Note: Descriptions are shown in the official language in which they were submitted.
WO 9S/12720 21 7 ~ 9 3 0 PCTJNZg4/00128
A SHUTTER BLOCK USED IN A METEIOD OF C()~ UN~LAu~ ON
The invention relates to a shutter block, such
as a polystyrene shutter block, used in a method of
concrete construction.
The existing shutter blocks such as those
r~ rrihed in European Patent Nos. û13710S and
0092693 can be difficult to use. This is due to
the complex means of ~oining one block to another
and often the lack of a suitable means for
supporting reinforcing rods within the shutter
block .
These existing shutter blocks rely on a
complex ~rr;-n,3 L of spigots and recesses which
require an exact fit. The spigots are easily
damaged. The recesses are easily filled with
foreign body material such as dust and concrete.
Due to the size of the ~ ~ce~s~s it is i ~ f f ~ rll 1 t to
detect and remove the foreign material. Such
damage or contaminations make it ~iffirult and at
times impossible for the shutter blocks to fit
exactly . An exact f it is required to prevent
concrete slurry leakage. The ~oining means for
existing shutter blocks means the shutter blocks
cannot be slid along the top of one another hence
WO 95/12720 ~ 5 9 3 ~ F~ ~ 128 --
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it is ~liffirlllt to compensate for irregular ~oin~
in walls.
The reinforcing rods required for many
concrete constructions are difficult to situate and
keep in place using the existing shutter blocks.
This is particularly so when an exact fit between
separate shutter blocks is not possible.
An object of the present invention is to
provide a simple and quick means of joining one
shutter block to another while ~n;~hl in~ reinforcing
rods to be quickly a~d firmly fixed in place. This
will enable a quick and ~ffir1~nt method of
concrete construction.
Other ob~ects and advantages of the invention
will be apparent from the following description.
In one aspect, this invention provides for a
shutter block, the shutter block including two
regularly spaced shutter walls, each shutter wall
has a cnntinllml~ ridge on its top and a cnnfin~
recess in its bottom, webs are used to connect the
shutter walls and the webs are adapted to hold
reinforcing rods relative to either the top and/or
the bottom of the web.
WO95/12720 ~1 7~93~ P~ CI~
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. .
It is to be appreciated the reverse
orientation of the cnntin~-~ us recesfi and crntinlln~
groove is ; ntc-nrl~ to be covered by the invention .
Preferably one or more dividers can be used to
close the, or any, open ends of the shutter blocks
or can be used to create sections within the
shutter block. The pl ~r ~ L of one or more
individual shutter blocks together will form larger
shutter walls, ~oined by one or more webs adapted
to hold reinforcing rods relative to the top and
bottom of a web.
Preerably the intrrn~l faces of the shutter
walls will include 6haped grooves in which
complementary parts of the divider can fit to close
an open end of the shutter or be used to create a
section within the shutter block.
Preferably the shaped grooves can be dove-
tailed or approximately dove-tailed with curved
edges .
One of the ~Yt~rn~l faces of the shutter walls
can include dovetailed or the like shaped grooves
WO 95112720 2 1 7 5 9 3 0 ; P ~
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which assist an ~Yt~rnAl plaster coating to key to
the wall.
Preferably the shutter walls are corrugated on
their outer and end faces.
By ~_ inin~ different numbers and different
shapes of shutter blocks a preferred shape of
concrete CGA::I Ll u- Lion can be obtained .
A further aspect of the invention provides for
a means of manufacturing the shutter blocks in
which a web or webs is or are placed between two
moulds of a shutter wall which have been f illed
with poly~ Ly~ c balls or a similar material . The
poly~Ly~ e balls in the mould are heated and
expand to form two shutter walls ~oined by the at
least one web.
Preferably a mould filled with poly~Lyr~ e
balls can be heated to form a divider.
A further aspect of the invention provides for
a means of manufacturing the shutter blocks in
which a mould of the divider is f illed with
polystyrene balls or similar material. The
~I WO 9$/12720 2 1 7 5 9 3 ~ . P~
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PO1YD Lylell~ balls in the mould are heated and
expand to f orm a divider .
The shutter walls and dividers can be e~ected
from the moulds by a blast of compressed air.
Further aspects of the invention which should
be considered in all its novel a8pects will become
apparent from the following descriptions which are
given by way of example, onl1r.
