Note: Descriptions are shown in the official language in which they were submitted.
CA 02298319 2006-08-30
EXTRUDED PERMANENT FORM=WORK FOR CONCRETE
This Invention relates to a set of extruded form-work panels which are
interconnected in use to define a form-work for casting of concrete and which
are
intended to remain in place after the concrete is cured to define inner and
outer
surfaces of the finished concrete structure.
BACKGROUND OF THE INVENTION
There have been many attempts over the years to generate an
alternative form of building construction which utilizes permanent forms into
which
concrete is poured and cured to provide the structurai strength for the
exterior form
work. The use of plastic extruded panels for the formwork has previously been
proposed and these can be readily assembled on sight to provide a structure
into
which reinforcing bars can be inserted and into which the concrete can be
inserted
and into which the concrete can be poured. The plastic panels then remain in
place
forming inside and outside surfaces for the concrete structure thus avoiding
the
necessity for additional cladding and providing in one step a finished
attractive
appearance.
One example and arrangement of this type is shown in Canadian
Patent 957,816 (Rodighiero et al) issued November 19, 1974 which discloses
inside
wall panels and outside wall panels which are connected edge to edge so as to
form
inside and outside walls respectively. The panels are connected edge to edge
and
supported in their spaced position by transverse connecting walls. Embodiments
are disclosed in which an insulation material can be applied between the
concrete
and one of the side walls. The side wall which supports the concrete is
prevented
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2
from bowing primarily by transversely extending stiffening ribs. However
additional
wali portions can be provided connected to the side wali and extending
generally at
right angles thereto so as to hold the side wall against bowing outwardly
under the
weight of the concrete.
A further arrangement which has achieved some commercial success
is shown in US Patent 5,218,$83 (Nessa et al) issued June 8, 1993. This
discloses
a generally cylindrical structure with one open face where the cylindrical
elements
slide each into the next using maie and female couplings to form a similar
permanent form work structure to develop the above patent but in which the
structure takes the form of a series of interconnected columns.
Canadian Patents 2,215,939, 2,218,600 and 2,226,497 of Piccone
disclose various constructions of fonn work of a similar nature to that shown
in the
above patent of Rodighiero but many shaped to form the column structure
similar to
that of Nessa.
It has been determined recently that the most commercial structure for
arrangements of this type is one in which the inside and outside walls are
generally
flat and of course the materials are kept substantially to a minimum so as to
reduce
the construction cost of the initial formwork. It is of course important also
to
minimize the labour involved in assembly of the structures on site.
One problem which arises In meeting the above criteria is to ensure
that the structure is stable and prevents the bowing of the side wall which Is
contact
with the concrete.
CA 02298319 2006-08-30
SUMMARY OF THE INVENTION
It is one object of the present invention, therefore, to provide an
improved set of extruded form-work panels for use in defining a form-work for
casting of concrete structures.
According to one aspect of the invention there is provided a set of
extruded panels for use in constructing a form-work for concrete comprising;
a plurality of first side wall panels which are extruded longitudinally to
define a constant cross section along a length of the panel including two
opposed
side edges and an intermediate panel wall portion and which are arranged to be
connected edge to edge to form a first side wall with a height of the first
side wall
defined by the length of the panels and a width of each panel defining a part
of a
width of the first side wall;
a plurality of second side wall panels which are extruded longitudinally
to define a constant cross section along a length of the panel including two
opposed
side edges and an intermediate panel wall portion and which are arranged to be
connected edge to edge to form a second side wall with a height of the second
side
wall defined by the length of the panels and a width of each panel defining a
part of
a width of the first second wall;
a plurality of connecting wall panels which are extruded longitudinally
to define a constant cross section along a length of the panel including two
opposed
side edges and an intermediate panel wall portion;
each connecting wall panel being arranged to span between the first
and second side walls at with a first side edge of the connecting wall panel
being
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4
connected to the side edges of an adjacent pair of the first side wall panels
and with
a second side edge of the connecting wall panel being connected to the side
edges
of an adjacent pair of the second side wall panels to hold the first and
second walls
apart and define a hollow interior therebetween including a plurality of cells
formed
between each connecting wall panel and the next;
each connecting wall panel having a plurality of holes for
communication of concrete and reinforcing bars between each cell and the next;
each connecting wail panel having a first pair of connector element at
said first side edge for attachment to respective ones of the adjacent pair of
first wall
panels and a second pair of connector element at said second side edge for
attachment to respective ones of the adjacent pair of second wall panels;
the first side wall panels being arranged to support without bowing cast
concrete poured into the interior within each cell;
and a plurality of additional support walls which are extruded
longitudinally to define a constant cross section along a length thereof;
each additional support wall being located between a respective pair of
the connecting wall panels and extending generally parallel thereto and thus
at right
angles to the first side wall panel so as to support the first side wall
panels against
bowing;
each additional support wall being connected at its edges to an
inwardly facing surface of the first and second side wall panels at positions
thereon
spaced from the side edges of the first and second side wall panels;
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wherein the first and second pairs of connector elements on the
connecting wall panels each comprise a T-shaped members for engagement into a
respective co-operating C-shaped members on an inner surface of a respective
one
of the first and second panels at the respective side edge thereof.
