U.S. patent application number 12/087750 was filed with the patent office on 2010-10-07 for spacer and associated apparatus and method.
Invention is credited to Michael Hoesli, Falekava Mahe.
Application Number | 20100251651 12/087750 |
Document ID | / |
Family ID | 38255895 |
Filed Date | 2010-10-07 |
United States Patent
Application |
20100251651 |
Kind Code |
A1 |
Mahe; Falekava ; et
al. |
October 7, 2010 |
Spacer and Associated Apparatus and Method
Abstract
The spacer 1 defines a body (2) having two opposed sides (3) and
(4). The body (2) defines a separation distance between the opposed
sides (3) and (4) for use as a spacer intermediate at least two
concrete containment panels (5) and (6). Various preferred
embodiments have separation distances suitable for forming walls
having concrete thicknesses of 50 mm, 120 mm or 150 mm, for
example. Each of the opposed sides (3) and (4) include fastening
means (7) and (8) adapted for fastening of a cladding panel (16)
disposed external to the concrete containment panels (5) and (6),
as shown for example in FIGS. (32) and (33). To counter bulging of
the concrete containment panels (5) due to the weight of the
concrete a brace (49) adapted for fastening engagement with the
spacers (1) may be used, as shown in FIGS. (50) to (55). The brace
49 includes an abutment member (50) for abutment with the concrete
containment panels (5). A plurality of fastening means (51) are
disposed on the abutment member (50) for fastening engagement with
spacers (1). The fastening means (51) each define a leading portion
(52) and a trailing portion (53). As shown for example in FIG.
(50), the leading portion (52) has a width greater than a width of
the trailing portion (53). A pair of opposed lips (54) and (55) are
disposed on the leading portion (52). To fasten the abutment member
(50) of the brace (49) to the spacers (1), the leading portion (52)
of the fastening means (51) is inserted between a pair of
projections {9 and 10} on the spacer. Once the lips (54) and (55)
clear the projections (9) and (10), the projections resiliently
snap toward their resting position and engage the trailing portion
(53) so as to fasten the abutment member (50) to the spacer (1).
This is repeated with other spacers (1) as required until the
abutment member (50) provides the desired level of support to
counter bulging of the concrete containment panels (5).
Inventors: |
Mahe; Falekava; (New South
Wales, AU) ; Hoesli; Michael; (New South Wales,
AU) |
Correspondence
Address: |
Mark F Smith
905 Ohio - Pike
Cincinnati
OH
45245
US
|
Family ID: |
38255895 |
Appl. No.: |
12/087750 |
Filed: |
December 8, 2006 |
PCT Filed: |
December 8, 2006 |
PCT NO: |
PCT/AU2006/001860 |
371 Date: |
November 10, 2008 |
Current U.S.
Class: |
52/426 ; 52/479;
52/582.1; 52/742.14 |
Current CPC
Class: |
E04G 21/26 20130101;
E04B 2002/8688 20130101; E04G 5/062 20130101; E04G 5/067 20130101;
E04B 2002/8676 20130101; E04B 2/8652 20130101; E04B 2002/867
20130101 |
Class at
Publication: |
52/426 ; 52/479;
52/742.14; 52/582.1 |
International
Class: |
E04B 2/84 20060101
E04B002/84; E04B 2/08 20060101 E04B002/08; E04G 17/06 20060101
E04G017/06 |
Foreign Application Data
Date |
Code |
Application Number |
Jan 12, 2006 |
AU |
2006900125 |
Claims
1. A spacer defining a body having two opposed sides, said body
defining a separation distance between said opposed sides for use
as a spacer intermediate at least two concrete containment panels,
at least one of said sides including fastening means adapted for
fastening of at least one cladding panel disposed external to at
least one of said concrete containment panels, wherein said
fastening means is a snap lockable connector.
2. A spacer according to claim 1 wherein said snap lockable
connector includes at least one projection disposed on one of the
spacer or the cladding panel. Said projection being resiliently
biased for interlocking engagement with a corresponding formation
provided upon the other of the spacer or the cladding panel.
3. (canceled)
4. (canceled)
5. (canceled)
6. (canceled)
7. (canceled)
8. A spacer defining a body having two opposed sides, said body
defining a separation distance between said opposed sides for use
as a spacer intermediate at least one concrete containment panels,
at least one of said sides including fastening means adapted for
fastening of at least one cladding panel to disposed external to at
least one of said concrete containment panels, wherein said
fastener includes a slot disposed in one of the spacer or the
cladding panel, said slot defining at least one detent; and an
elongate member disposed on the other of the spacer or the cladding
panel, said elongate member including a formation adapted for
engagement with said detent.
9. (canceled)
10. A spacer according to claim 1 wherein said fastening means is
adapted for press fit fastening of the cladding panel to the
spacer.
11. A spacer according to claim 1 wherein said fastening means is
adapted for fastening of the spacer to the cladding panel through
an opening provided within at least one of said concrete
containment panels.
12. A spacer according to claim 1 wherein said fastening means
includes at least one tongue disposed on one of said spacer or
cladding panel and at least one groove disposed on the other of
said spacer or cladding panel.
13. A spacer according to claim 12 wherein a T shaped member
defines a pair of opposed tongues, each of said tongues being
separately engageable with corresponding grooves provided upon two
adjacent cladding panels.
