about 3.0 mm depth that extend vertically at least
substantially between the base wall 15 and an upper end of the side
wall 17. The ribs 21 illustratively are deep ribs and consequently
make it possible for the side walls 17 to act compositely with the
concrete layer. In addition, the ribs 21 make it possible to use
lighter gauge steel to make the side wall 17 than would otherwise
be the case.
[0074] Illustratively, the base wall 15 of each formwork element 9
is shaped to interlock with the profiled decking sheet 7.
[0075] For example and without limitation, the base wall 15 of each
formwork element 9 includes an upturned lip 37 that is configured
to extend into and engage the closest rib 33 to the formwork
element 9. In addition, the length L (see FIG. 2) of the base wall
15 of each formwork element 9 is selected so that, when the
formwork element 9 is positioned with the base wall 15 against an
undersurface of the profiled decking sheet 7 and with the lip 37
extending into and engaging the rib 35, the side wall 17 of the
element 9 bears against the outer side edge formation 35 of the
sheet 7, with the result that the formwork element 9 and the
profiled decking sheet 7 are generally connected or interlocked
together.
[0076] Illustratively, the side wall 17 of each formwork element 9
includes an end formation 39 at an upper end thereof. The end
formation 39 defines a platform on which one or more than one
profiled decking sheet 7 for the base of the floor sections 5 are
located and secured by fasteners 41.
[0077] Illustratively, the upper end formation 39 of the side wall
17 of each formwork element 9 includes a lip 43 that contacts the
edges, which are typically sharp edges, of the ends of profiled
decking sheets 7 of the base of the slab sections 5 that are on the
end formation 39. The lip 43 illustratively is provided as a safety
feature to minimize injury during construction of the concrete
slab. Moreover, for safety reasons, the lip 43 may have a small
rounded return at the upper end so that it does not present a sharp
edge. In addition, the lip 43 functions as an end cap for the ribs
of the profiled decking sheets 7 of the base of the slab sections 5
that prevent flow of wet concrete from the beam 3 via the ribs.
Specifically, the ribs define openings below the profiled decking
sheets 7 through which wet concrete could flow outwardly and
downwardly from the beam 3.
[0078] Illustratively, the profiled decking sheets 7 and the
formwork elements 9 can be readily manufactured and transported to
a construction site and are configured to be assembled together on
the ground at the site and thereafter lifted by a crane into a
required location for a building under construction.
[0079] One or more than one safety rail (not shown) may be
positioned on the assembly for subsequent use as a safety measure
after the assembly has been lifted into position and as a means of
improving the rigidity of the assembly.
[0080] Many modifications may be made to the embodiment of the
present invention described above without departing from the spirit
and scope of the invention.
[0081] By way of example, while the description of the illustrative
embodiment indicates that the profiled decking sheets 7 and the
formwork elements 9 can be assembled together to form the formwork
on the ground at a building site and thereafter lifted by a crane
into a required location on a building under construction, the
present invention is not so limited and extends to arrangements in
which the profiled decking sheets 7 and the formwork elements 9 are
separately lifted from the ground to a building and assembled
together to form the formwork on the building.
[0082] By way of further example, while the embodiment of the
formwork shown in the drawings includes profiled decking sheets 7
that have three pans 31 separated by parallel open ribs 33 and side
edge formations 35, the present invention is not limited to this
configuration of the profiled decking sheet.
[0083] By way of further example, while the embodiment of the
formwork element 9 shown in the drawings is made form small gauge
steel having a thickness of about 0.75 mm, the present invention is
not so limited and extends to formwork elements made from any
suitable material of any suitable thickness and is not confined to
small gauge steel of the stated thickness of about 0.75 mm.
[0084] While the invention has been illustrated and described in
detail in the foregoing drawings and description, the same is to be
considered as illustrative and not restrictive in character, it
being understood that only illustrative embodiments thereof have
been shown and described and that all changes and modifications
that come within the spirit of the invention are desired to be
protected.
* * * * *