5 Preferably the connecting wall panels each include a pair of projecting
tongues extending therefrom generally at right angles thereto at a position
adjacent
to and spaced from the second wall panels for locating between the tongues and
the
second wall panels pieces of rigid foam insulation.
Preferably the second wall panels each include a plurality of
longitudinally extending ribs, each rib including a pair of sides and a panei
portion.
According to a second aspect of the invention there is provided a set of
extruded panels for use in constructing a form-work for concrete comprising:
a plurality of first side wall panels which are extruded longitudinally to
define a constant cross section along a length of the panel including two
opposed
side edges and an intermediate panel wall portion and which are arranged to be
connected edge to edge to form a first side wall with a height of the first
side wall
defined by the length of the panels and a width of each panel defining a part
of a
width of the first side wall;
a plurality of second side wall panels which are extruded longitudinally
to define a constant cross section along a length of the panel including two
opposed
side edges and an intermediate panel wall portion and which are arranged to be
connected edge to edge to form a second side wall with a height of the second
side
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wall defined by the length of the panels and a width of each panel defining a
part of
a width of the first second wall;
a plurality of connecting wall panels which are extruded longitudinally
to define a constant cross section along a length of the panel including two
opposed
6 side edges and an intermediate panel wall portion;
each connecting wall panel being arranged to span between the first
and second side walls at with a first side edge of the connecting wall panel
being
connected to the side edges of an adjacent pair of the first side wall panels
and with
a second side edge of the conneoting wall panel being connected to the side
edges
of an adjacent pair of the second side wali panels to hold the first and
second walls
apart and define a hollow interior therebetween including a plural-ty of cells
formed
between each connecting wall panel and the next;
each connecting wall panel having a plurality of holes for
communication of concrete and reinforcing bars between each cell and the next;
each connecting wall panel having a first pair of connector element at
said first side edge for attachment to respective ones of the adjacent pair of
first wall
panels and a second pair of connector element at said second side edge for
attachment to respective ones of the adjacent pair of second wall panels;
the first side wall panels being arranged to support without bowing cast
concrete poured into the interior within each cell;
and a plurality of additional support walls which are extruded
longitudinally to define a constant cross section along a length thereof;
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each additional support wall being located between a respective pair of
the connecting wall panels and extending generally parallel thereto and thus
at right
angles to the first side wall panel so as to support the first side wall
panels against
bowing;
each additional support wall being connected at its edges to an
inwardly facing surface of the first and second side wall panels at positions
thereon
spaced from the side edges of the first and second side wali panels;
wherein the wall portions and the connecting walls are identical.