14. A spacer according to claim 1 wherein said fastening means
includes a lug removably attachable to said at least one opposed
side, said lug including cladding panel retaining formations.
15. A spacer according to claim 14 wherein said lug is T
shaped.
16. A spacer according to claim 14 wherein said lug includes a
handle for removal of the lug upon adhesion of the cladding panel
to the at least one opposed side and/or to the concrete containment
panel.
17. A spacer according to claim 1 wherein said fastener includes a
connection component fastenable to said at least one side, said
connection component being slidably matable with said cladding
panel.
18. A spacer according to claim 1 wherein said cladding panel is
fastenable to said at least one opposed side at any one of a
plurality of selectable connection points lying on said cladding
panel.
19. (canceled)
20. (canceled)
21. (canceled)
22. (canceled)
23. (canceled)
24. (canceled)
25. (canceled)
26. (canceled)
27. (canceled)
28. A concrete containment panel adapted for disposition
intermediate a spacer according to any one of claim 1 at least one
concrete containment panel having at least one opening sized for
fastening engagement of the spacer with the cladding panel through
the at least one opening.
29. A concrete containment panel according to claim 28 including a
first slot disposed adjacent said opening for receipt of at least
part of an opposed end of the spacer and a second slot disposed
adjacent said opening for receipt of at least part of the body of
the spacer.
30. A concrete containment panel according to claim 28 wherein said
concrete containment panel defines a plurality of sides adapted for
engagement with like sides of like concrete containment panels,
some of said sides defining tongues and others of said sides
defining corresponding grooves.
31. (canceled)
32. (canceled)
33. (canceled)
34. (canceled)
35. A cladding panel according to claim 1 wherein said cladding
panel includes first and second panels disposed at a preselected
angular relationship relative to each other.
36. A cladding panel according to claim 35 wherein said preselected
angular relationship is 90.degree. and wherein said cladding panel
is for use at a corner.
37. (canceled)
38. (canceled)
39. A brace adapted for fastening engagement with a spacer
according to claim 1 including an abutment member for abutment with
a concrete containment panel, at least two fastening means being
disposed on said abutment member for fastening engagement with a
respective pair of spacers.
40. A brace according to claim 39 wherein said at least two
fastening means each define a leading portion and a trailing
portion, said leading portion having a width greater than a width
of said trailing portion.
41. (canceled)
42. (canceled)
43. A brace according to any one of claim 39 further including a
strut defining a proximal end disposed on the abutment member and a
distal end for fastening to a support surface.
44. A brace according to claim 43 wherein said strut is centrally
disposed on the abutment member.
45. A brace according to claim 43 wherein said strut is rotatably
disposed on the abutment member.
46. A formwork construction kit including: a plurality of spacers;
a plurality of concrete containment panels; and a plurality of
cladding panels wherein at least one of said cladding panels are
attached to at least one of said spacers by at least one snap
lockable connectors.
47. A formwork construction kit according to claim 46 further
including at least one brace adapted for fastening engagement with
at least one spacer.
48. A method of formwork construction including the steps of:
providing formwork constructions kit wherein at least two spacers
are intermediate at least two concrete containment panels so as to
form a concrete receptacle; pouring concrete into said concrete
receptacle; and fastening at least one cladding panel onto said at
least two spacers using a snap lockable connector, such that said
cladding panel is external to at least one of said concrete
containment panels.
49. A method according to claim 48 wherein the step of "pouring
concrete into said concrete receptacle" includes the further steps
of: fastening a brace onto said at least two spacers; pouring
concrete into said concrete receptacle; allowing the concrete to
harden; and detaching said brace from said at least two
spacers.
50. A wall comprising a plurality of spacers each spacer having a
body comprising two opposed sides, said body defining a separation
distance between said opposed sides for use as a spacer; and a
plurality of panels attached to said spacers using a snap lockable
connector.
51. The wall of claim 50 wherein said panels are concrete
containment panels.
52. The wall of claim 50 wherein said panels are cladding
panels.
53. A structure comprising a spacer defining a body having two
opposed sides, said body defining a separation distance between
said opposed sides for use as a spacer between two cladding panels,
wherein said cladding panels are supported by said spacer using a
fastening means comprising at least one snap lockable
connector.
54. The structure of claim 53 further comprising at least one
concrete containing panel disposed between said two opposed sides.
Description
FIELD OF THE INVENTION
[0001] The present invention relates to a spacer and associated
concrete containment panels, cladding panels, braces and methods of
use thereof. Preferred embodiments of the invention are typically
used in the construction field, for example in relation to concrete
formwork construction methods.
BACKGROUND
[0002] The discussion of the prior art within this specification is
not, and should not be taken as, an admission of the extent of
common general knowledge in the field of the invention. Rather, the
discussion of the prior art is provided merely to assist the
addressee to understand the invention and is included without
prejudice.
[0003] Existing techniques for in-situ construction of concrete
structures typically require erection of formwork from generic
materials such as plywood. This can be labour intensive and
therefore costly. Additionally, input from skilled tradespeople is
typically required, both to erect the formwork and to apply
finishes such as rendering, gyprock, tiles or other cladding
materials to the resultant concrete structures. Improvements to the
efficiency of any of these processes are likely to be highly
advantageous within the notoriously competitive construction
industry.
SUMMARY OF THE INVENTION
[0004] It is an object of the invention to overcome, or
substantially ameliorate, at least one of the disadvantages of the
prior art, or to provide a useful alternative.