Examples of the invention will now be
described with reference to the r-- ~ ying
drawings in which:
Fiqure 1 shows a side elevational view of a
shutter wall (being part of an example of the
invention);
Fiqure 2 shows a plan view of a pair of
shutter wall~ linked by webs to form an example of
shutter block according to the invention;
Figure 3 shows an end elevational view of the
shutter walls shown in Figure 2 with a web joining
them together;
WO95/12720 ~ 9~ PCT/NZ94/00128 0
-- 6 --
Figure 4 shows a pe~ ~,~e~:Live view of the
shutter block according to the invention;
Fiqure 5 shows a plan view of an end wall
block or divider for the shutter block shown in
Figure 2;
Fiqure 6 shows an end view of the end wall or
divider shown in Figure 5;
Figure 7 shows a side view of the end wall or
divider shown in Figures 5 and 6;
Fiqure 8 shows an isometric view of the end
wall or divider shown in Figures 7 and 8;
Fiqure g shows a side view, partly formed, of
a web for the shutter block shown in Figure 2;
Fiqure 10 shows a sectional end view of the
f ormed web shown in Figure 9;
Fiqure 11 sho~s an isometric view of the
formed web shown in Figures 9 and 10;
Figure 12 shows a plan view of a right turn
corner block according to the invention;
~ WO 9~12720 21 7S9 3 0 ~ c 28
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Fiqure 13 shows an elevational view in the
direction of arrows X-X of the right turn corner
block shown in Figure 12;
Fiqure 14 shows ~n elevational view in the
direction of arrows Y-Y ( Figure 12 ~ of the corner
block shown in Figures 12 and 13;
Fiqure 15 shows an isometric . view of the
corner block shown in Figures 12 and 13;
Fiqure 16 shows a plan view of a high f loor
unit for use with the shutter block and end wall
blocks shown in Figures 2 and 5;
Fiqure 17 shown an elevational view of the
high floor unit shown in Figure 16;
Fiqure 18 shows an end elevational view of the
high floor unit shown in Flgures 16 and 17; and
Fiqure 19 shows an i ~, L- ic view of the high
floor unit shown in Figures 16 to 18.
WO 95/12720 2~ r~ l28
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A8 shown in Figures 1 to 4 of the drawings the
shutter block consists of two regularly spaced
shutter walls 1, 2 of equal similar dimensions.
The int~rn~l face of each of the shutter walls
1, 2 includes a plurality of similarly dimensioned
and dove-tail shaped Anrhr~ri n~ grooves 4 . The
dove-tailed grooves 4 are grouped in sets of four 5
and the sets are spaced regularly along the shutter
walls. The shutter walls 1, 2 are ~oined by webs 3
(shown in detail in Figures 9 to 11) positioned at
intervals 6 along the shutter walls between the
sets of grooves 5. The space between each set 5 of
grooves 4 is at least twice space 8 between each
individual dove-tailed groove 4 of a set 5.
Each shutter wall 1, 2 has on its top or
bottom face a c~nt;nlltnl~ ridge 9 or rnnt;nllr~u~
recess 10 (Figure 3). Where the shutter wall 1, 2
has the continuous recess 10 on its top the bottom
will have the continuous ridge 9 . The Cnnt; nlll'Uf~
ridge 9 is of such a proportion that it f its in the
cr~nt;nl~n~ recess 10 of a similar shutter wall
above or below.
The outer face 11 and end face 12 of each
shutter wall 1, 2 are preferably coLLu~c.ted.
WO 95/12720 ~ I . P~, I ,. . L'~ ~12&
2I 7S930 ~ ~
g
The shutter walls 1, ~2 can be connected by at
least one of the webs 3. The webs 3 ~oin the two
shutter walls 1, 2 and have a width of smaller
dimensions than the overall ~idth of the pair of
shutter wall ~, 2 as shown in Figures 2, 3 and 4 .
The webs 3 can be stamped from or moulded from
a sheet of material which is preferably metal. The
confLguration of an example of the web is shown in
Figures 9 to 11. In Figure 9 is shown a web 3
before it is folded into the shape shown in Figures
10 and 11.
The shape and dimension of a web is
D~ ical about the horizontal axis A-A and the
vertical axis B-B.
In use the web 3 is bent along the h~lri 7~nl-
~bend lines C-C and D-D and t alternatively not
shown) can be bent along vertical bend lines.
The web 3 is also bent along lines E-E and F-F
o fo~ fl~Dge- 15 And IC ~t ~ither ~de of th~ wel7
Wo95112720 ~a~,1$93 PcrlNzs4/00l28 ~
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The web 3 ;nr~ four similar sites 16 for
the fixing of reinforcing rods. The sites 16
include lugs 17 which can be twisted to an open
position 80 that a reinforcing rod of smaller
diameter than the recess formed between the site~
16 and lugs 17 can easily be placed in the reces~.
The lug 17 can then be twisted back to the closed
position, as shown in Figures 9 and 11, 80 the
reinforcing rod is fixed in place. It should be
appreciated that there may be variations in the
number and rl A~ L of the sites 80 long as there
is at least one site on the top and bottom of the
web 3.