According to a third aspect of the invention there is provided a set of
extruded panels for use in constructing a form-work for concrete comprising:
a pfurality of first side wall panels which are extruded longitudinally to
define a constant cross section along a length of the panel including two
opposed
side edges and an intermediate panel wall portion and which are arranged to be
connected edge to edge to form a first side waii with a height of the first
side wall
defined by the length of the panels and a width of each panel defining a part
of a
width of the first side wall;
a plurality of second side wall panels which are extruded longitudinally
to define a constant cross section along a length of the panel including two
opposed
side edges and an intermediate panel wall portion and which are arranged to be
connected edge to edge to form a second side wall with a height of the second
side
wall defined by the length of the panels and a width of each panel defining a
part of
a width of the first second wall;
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a plurality of connecting wall panels which are extruded longitudinally
to define a constant cross section along a length of the panel including two
opposed
side edges and an intermediate panel wall portion;
each connecting wall panel being arranged to span between the first
and second side walls at with a first side edge of the connecting wall panel
being
connected to the side edges of an adjacent pair of the first side wall panels
and with
a second side edge of the connecting wall panel being connected to the side
edges
of an adjacent pair of the second side wall panels to hold the first and
second walls
apart and define a hollow interior therebetween including a plurality of cells
formed
between each connecting wall panel and the next;
each connecting wall panel having a plurality of holes for
communication of ooncrete and reinforcing bars between each cell and the next;
each connecting wall panel having a first pair of connector element at
said first side edge for attachment to respective ones of the adjacent pair of
first wall
panels and a second pair of connector element at said second side edge for
attachment to respective ones of the adjacent pair of second wall panels;
the first side wall panels being arranged to support without bowing cast
concrete poured into the interior within each cell;
and a plurality of additional support walls which are extruded
longitudinally to define a constant cross section along a length thereof;
each between a respective pair of the connecting wall panels and
extending generally parallel thereto and thus at right angles to the first
side wall
panel so as to support the first side wall panels against bowing;
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~
wherein each additional support wall is located between a respective
pair of the connecting wall panels and extending generally parallel thereto
and thus
at right angles to the first side wall panel so as to support the first side
wall panels
against bowing;
each additional support wall being connected at its edges to an
inwardly facing surface of the first and second side wall panels at positions
thereon
spaced from the side edges of the first and second side wall panels;
wherein the first and second pairs of connector elements on the
connecting wall panels each comprise a T-shaped members for engagement into a
respective co-operating C-shaped members on an inner surface of a respective
one
of the first and second panels at the respective side edge thereof;
and wherein each of the additi~onal support wells includes T-shaped
members identical to those of the connector walls and wherein the first and
second
wall panels include two C-shaped receptacles facing each other at a mid point
on an
inside surface thereof for receiving the T-shaped members of the support wall.
BRIEF DESCRIPTION OF THE L1RAWINGS
Three alternative embodiments of the invention will now be described
in conjunction with the accompanying drawings in which:
Figure 1 is an isometric view showing in general a form-work for
casting of concrete.
Figure 2 is a horizontal cross sectional view of a first embodiment of
the panels according to the present invention to provide a form-work of the
general
construction shown in Figure 1.
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Figure 3 is a horizontal cross sectional view of a second embodiment
of the panels according to the present invention to provide a form-work of the
general construction shown in Figure 1.
Figure 4 is a horizontal cross sectional view of a third embodiment of
5 the panels according to the present invention to provide a form-work of the
general
construction shown in Figure 1.
DETAILED DESCRIPTION
In Figure 1 is shown a formwork of the general type shown in the
above Canadian patent of Rodighiero. Thus the construction includes a
plursiity of
10 inside wall panels 10 which stand vertically upwardly and are connected at
side
edges 11 and 12 to form an inside wall structure 13. A similar outside wall
structure
14 includes outside wall panels 15 and 16 connected together at edges 17 and
18.
The inside wall structure 13 and the outside wall structure 14 are
interconnected by connecting wall panels 19 which bridge the space between the
inside and outside wall and also act to connect together the panels at their
edges 11,
12 and 17, 18. The connecting wall panels 19 include holes 20 which allow
concrete
poured into the individual cells defined between the connecting members to
pass
between the cells and thus form an integral concrete structure throughout the
formwork defined between the side walls. Prior to pouring the concrete,
suitable
reinforcing bars 21 can be inserted through the aligned holes in the
connecting
members 20.