[0005] According to a first aspect of the invention there is
provided a spacer defining a body having two opposed sides, said
body defining a separation distance between said opposed sides for
use as a spacer intermediate at least two concrete containment
panels, at least one of said sides including fastening means
adapted for fastening of at least one cladding panel disposed
external to at least one of said concrete containment panels.
[0006] In one preferred embodiment of the spacer, the fastening
means is a snap lockable connector including at least a first
projection disposed on one of the spacer or the cladding panel, the
projection being resiliently biased for interlocking engagement
with a corresponding formation provided upon the other of the
spacer or the cladding panel. This embodiment includes a second
projection opposed to the first projection, the second projection
being resiliently biased for interlocking engagement with a
corresponding formation provided upon the other of the spacer or
the cladding panel. The corresponding formation of this preferred
embodiment has a cross sectional profile defining a leading portion
having a width greater than a width between respective ends of the
first and second projections, the cross sectional profile further
defining a trailing portion having a width less than the width of
the leading portion.
[0007] In another preferred embodiment of the spacer the snap
lockable connector includes a first pair of opposed projections
disposed adjacent a second pair of opposed projections on one of
the spacer or the cladding panel, each of the projections being
resiliently biased for interlocking engagement with one or more
corresponding formations provided upon the other of the spacer or
the cladding panel. Preferably the first and second pair of opposed
projections are disposed on one or both of the opposed sides, the
first and second pairs of projections being respectively fastenable
with a first corresponding formation disposed on a first cladding
panel and a second corresponding formation disposed on a second
cladding panel.
[0008] In another preferred embodiment of the spacer the fastener
is an interference fit fastener.
[0009] In yet another preferred embodiment of the spacer the
fastener includes: [0010] a slot disposed in one of the spacer or
the cladding panel, the slot defining at least one detent; and
[0011] an elongate member disposed in the other of the spacer or
the cladding panel, the elongate member including a formation
adapted for engagement with the detent.
[0012] Preferably the fastening means is adapted for press fit
fastening of the cladding panel to the spacer.
[0013] Also preferably the fastening means is adapted for fastening
of the spacer to the cladding panel through an opening provided
within at least one of said concrete containment panels.
[0014] In a preferred embodiment of the spacer the fastening means
includes at least one tongue disposed on one of the spacer or
cladding panel and at least one groove disposed on the other of the
spacer or cladding panel. Preferably a T shaped member defines a
pair of opposed tongues, each of the tongues being separately
engageable with corresponding grooves provided upon two adjacent
cladding panels.
[0015] In another preferred embodiment of the spacer the fastening
means includes a lug removably attachable to the at least one
opposed side, the lug including cladding panel retaining
formations. Preferably the lug is T shaped and includes a handle
for removal of the lug upon adhesion of the cladding panel to the
at least one opposed side and/or to the concrete containment
panel.
[0016] In yet another preferred embodiment of the spacer the
fastener includes a connection component fastenable to the at least
one side, the connection component being slidably matable with the
cladding panel.
[0017] Preferably the cladding panel is fastenable to the at least
one opposed side at any one of a plurality of selectable connection
points lying on the cladding panel. In such an embodiment a groove
is defined by the cladding panel and the connection point is
selected from a locus of points defined by said groove.
[0018] A further preferred embodiment of the spacer includes a
planar surface disposed at the at least one side, the concrete
containment panel being adapted for engagement with the planar
surface. Preferably the concrete containment panel includes a slot
adapted to receive the planar surface.
[0019] In a preferred embodiment of the spacer the body includes at
least one webbing member extending intermediate said opposed sides.
In this preferred embodiment the body also includes at least one
positioning formation adapted for positioning of an elongate member
extending transverse to the spacer body, for example a plumbing
pipe or conduit, a utility cable or the like.
[0020] Preferably the body includes at least one transverse
projection disposed such that, in use, an end of the projection
abuts, or is adjacent to, the concrete containment panel.
[0021] A preferred embodiment of the spacer consists of at least
two interengagable components. Preferably this embodiment of the
spacer consists of two click-lockingly interengagable components,
each component respectively defining one of the opposed sides.
[0022] According to a second aspect of the invention there is
provided a concrete containment panel adapted for disposition
intermediate a spacer according to the first aspect and a cladding
panel, the concrete containment panel having at least one opening
sized for fastening engagement of the spacer with the cladding
panel through the at least one opening.
[0023] A preferred embodiment of the concrete containment panel
includes a first slot disposed adjacent the opening for receipt of
at least part of an opposed end of the spacer and a second slot
disposed adjacent the opening for receipt of at least part of the
body of the spacer.
[0024] Preferably the concrete containment panel defines a
plurality of sides adapted for engagement with like sides of like
concrete containment panels, some of the sides defining tongues and
others of the sides defining corresponding grooves.
[0025] In some preferred embodiments the concrete containment panel
defines an external surface adapted for adhesion of a cladding
panel. In one such embodiment external surface includes a plurality
of slots.
[0026] A preferred embodiment of the concrete containment panel
suitable for use as an end cap has a U shaped cross section.
[0027] According to a third aspect of the invention there is
provided a cladding panel adapted for fastening engagement with a
spacer according to the first aspect.
