Note: Descriptions are shown in the official language in which they were submitted.
CA 02594374 2007-08-01
EXTRUDED PERMANENT FORM-WORK FOR CONCRETE
This invention relates to a set of extruded fomrwork 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.
B6CKGROUND OF THE INVENTION
There have been many attempts over the years to generate an
altemative form of building construction which utilizes permanent forms into
which
concrete Is poured and cured to provide the structural strength for the
exterior form
work. The use of plastic extruded panels for the formwo~k has previously been
proposed and these can be readily assembled on sight to provide a sbucture
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 dadding and providing in one step a finished
attractive
appearance.
One example and arrangement of this type is shown in Canadian
Patent 967,816 (Rodighiero et ai) 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
CA 02594374 2007-08-01
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from bowing primarRy by transversely extendicg stiffening ribs. However
additionai
wall portions can be provided connected to the side wall 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 5,216,863 (Nessa et al) issued June 8, 1993. This
discloses
a generally cyiindrical structure with one open face where the cylindrical
elements
slide each Into the next using male and female couplings to form a similar
permanent farm work structure to develop the above patent but in which the
structure takes the form of a series of interconnected coiumns.
Canadian Patents 2,215,939, 2,218.600 and 2,226,497 of Piccone
disclose various constructions of form work of a similar nature to that shown
in the
above patent of Rodighiero but many shaped to form the coiumn strueture
similar to
that of Nessa.
It has been determined recently that the most commerciai 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 substantialiy to a minimum so as to
reduce
the construction cost of the initiai formwork. It Is of course important also
to
minimize the labour Involved in assembly of the structures on site.
One problem which arises in meating 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 02594374 2007-08-01
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SUMMARY OF THE INVENTION
It is one object of the present invention, therefore, to provide an
improved set of extnided 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 pluralfty 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 oonnecting 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- portlon and which are arraraged to
span
between the first and second side walls at spaced positions across the width
of the
side walls to hold the first and second walls apart and define a hollow
interior
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therebetween including a plurality of cells farmed 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 connectfng wall panel having a first pair of connector element at
one edge for attachment to respactive ones of the first wall panels and a
second pair
of connector element at an opposed edge for attachment to respective ones of
the
second wall paneis;
the first side wall panels being arranged to support without bowing cast
concrete poured into the interior within each cell;
the flrst side wall panels being supported against bowing by a wall
portion between the connecting wall panels and extending generally parallel
thereto
and thus at right angles to the first side wall panel.
Preferably the connecting walls each InGude a pair of projecting
tongues extending therefrom generally at right angles therato 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 wail paneis indude a plurality of iongitudinally
extending ribs,.each rib including a pair of sides and a pan el portion.
Preferably the connector elements on the connector walls comprise T
shaped members for engagement into co-operating C-shaped members on an inner
surface of the first and second panels.
CA 02594374 2007-08-01
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 plurWity of first side wall panels which are extruded longitudinally to
define a constant cross section along a length of the panel inciuding iwo
opposed
5 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 wail;
a plurality of second slde wall panels which are extruded iongitudinally
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 der['ine a constant cross section along a length of the panel including two
opposed
side edges and an intermediate panel wall portion and which are ananged
to,span
between the first and second side walls at spaced positions across the width
of the
side walls 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 conneefing wall panel having a piurality of' holes for
communicati:on of concrete and reinforcing bars between each cell and the
next;
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s
each connecting wall panel having a first pair of connector element at
one edge for attachment to resperbve ones of the first wall panels and a
second pair
of connector element at an opposed edge for attachment to respective ones of
the
second wall panels:
the first side wall panels being arranged to support without bowing cast
concrete poured into the interior within each cell;
the first side wall paneis including an outer wall facing outwardly of the
interior and an Inner wall generally parallel to the outer wall and spaced
inwardly
therefrom, the outer wall being supported against bowing by a wall portion
between
the cannecfing wall panels and extending generally parallel thereto and thus
at right
angles to the first side wall panel, the wall portion being formed integrally
with the
Inner and outer walls.
Preferably there is provided a plurality of parallel wall portions
interconnecting the inner and outer walls.
Preferably the Inner wall is closed to prevent entry of concrete between
the inner and outer walls.
AcxoFding to a third aspect of the Invention there is provided a set of
extruded panels for use in constructing a fiorm-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 incauding two
opposed
side edges and an intermediate panel wall portion and which are arrariged to
be
connected edge to edge to form a first side wall with a height of the first
side wall
CA 02594374 2007-08-01
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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 cxoss section along a iength 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 longitudinaity
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
span
between the first and second side waHs at spaced positions across the width of
the
side walls to hold the first and second walls apart and define a hollow
intertor
therebetween including a plurality of cells formed between each connecting
wall
panel and the next;
each connecting wa11 panel having a* plurality of holes for
eommunication of concrete and reinforcing bars between each cell and the next;
each eonnecft wall panel having a first pair of connector element at
one edge for attachment to respective ones of the first wall panels and a
second pair
of eonnector element at an opposed edge for attachment to respective ones of
the
second wall panels;
the first side wall panels being arranged to support without bowing cast
concrete poured into the intenor within each cell;
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each first side wall panel being associated with a respective one of a
plurality of inner walls generally parallel to the side wall panel and spaced
inwardly
therefrom, the first side wali panel being supported against bowing by a wall
portion
located between the connecdng wall panels and extending generally parallel
thereto
= 5 and thus at right angles to the first side wall panel. the wall portion
being connected
between the first side panel and the inner wall so as to communicate forces
therebetween.
Preferably the Inner wall and the wall porlion have holes for
penetration of concaeta.
Preferably the inner wall and the first wall panel each have a female
connector thereon for receiving a male connector at the end of the wall
portion.