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All of the panels are formed by extrusion so that they have a constant
cross section and details of the panels are shown and described in Figures 2,
3 and
4 as set out hereinafter.
The connecting walls 19 have a pair of right angles tongues 22 and 23
projecting outwardly from the sides thereof parallel to the side wall 14 and
closer to
the side wall 14. The tongues thus define a channel for receiving a portion 24
of
rigid foamed insulation material which is cut to the required shape and
inserted into
the cell adjacent the side wall 14 and outside the tongues 22 and 23. The
concrete
is thus restricted to the area between the foam insulation material 24 and the
inside
wall 13.
The connector walls 19 include at each edge a pair of male connectors
25 for insertion into female receptacles 26 at the edges 11 and 12 of the
panels 10
and at the edges 17 and 18 of the panels 15.
In between the edges, it is necessary to provide support for the panels
10 to prevent their bowing inwardly into the building under the weight of the
concrete
prior to its curing. Thus the panels are supported by support walls 30 shown
schematically in Figure 1 and shown in further detail and in different
altematives in
Figures 2, 3 and 4.
Turning firstly to Figure 2, it will be noted that the male connectors on
the interconnecting walls 19 are generally T-shaped with a leg of the T
connected to
the connecting wall 19 at its edge and the top of the T generally parallel to
the
connecting wall.
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It will be further noted that the female naceptades 26 are generally C-
shaped so as to wrap around the top of the T-shaped connector 25. Thus the C-
shape includes a base 26A parallel to the top of the T bar and two legs which
wrap
around the T bar and extend toward the leg of the T bar. Thus the ends of the
legs
on the inside surface of the T bar lies adjacent or in contact with the
respective side
surface of the connecting wall 19. The other leg of the C-shape as indicated
at 26B
is provided on the exposed surface of the side wall panel 10 and forms a
portion or
edge 26C which abuts with the corresponding edge of the next adjacent panel so
that the connecting wall panel 19 is not itself visible from the outside of
the structure.
Thus the interconnections between the panels are in the form of a single
vertical line
providing an attractive appearance.
The interconnection with the outer wall 14 is identical and is again
formed by the T-shaped male members on the connecting wall 19 and a female C
shaped receptacles on the outer wall panels 15, 16.
The right angles tongs 22 and 23 are visible in Figure 2 spaced from
the outer wall 14 by a distance D which is substantially equal to the
thickness of the
foam insert of insulation material.
An additional T-shaped male member 31 is provide don the connecting
wall at a position adjacent to the inner wall 10, This is not used in the
construction of
Figure 2 but is provided as an alternative mounting arrangement to allow
flexibility in
the construction to accommodate different structural arrangements and
particularly
the arrangement shown in Figure 3 which may be adopted in some circumstances.
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The outer wall panels 15 are shaped so as to define a generally flat
plane 32 forming a flat wall structure. However in order to provide an
attractive
appearance and in order to accommodate expansion and contraction which will
occur due to significant temperature changes at the outside surface, the outer
wall
panels 15 include ribs 33 and 34 each of which is defined by an inclined side
wall
35, an outer panel portion 36 parallel to the plane 32 and a second inclined
side wall
35. This arrangement aUows the expansion which will occur to be taken up in
slight
changes in angle in the inclined walls 35. A projecting flange 37 is provided
on the
inside of the rib. From the aesthetics point of view, therefore, the ribs
break up the
appearance of the flat surface so that any imperfections in what would
otherwise be
a totally flat surface are not immediately apparent to the eye. Slight changes
in
angle or surface shape are therefore not visible due to the presence of the
ribs and
the changes of shading which occur due to light pattems formed by those ribs.
However the centre section between the ribs lies in a common plane 32 and
therefore the side wall is basically flat.
In the embodiment of Figure 2, the inside wall 10 supports the concrete
within the cell and is prevented from bowing by the construction generally
indicated
at 30. In the embodiment of Figure 2 the arrangement which prevents the bowing
is
defined by an additional inside wall 40 and three transverse support wafls 41,
42 and
43. The inside wali 40 is equal in width to the panel and forms a contiguous
extension of the inside leg of the C-shaped receptacle 26.