[0028] In some preferred embodiments the cladding panel includes
first and second panels disposed at a preselected angular
relationship relative to each other. In one such embodiment
suitable for use at a corner the preselected angular relationship
is 90.degree.. In this preferred embodiment fastening formations
are disposed on an interior side of the first panel and the
interior side of the second panel is substantially planar.
[0029] According to a fourth aspect of the invention there is
provided a brace adapted for fastening engagement with a spacer
according to the first aspect.
[0030] A preferred embodiment of the brace includes an abutment
member for abutment with a concrete containment panel, at least two
fastening means being disposed on the abutment member for fastening
engagement with a respective pair of spacers.
[0031] In one preferred embodiment of the brace the fastening means
each define a leading portion and a trailing portion, the leading
portion having a width greater than a width of the trailing
portion. Preferable each of said fastening means includes a pair of
opposed lips disposed at the leading portion. Also preferably, the
fastening means are slidably disposed on the abutment member.
[0032] A preferred embodiment of the brace further includes a strut
defining a proximal end disposed on the abutment member and a
distal end for fastening to a support surface, for example a floor.
Preferably the strut is centrally disposed on the abutment member.
Also preferably the strut is rotatably disposed on the abutment
member.
[0033] According to a fifth aspect of the invention there is
provided a formwork construction kit including: [0034] a plurality
of spacers in accordance with the first aspect; [0035] a plurality
of concrete containment panels in accordance with the second
aspect; and [0036] a plurality of cladding panels in accordance
with the third aspect.
[0037] A preferred embodiment of the formwork construction kit
further includes at least one brace in accordance with the fourth
aspect.
[0038] According to a sixth aspect of the invention there is
provided a method of formwork construction including the steps of:
[0039] providing formwork constructions kit in accordance with the
fifth aspect; [0040] disposing at least two spacers intermediate at
least two concrete containment panels so as to form a concrete
receptacle; [0041] pouring concrete into said concrete receptacle;
and [0042] fastening at least one cladding panel onto said at least
two spacers, such that said cladding panel is external to at least
one of said concrete containment panels.
[0043] Preferably the step of "pouring concrete into said concrete
receptacle" includes the further steps of: [0044] fastening a brace
according to the fourth aspect onto the at least two spacers;
[0045] pouring concrete into the concrete receptacle; [0046]
allowing the concrete to harden; and [0047] detaching the brace
from the at least two spacers.
[0048] According to a seventh aspect of the invention there is
provided a wall constructed in accordance with a method according
to the sixth aspect.
[0049] According to another aspect of the invention there is
provided a structure including walls according to the seventh
aspect.
BRIEF DESCRIPTION OF THE DRAWINGS
[0050] Preferred embodiments of the invention will now be
described, by way of example only, with reference to the
accompanying drawings, in which:
[0051] FIG. 1 is a front view of a first preferred embodiment of a
spacer according to the first aspect of the invention;
[0052] FIG. 2 is a side view of the first preferred embodiment of
the spacer;
[0053] FIG. 3 is a perspective view of the first preferred
embodiment of the spacer;
[0054] FIG. 4 is a plan view of the first preferred embodiment of
the spacer;
[0055] FIG. 5 is a perspective view of a second preferred
embodiment of a spacer according to the first aspect of the
invention;
[0056] FIG. 6 is a plan view of the second preferred embodiment of
the spacer;
[0057] FIG. 7 is a front view of the second preferred embodiment of
the spacer;
[0058] FIG. 8 is a side view of the second preferred embodiment of
the spacer;
[0059] FIG. 9 is a front view of the second preferred embodiment of
the spacer showing on the left hand side a lug fastening two
cladding panels to the spacer and on the right hand side showing
two cladding panels that have been adhered to the spacer;
[0060] FIG. 10 is a perspective view of a third embodiment of a
spacer according to the first aspect of the invention;
[0061] FIG. 11 is a plan view of the third preferred embodiment of
the spacer;
[0062] FIG. 12 is a front view of the third preferred embodiment of
the spacer;
[0063] FIG. 13 is a side view of the third preferred embodiment of
the spacer;
[0064] FIG. 14 is a front view of parts of four cladding panels
fastened to the third preferred embodiment of the spacer;
[0065] FIGS. 15 and 16 show the first embodiment of the spacer in
close proximity to removably attachable lugs;
[0066] FIGS. 17, 18 and 19 show another embodiment of removably
attachable lugs;
[0067] FIGS. 20, 21 and 22 are further depictions of the removable
lugs shown in FIGS. 15 and 16;
[0068] FIGS. 23, 24, 25 and 26 are depictions of the first
embodiment of the spacer in engagement with the two embodiments of
removable lugs shown in FIGS. 17 to 19 and FIGS. 20 to 23;
[0069] FIGS. 27 and 28 show cladding panels fastened to the first
embodiment of the spacer using the two embodiments of removable
lugs shown in FIGS. 17 to 19 and FIGS. 20 to 23
[0070] FIG. 29 shows cladding panels fastened to the first