The web 3 is ~urther configured to include two
larger recesses 19 and 20 for fixing one or more
reinforcing rods tnot shown) to enable a bond be~
to be f ormed when the space between the shutter
walls is filled with concrete. Any reinforcing
held in larger ~ ~cesses 19, 20 is held in position
by wire ties ( not shown ) .
The top or bottom face 21, 22 of a divider 13
or end wall (Figures 5 to 8) has a single
ridge 14 or a single anchoring recess 15. Where a
divider 13 has the single Anrhnri n~ ridge 14 on its
bottom face it has on its top face the single
~ WO9r7/12720 ~ J~ rl~7
~7nrhr~r;n~ recess 15. The single ~nrhnr7n~ ridge 14
i8 of such a proportion that it fits in the single
Anrh~7rin~ recess. The side faces 23 of the divider
13 nre dove-tailed 80 that they are an insertable
f it into the dove-tailed grooves 4 of a shutter
wall. The divider 13 can be inserted ~o that the
single ~nrhr7ri77~ ridge 14 on the top of the divider
13 LU~ 7~0ndS to the c~7nt i n"r7u8 ridge 15 on the
top of the shutter wall . Another option is f or the
single anchoring recess 15 on the top o~ a divider
13 to CG ~ ~olld to the continuous recess on the
top of a shutter wall.
In use a shutter block is formed by
positioning at least one web in a mould, before two
shutter walls are formed by heating poly~7 Ly . ~
balls placed in the mould. A divider is formed by
heating a mould filled with poly~Lyr ~ e beads for
an end wall.
In Figures 12 to 15 is shown an example of
corner shutter block 24. This construction of
blo~k has similar webs 3 to the webs shown in
Figures 9 to 11. The overall length of the walls
25, 26 are modular lengths of a standard block
shown in Figure 4. This enables a standard block
wall crnf i ,777rAtion to be b~ilt with the blocks .
Wo 95112~20 ~ ~ rt S 9 3 0 - F
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The internal walls 27 of the block 24 have
dovetailed grooves 4 in a similar format to that of
the standard block. simi 1 ~r~y the upper edge 8 has
a ridge 29 while the lower edge 30 has a
Lary recess 31.
In Pigures 16 to 19 is shown a high floor unit
32. The unit 32 is used on the periphery of a
floor slab, for example where a door or window i8
to be situated. In this situation the edge 33 of
the unit 32 is aligned with an outside wall of the
floor slab. Concrete can then be s~Le,ed~d off
level with the top surface 34 of the unit 32. Tlle
inner face 35 of the unit 32 is 2,uy~oLLed by
spacers 36 which in this example are also
~u--~,LLu~:Led from the polystyrene material. The
spacers 36 are I-shaped (Figures 18 and 19) to
enable reinforcing to be fitted along the edge of
the floor slab.
In use after a floor slab has been poured in
situ a plurality of the shutter blocks are
positioned in place leaving space6 for windows and
doors. These spaces may be relatively easily
formed to plan dimensions by cutting the
polystyrene material as required. Dividers are
~ WO95/12720 17$930 . i F~~ La~
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positioned where n~c~sary to close off any open
ends of the blocks.
After reinforcing is placed in position and
tied down as required the space between the walls
of the blocks is filled with an a~uy~late
cementitious mix . The ~ ri flr and interior can
then be f i n ~ ~h~d of f with an outer plaster or
similar coating as required or by the pl~r L of
an interior lining like gib-board on the inside
shutter wall.
In use the erected block walls can be
stâbilised by reusable braci:ng formed from
galvanised iron metal sectio~s which are mounted
alongside an inner f2ce of the erected walls with
angled sections tied or braced down to the f loor
slab and fixed by dyna bolts or the like to the
f loor pad .
The exterior wall of the blocks being tied by
wire ties to the inside bracing to for7~ a rigid
7 ' for a concrete pour in the blocks.
The ~hutter blocks for7n a ~Llu~Lule which can
with ~ .. , h and bracing }~e used to create two
WO 95112720 PCTINZ94/00128
217593
~torey ~Llu~_Lul~: as well ns a single storey
r~ Ll u.: L ul ~ .
It is possible to use the shutter block for a
range of constructions or structures which include
concrete wall6 , these include r~R ~ n~ i A 1,
commercial and industrial b~ i 1 rl 1 nqç: .
It is rn~R;h~ that by r ' inin~ all of the
above ~ c to produce a shutter block which may
be used with reinf orcing rods in concrete
construction .
It is to be Ulldl~ l Lood that the scope of the
invention is not limited to the ~ rri hed
-~i c and therefore that numerous variation~
and ~ifiratinnçt may be made to thege: ~ ~1 Ls
without departing from the scope of the invention
~18 set out in this sp~rif~ration and the ~ d
claims .