The outer wall 10A of the panel is integrally extruded with the C-
shaped receptacles 26, with the inner wall 40 and with the transverse
connecting
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walls 41, 42 and 43 to form an integrai closed structune defining four hollow
interior
cells between the transverse walls. The inner wall 40 is fully closed so that
concrete
is prevented from entering into the hollow interior cells. The width of the
wall 42 is
slightly greater then that of the watls 41 and 43 and also slightly greater
than the
cross bar 26A of the C-shape receptacle 26 so that the wall 40 is slightly V-
shaped
reaching an apex at the wall 42.
The double wall integral structure thus formed as a simple single
extrusion of the embodiment of Figure 2 thus supports the concrete and
prevents
bowing of the inside wall panel 10. The hollow cells can also provide a space
for
receiving utilities such as wiring and the like.
Turning now to Figure 3, there is shown an alternative construction
which uses the same connector walls 19 and the same outer wall panels 15 as
that
of Figure 2.
In this embodiment the inner wall panel 10 includes the same C-
shaped receptacles 26 but is formed only from a single sheet of plastics
material as
indicated at 50. In this embodiment the single wall 50 includes two female
receptacles 51 and 52 on the inside surface of the panel 50 with the C-shaped
receptacles facing each other and spaced so as to receive the T-shaped male
members 53 of a supporting wall portion 54. Thus the C-shaped receptacles 51
and
52 include as one side of the C-shape, the panel 50 itself and extend from the
panel
at right angles to the panel a leg which wraps around the T bar top of the T-
shape
members 53.
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The wall portion 54 thus is supported by the female receptacles 51 and
52 and projects generally at right angles to the wall 50 to an opposed end 55
spaced
from the panel 50,
An additional wall panel 56 which is identical in cross section to the
5 inner wall panel 10 is attached to the end 55 and to the T-shaped members 31
on
the connector walls 19. The additional wall 56 is thus parallel to the wall 50
and
spaced therefrom across the hollow Interior of the cell. Both the support wall
54 and
the additional wall 56 have holes which allow the concrete to pass through
those
holes from the interior of the cell to enter and fill the rectangular areas
between the
10 walls 50 and 56. Thus the whole of the structure is filled with concrete up
to the wall
50 and the addi'tional wall 56 and the support wall 54 are present merely to
provide
support for the wall 50 during installation.
Turning now to Figure 4, there is shown a further altemative
arrangement which uses the same inside wall panel 50 and connecting walls 19
as
15 that shown in Figure 3. Thus the inside wall panel 50 is connected using
the
receptacles 26 to the male connectors at the edge of the conneGting wall 19.
In this embodiment, the support 30 is provided by an additional support
wall 60 which is identical in cross section to the connecting walls 19 and
extends
thus across the full width of the cell from the side wall 50 to the outside
wall panel
15A. Thus the outside panel 15A is modified relative to that of the previous
embodiment by the addition of C-shaped receptacles 51A and 52A identical in
construction to the receptacles 51 and 52 on the panel 50. Thus the T-shaped
male
connectors on the edge of the support wall are engaged into the receptacle
defined
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16
by the receptacle portions 51A and 52A and at the same time the male
connectors
on the other edge of the wall 60 are engaged into the receptacles 51 and 52.
Thus
the support wall bridges the whole width of the cell and communicates bowing
forces
on the panel across the width of the structure to the outer wall panel 15A,
In this embodiment, the construction is simplified by the fact that the
support wall 60 is identical in cross section to the connecting walls 19 thus
reducing
manufacturing cost and inventory problems.
The arrangements described above therefore provide an effective
support for the inside wall panel to prevent its bowing while allowing use of
simple
forms and reducing manufacturing costs by use of the same cross sectional
elements at different locations in the structure.
Since various modifications can be made in my invention as herein
above described, and many apparently widely different embodiments of same made
within the spirit and scope of the claims without departing from such spirit
and
scope, it is intended that all matter contained in the accompanying
specification shall
be interpreted as illustrative only and not in a limiting sense.