embodiment of the spacer using the two embodiments of removable
lugs;
[0071] FIG. 30 is a perspective view of a cladding panel;
[0072] FIG. 31 depicts a plurality of cladding panels fastened to a
plurality of spacers;
[0073] FIG. 32 is a cross sectional view with the left hand end of
a spacer engaged with a piece of plywood concrete containment panel
and the right hand end of the spacer engaged with a polystyrene
concrete containment panel and a cladding panel;
[0074] FIG. 33 is a cross sectional view of a part of a spacer
extending through a concrete containment panel for fastening
engagement with a cladding panel;
[0075] FIG. 34 is a perspective view of a formwork wall prior to
pouring of concrete;
[0076] FIGS. 35, 36, 37 and 38 are views of a straight concrete
containment panel;
[0077] FIGS. 39, 40, 41, and 42 are views of a corner concrete
containment panel;
[0078] FIGS. 43, 44, 45, and 46 are views of an end cap concrete
containment panel;
[0079] FIG. 47 is a perspective view of a straight cladding
panel;
[0080] FIG. 48 is a perspective view of a corner cladding
panel;
[0081] FIG. 49 is a perspective cut away view of a concrete wall
being constructed using preferred embodiments of the present
invention;
[0082] FIGS. 50 and 51 show fastening engagement of a part of a
brace with part of a spacer;
[0083] FIGS. 52, 53 and 54 show an embodiment of a brace;
[0084] FIG. 55 is a perspective view of a plurality of braces
supporting a platform;
[0085] FIG. 56 is a perspective view of some alternative
embodiments of concrete containment panels;
[0086] FIG. 57 is a perspective view of a straight concrete
containment panel;
[0087] FIGS. 58 to 62 are views of a half-component of an
alternative embodiment of the spacer according to the
invention;
[0088] FIGS. 63 to 65 are views of the embodiment of the spacer
formed by inter-engagement of two half-components; and
[0089] FIG. 66 is a front view of a concrete containment panel
adapted for use with the spacer embodiments illustrated in FIGS. 63
to 65; and
[0090] FIGS. 67 to 69 are views of the spacers of FIGS. 63 to 65
when assembled with the concrete containment panels of FIG. 66.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0091] Referring to the drawings, the spacer 1 defines a body 2
having two opposed sides 3 and 4. The body 2 defines a separation
distance between the opposed sides 3 and 4 for use as a spacer
intermediate at least two concrete containment panels 5 and 6.
Various preferred embodiments have separation distances suitable
for forming walls having concrete thicknesses of 50 mm, 120 mm or
150 mm, for example. Each of the opposed sides 3 and 4 include
fastening means 7 and 8 adapted for fastening of a cladding panel
16 disposed external to the concrete containment panels 5 and 6, as
shown for example in FIGS. 32 and 33.
[0092] The fastening means depicted for example in FIGS. 1 to 9 are
in the form of snap lockable connectors. As shown in FIG. 1, one
embodiment of the snap lockable connector includes four projections
9, 10, 11 and 12 disposed on each side of the spacer 1. Each of the
projections 9, 10, 11 and 12 are resiliently biased for
interlocking engagement with a corresponding formation 13 provided
upon the cladding panel 16. The four projections per side form two
pairs of opposed projections: {9 and 10}; and {11 and 12} disposed
adjacent each other. As shown for example in FIG. 32, the
corresponding formation 13 has a cross sectional profile defining a
leading portion 14 having a width greater than a width between
respective ends of a pair of projections {9 and 10} or {11 and 12}.
The cross sectional profile of the corresponding formation 13 also
has a trailing portion 15 having a width less than the width of the
leading portion 14. Hence, insertion of the leading portion 14 of
the corresponding formation 13 between a pair of projections {9 and
10} causes the projections to bend so as to allow the leading
portion 14 to pass through the gap between the pair of projections
{9 and 10}. Once the leading portion 14 has passed through the gap,
the projections 9 and 10 resiliently snap toward their resting
positions so as to abut the trailing portion 15 and thereby snap
lockingly fasten the cladding panel 16 to the spacer 1.
[0093] The first pair of projections {9 and 10} are fastenable with
a first corresponding formation 13 disposed on a first cladding
panel 16. Similarly, the second pair of projections {11 and 12} are
fastenable with a second corresponding formation 17 disposed on a
second cladding panel 18. This allows each spacer 1 to fasten the
edges of two adjacent cladding panels 16 and 18.
[0094] Whilst four projections per side are utilized in the
embodiment illustrated in FIG. 1, it will be appreciated that a
greater or lesser number of projections may be utilized in other
embodiments. For example, a single projection will suffice in some
circumstances.
[0095] In other embodiments (not illustrated) the projections are
disposed upon the cladding panels and the corresponding formations
are disposed on the spacers. That is, the disposition of the male
and female connectors is reversed from that shown in FIG. 32. It
will be appreciated by those skilled in the art that such reversal
is also possible for many of the other forms of fastening means
disclosed in this specification.
[0096] In other embodiments (not illustrated) the fastener is an
interference fit fastener.
[0097] As shown for example in FIGS. 5 to 9, 15 to 29 and 31, some
embodiments of the fastening means 7 include a lug 25 that is
removably attachable to side 3 or 4 of the spacer 1.
[0098] In the embodiment illustrated in FIGS. 5 to 9 the fastening
means 7 includes a slot 19 disposed in the spacer 1. The slot 19
defines a detent 20. A corresponding elongate member 21 is disposed
on lug 25. The lug 25 is removably attachable to the cladding panel
22, as shown in FIG. 9. The lug 25 includes cladding panel
retaining formations in the form of oval shaped handle 24. The
elongate member 21 includes a transversely extending formation 23
adapted for engagement with the detent 20. Insertion of the
elongate member 21 into the slot 19 results in press fit fastening
of the lug 25 to the spacer 1, as shown on the right hand side of
FIG. 7. Two adjacent cladding panels 22 and 26 may be sandwiched
between the spacer 1 and the handle 24 of the lug 25, as shown on
the left hand side of FIG. 9, so as to fasten the cladding panels
22 and 26 to the spacer 1. Prior to fastening in this manner,
adhesive may be applied to the edges of the panels 22 and 26 where
they abut the spacer 1 or the concrete containment panel 5. Once
the adhesive has set, and the cladding panel 22 is adhered to the
spacer 1 and/or the concrete containment panel 5, the external
portion of the lug 25 may be removed by either twisting the handle
24 until it snaps off the elongate member 21 or alternatively, by
pulling on the handle 24 until the formation 23 disengages from the
detent 20 and the elongate member 24 is withdrawn from the slot 19.
A suitable finishing, such as grout, may then be applied to the
gaps left between adjacent cladding panels 22 and 26.
[0099] In another embodiment, the lug 25 dispenses with the
elongate member 21 and instead uses the conesponding formations 13
described above to connect to the spacer 1, as shown in FIGS. 15
and 16. In one embodiment this lug includes an oval shaped handle
24 and in another embodiment the lug includes a connection
component in the form of a T shaped member defining two tongues 29
and 30. The connection component is slidably matable with grooves
31 respectively disposed along two opposed edges of the cladding
panel 33. Hence, the cladding panel 33 is fastenable to the side 3
or 4 of the spacer 1 at any one of a plurality of selectable
connection points lying on the locus of points defined by the
groove 31.
[0100] With reference to the embodiment shown in FIGS. 10 to 14,
the fastening means 7 fixedly disposed on each of the opposed sides
3 and 4 includes a T shaped member 28 defining a pair of opposed
tongues 29 and 30. Each of the tongues 29 and 30 are separately
engageable with conesponding grooves 31 and 32 provided upon two
adjacent cladding panels 33 and 34, as best shown in FIG. 14.
[0101] In yet another embodiment, as shown on the right hand side
of FIG. 29, adhesive is provided upon an external side 65 of the
removable lug 25 and the adhesive is used to fasten the cladding
panel 66 to the removable lug 25.
[0102] The concrete containment panel 5 includes openings 27 to
allow the fastening means 7 to fasten the spacer 1 to the cladding
panel 16 with the concrete containment panel 5 intermediate the
spacer 1 and the cladding panel 16. In some embodiments, such as
that shown in FIG. 57, the openings 27 are disposed at an edge of
the concrete containment panel 5. In other embodiments, such as
that shown in FIG. 66, the openings 73 are disposed remote the
edge, for example in a central region of the concrete containment
panel 72.
[0103] The concrete containment panels 5 of some of the preferred
embodiment are sized so as to correspond with, or be a multiple of,
standard sizing for windows, doors and other typical construction
apparatus. In some preferred embodiments, each of the concrete
containment panels 5 have a height of 300 mm. Advantageously, the
polystyrene from which the concrete containment panels 5 are
constructed provides good insulation properties for the finalized
structure.
[0104] The spacer 1 includes a planar surface 35 disposed at each
of the opposed sides 3 and 4 for engagement with concrete
containment panel 5. More particularly, the concrete containment
panel 5 includes a first slot 36 adapted to receive the planar
surface 35. The body 2 of the spacer 1 also includes two webbing
members 37 and 38 extending intermediate the opposed sides 3 and 4.
The concrete containment panel 5 includes a second slot 39 which
receives the edge of the webbing members 37 and 38 when the planar
surface 35 slides into the first slot 36.
[0105] The body 2 also includes a plurality of positioning
formations 40 adapted for positioning of an elongate member
extending transverse to the spacer body, for example to position a
plumbing pipe, conduit, electrical cable or concrete reinforcing
bar. The positioning formations 40 are in the form of semicircular
ridges upon which the elongate member may securely rest. This
assists in the routing of utilities and reinforcing prior to
pouring of the concrete 67.
[0106] The body 2 also includes two transverse projections 41
disposed such that, in use, an end of the projection 41 abuts, or
is adjacent to, the concrete containment panel 5; thereby further
contributing to the secure engagement of the spacer 1 with the
concrete containment panel 5.
[0107] With reference to FIGS. 57 to 46 the concrete containment
panels 5 are adapted for disposition intermediate the spacer 1 and
the cladding panels 16 and are typically formed from polystyrene or
plywood. The concrete containment panels 5 each define at least
four sides adapted for engagement with like sides of like concrete
containment panels 5. Two of the sides have tongues 42 and the
other two sides have corresponding grooves 43. This assists in the
vertical stacking of concrete containment panels 5 when erecting
the formwork structure. Other embodiments dispense with the tongue
and groove arrangement and instead utilize alternative forms of
interlocking formations, such as the interlocking teeth 62 disposed
on the tops and bottoms of the concrete containment panels 5 shown
in FIG. 56.
[0108] As shown for example in FIG. 57, the concrete containment
panels 5 define an external surface 44 adapted for adhesion of the
cladding panels 16. In the illustrated embodiment this takes the
form of a plurality of parallel slots 45, however any other surface
treatments that prompt adhesion may alternatively be used.
[0109] Straight sections of formwork are erected using the straight
concrete containment panels 5 illustrated in FIGS. 35 to 38 and 57.
The concrete containment panels 5 shown in FIGS. 39 to 42 are
utilized on corners. To further strengthen the formwork the corner
concrete containment panels 5 include diagonal openings 63 and
slots 64 for engagement of a diagonally oriented spacer 1 adjacent
the corner. The concrete containment panels 5 shown in FIGS. 43 to
46 have U shaped cross sections and are used as formwork end
caps.
[0110] An example of a straight cladding panel 16 is shown in FIG.
47 and a cladding panel 46 adapted for use at a corner is shown in
FIG. 48. The corner cladding panel 46 has a first panel 47 and a
second panel 48 disposed at a preselected angular relationship
relative to each other. Typically the angular relationship is
90.degree.; however other geometries may be required for somewhat
atypical applications. On the corner cladding panels 46, the
fastening formations, in the form of corresponding formations 13,
are disposed on an interior side of the first panel 47. No such
formations 13 are disposed on the second panel 48, which is
substantially planar. This arrangement facilitates fastening of the
corner cladding panel 46 onto spacers 1 from a single direction,
without interference from formations projecting from the second
panel 48.
[0111] Various external finishes are provided upon different
embodiments of the cladding panels 16. For example, some cladding
panels 16 have an external surface finish that mimics or is made
from sandstone, tiles, weatherboard. Yet other embodiments of the
cladding panels 16 are made from gyprock or other suitable cladding
materials.
[0112] Finishes that are typically suitable for use on either an
internal or an external side of a structure are provided upon
various embodiments of the cladding panels 16.
[0113] To counter bulging of the concrete containment panels 5 due
to the weight of the concrete a brace 49 adapted for fastening
engagement with the spacers 1 may be used, as shown in FIGS. 50 to
55. The brace 49 includes an abutment member 50 for abutment with
the concrete containment panels 5. A plurality of fastening means
51 are disposed on the abutment member 50 for fastening engagement
with spacers 1. The fastening means 51 each define a leading
portion 52 and a trailing portion 53. As shown for example in FIG.
50, the leading portion 52 has a width greater than a width of the
trailing portion 53. A pair of opposed lips 54 and 55 are disposed
on the leading portion 52. To fasten the abutment member 50 of the
brace 49 to the spacers 1, the leading portion 52 of the fastening
means 51 is inserted between a pair of projections {9 and 10} on
the spacer. Once the lips 54 and 55 clear the projections 9 and 10,
the projections resiliently snap toward their resting position and
engage the trailing portion 53 so as to fasten the abutment member
50 to the spacer 1. This is repeated with other spacers 1 as
required until the abutment member 50 provides the desired level of
support to counter bulging of the concrete containment panels
5.
[0114] As best shown in FIG. 51, to assist alignment of the
fastening mean 51 of the brace 49 with the fastening means 7 of the
spacers 1, the fastening means 51 of the brace 49 are slidably and
rotatably disposed on a bar 56 disposed upon the abutment member
50.
[0115] The brace 49 includes a strut 57 defining a proximal end 58
disposed on the abutment member 50 and a distal end 59 for
fastening to a support surface, for example a floor. The strut 57
provides further resistance against bulging of the concrete
containment panels 5 due to the weight of the concrete. The strut
57 is centrally and rotatably disposed on the abutment member 50.
In the illustrated embodiment the strut 57 is telescopically
extensible so as to provide a range of usable lengths. Once the
length of the strut has been set, the telescopic joint is lockable
so as to fix the strut 57 at the desired length.
[0116] A platform support bracket 60 is attachable to the brace 49
so as to mount an access platform 61 across a plurality of like
braces 49, as shown in FIG. 55. This provides a useful and stable
platform 61 for personnel to use when during construction, for
example when pouring the concrete.
[0117] An alternative preferred embodiment of the spacer 69 is
depicted in FIGS. 63 to 65. This embodiment consists of a first
component 70 (which is depicted in FIGS. 59 to 62) that is click
lockingly interengagable with a like second component 71 (which is
depicted in FIG. 58). A proximal side 75 of the component 70
defines one of the opposed sides 3 of the spacer 69. A like side 94
on the other component 71 defines the other of the opposed sides 4.
As previously described, each of the sides 3 and 4 define fastening
means 7. The distal end 76 of the component 70 defines an
interengagement means in the form of two prongs 77 and 78 defining
two respective teeth 88 and 89 that are adapted for click locking
interengagement with a corresponding pair of projections 79 and 80
disposed on the other like component 71. Once interengaged, the two
components 70 and 71 collectively form the spacer 69. The proximal
and distal ends 75 and 76 are connected by webbing member 83. As
best shown in FIG. 59, both the distal end 76 and the webbing
member 83 are disposed on one lateral side of the component 70 when
viewed in plan. The projections 86 and 87 are disposed on the other
lateral side. This allows the two like components 70 and 71 to be
placed in a side-by-side relationship as shown in plan view in FIG.
63 such that their respective webbing members are parallel to each
other and their respective prongs interengage with the other
component's projections. The width of the resulting spacer 69 is
substantially equal to the width of the earlier described spacer
1.
[0118] The embodiment of the spacer 69 illustrated in FIGS. 63 to
65 is adapted for use with an alternative embodiment of the
concrete containment panel 72, as illustrated in FIG. 66. The
opening 73 on this embodiment of the concrete containment panel 72
is not provided on or closely adjacent to one of the edges of the
panel (as was the case for the earlier described concrete
containment panel 5). Rather, the opening 73 on this embodiment is
disposed remote of the edges of the concrete containment panel 72.
The opening 73 includes slots 90 and 91 which are adapted to
receive webbing members 92 and 93, which are disposed on the
proximal end 75 of the component 70. The distal ends of the
components 70 and 71 are separately slidably receivable from either
side of the opening 73, with the component 70 or 71 being inserted
in a direction that is substantially perpendicular to the concrete
containment panel 72. (In contrast, for the earlier described
embodiment of the concrete containment panel 5, the spacers 1 are
received into the openings 27 by sliding them in a direction that
is substantially parallel to the concrete containment panel.) This
arrangement is particularly suitable for concrete containment
panels 72 that are taller than the typical 300 mm height of the
earlier embodiments of the concrete containment panels 5. In some
embodiments, the concrete containment panels 72 extend for the full
height of a wall, with a plurality of regularly spaced openings
provided thereupon.
[0119] To assemble formwork using the embodiments of the spacers 69
shown in FIGS. 63 to 65 first and second concrete containment
panels 72 and 82 are positioned parallel to each other such that
their respective openings 73 and 81 are in alignment. A first
component 70 is inserted through the first opening 73 and a second
component 71 is inserted in an opposite direction from the other
side of the formwork through the second opening 81 such that their
respective interengagement means connect and interengage. More
particularly, the teeth 88 and 89 on the prongs 77 and 78 of
component 70 snap lockingly engage the projections 79 and 80 of
component 71. Simultaneously, the teeth on prongs 84 and 85 of
component 71 snap lockingly engage the projections 86 and 87 of the
first component 70. Hence, the two components interengage so as to
form the spacer 69.
[0120] Embodiments of the invention are packaged as construction
kits which include a plurality of spacers 1, a plurality of
concrete containment panels 5, a plurality of cladding panels 16
and, optionally, at least one brace 49. Using such a kit, the
method of formwork construction of a wall includes the following
steps. [0121] If the wall is being erected on a concrete slab, the
slab should be clean, with no extraneous materials to obstruct the
construction process. [0122] Erection of the formwork commences
with a pair of corner concrete containment panels 5, as shown in
FIGS. 39 to 42. Once spacers 1 have been slotted into the spaces 27
and slots 36 and 39, the external corner concrete containment panel
5 is typically placed flush with the corner of the slab. [0123]
Erection of the formwork for the wall is then continued using the
straight concrete containment panels 5 as shown in FIGS. 35 to 38
and 57, or using the corner or end cap panels 5 as required.
Spacers 1 are slotted into these concrete containment panels 5,
which are then stacked onto other concrete containment panels 5
ensuring that the tongues 42 securely engage with the grooves 43
(or ensuring that the teeth 62 securely interengage if the concrete
panels of FIG. 56 are being used). The end cap concrete containment
panels 5 are utilized in positions in which windows, doors or the
like are to be installed. [0124] If non-standard sized concrete
containment panels 5 are required, a hotwire tool is used to cut
tongues and grooves into the polystyrene panels 5, as required.
[0125] The concrete containment panel 5 stacking process continues
so as to form a concrete receptacle, part of which is shown in FIG.
34 by way of example. [0126] Any pipes, conduits or utilities that
may be embedded within the concrete are placed on the positioning
formations 40. [0127] Any reinforcing that may be required, such as
metal rods, starter bars, etc, is disposed within the concrete
receptacle. [0128] If unacceptable bulging of the concrete
containment panels 5 is anticipated, the abutment members 50 of the
braces 49 are fastened onto some of the spacers 1 so as to abut and
thereby support the concrete containment panels 5. [0129] Concrete
67 is poured into the concrete receptacle and allowed to cure.
[0130] The braces 49 are detached from the relevant spacers 1.
[0131] Starting at the top corner of the wall, the corresponding
formations 13 on a corner cladding panel 16, as shown in FIG. 48,
is aligned with the fastening means 7 of the appropriate spacers 1
and press fit fastened into place. [0132] Working downwards, and
alternating sides on which the first and second panels 47 and 48
are fastened, the corner cladding panels 16 are progressively press
fit fastened onto the fastening means 7 of the spacers 1, such that
they are external to the concrete containment panels 5. This
process is continued with the straight cladding panels 16 as shown
in FIG. 47 until the wall is fully clad. Some embodiments make use
of adhesives, such as cornice cement and the like, to supplement
the fastening of the cladding panels 16. However, other embodiments
rely solely on the fastening provided by engagement of the
corresponding formations 13 into the fastening means 7. [0133]
Optionally, grout may be applied to any gaps between adjacent
cladding panels 16.
[0134] It will be appreciated that the step of fastening the
cladding panels 16 to the spacers 1 is relatively straight forward
and may therefore be carried out by unskilled workers. This
compares favorably with the majority of prior art cladding methods,
which typically require specific expertise. Further, the uniform
sizing of the concrete containment panels 5 results in uniformly
distributed spacers 1, which is turn results in regularly
distributed fastening means 7 for fastening of the cladding panels
16. This helps to ensure that the cladding panels are in correct
alignment once fastened.
[0135] Whilst the invention has been described with reference to
specific examples, those skilled in the art will appreciate that it
may be embodied in many other forms.
* * * * *