Preferably the female connector comprises a pair of C-shaped
receptacles facing each other and the male connectors comprise a pair of T-
shaped
members back to back.
Preferably the connector elements on the oonnector walls comp[rse T-
shaped members for engagement into co-operating C-shaped members on an inner
surface of the first and second panels.
Preferab[ythe innerwali and the first wall panel are identical_
Acaording to a fourth aspect of the invention there is provided a set of
extruded panefs for use in constructing a furm-work for concrete comprising:
a plurality of first side wall panels which are extruded longitudinally ta
define a constant cross section along a length of the panel incJuding two
opposed
side edges and an intermediate pane! wall pol#ion and which are arranged to be
CA 02594374 2007-08-01
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connected edge to edge to form a first side wall with a height of the first
stde 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 pluraGty of second side wail panels which are extn,ded longitudinally
to define a constant cross section along a length of the panel including two
opposed
side edges and an intermQdiate 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 paneis 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 poriian and which are arranged to
span
between the first and second side walls at spaced positions across the width
of the
side walls to hold the first and second walls apart and define a hollow
interior
therebetween including a plurality of celts '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
one edge for attachment to respective ones of the first wall panels and a
second pair
of connector element at an opposed edge for attachment to respective ones of
the.
second wal! panels;
CA 02594374 2007-08-01
the first side wall panels being arranged to support without bowing cast
concrete poured Into the Interior within each cell;
each of the fcrst side wall panels being supported against -bowing by a
wall portion located between the connecking wall panels and extending
generally
5 parallel themto and thus at right angles to the first side wall panel. the
wall portion
being connected at one end to the first side wall panel and at its other end
to the
second side wall panel.
Preferably the wall por6on and the connecting walls are Identical.
Preferably the connector elements on the connector walls comprise T-
10 shaped members for engagement into co-operating C-shaped members on an
inner
surface of the first and second panels and wheMn the wall portion 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
wall
portion.
BRIEF DFSCR,IPTIQN OF THE DROWlNCCg
Three altemative embodiments of the invention will now be descnbed
in conjunction with the accompanying drawings in which:
Figure 1 is an isametric view showing In general a fornt-work for
casting of concrete.
Figure 2 is a horizontal cross sectional view of a first embodiment of
the panels acconiing to the present invention to provide a form-work of -the
general
construction shown in Figure 1.
CA 02594374 2007-08-01
Figura 3 is a horizontal cross seotional viev-+ of a second ;embodiment
af the panels according to the present invention to provide a form4ork of the
general construction shown in Figure 1.
Figure 4 is a horizontal cross sectional view of a third embodiment of
the panels aooording to the present inventfon to provide a form work ot the
genera!
construction shown in Figure 1.
b~TA! .ED DESCRIPTIDN
In Figure 1 is shown a forrnwork of the general type shown In the
above Canadian patent of Rodighiero. Thus the construction includes a
plural"ity of
1.0 inside wall panels 10 which stand vertically upwardly and are connected at
side
edges 11 and 12 to fomn an inside wall structure 13. A similar outside wall
structure
14 includes outside wall panels 15 and 1e 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 allbw
concrete
poured into the individual cells defined between the connecting members to.
pass
between the oells 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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12
All of the panels are formed by extrusion so that they hav 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 tongue;s 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 a-nd
inserted into
the cell adjacent the side wall 14 and outside the tongues 22 and 23. The
ooncrete
is thus restricted to the area between the foam"insulation materia124 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.
Tuming firstly to Figure 2, it will be noted that the male connectors 5 on
the interconnecting walls 19 are generally T-shaped with a leg of the T
oonnected to
the connecting wall 19 at its edge and the top of the T generally pa~ailel to
the
connecting wail.
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13 ~
It will be further noted that the female receptacies 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 lop 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 268
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 pane! 19 is not itself visible from the outside of
the structure.
Thus the interconnections between the panels are in the fonr 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 ks substantially equal to the
thickness of the
foam insert of insulation n,aterial.
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
constniction of
Figure 2 but Is provided as an attemative mounting arrangement to allow
flexibility in
the construction to accommodate different structural arrangements and
particularly
the arrangement showri in Figure 3 which may be adopted in some
circuinstances.
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- , i
14
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 acoommodate expansion and contraction which will
occur due to significant temperature changes at the outside surface, ttie
outer wall
panels 15 include rib.s 33 and 34 each of which is defined by an inciiried
side wall
35, an outer panel portion 36 parallel to the plane 32 and a second indined
side wall
35. This arrangement allows 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 af 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 fanned by those ribs.
However the centre section between the ribs Iies 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 ceg and Is prevented from bowing by the constnaction generally
indicated
at 30. In the embodiment of Figure 2 the arrangement which prevents the bowing
is
deflhed by an additionai inside wall 40 and three transverse support wails 41,
42 and
43. The inside wall 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 receptades 26, with the inner wall 40 and with the transverse
connecting
CA 02594374 2007-08-01
walls 41, 42 and 43 to form an integral closed structure defining four hoilow
interior
cells,between the transverse walls. The Inner wall 40 is fully closed so tEiat
concrete
is prevented from entering into the hollow interior cells. The width of the
wall 42 is
slightly greater than that of the walls 41 and 43 and also slightly greater
than the
5 cross bar 26A of the Gshape receptacle 26 so that the wall 40 is slightly V-
shaped
reaching an apex at the wall 42.
The double wall integral stnicture 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 eells can also provide a space
for
10 receiving util'ifies such as wiring and the Iike.
Tuming now to Figure 3, there is shown an altemative constn,ction
which uses the same connector walls 19 and the same outer wall panel's 15 as
that
of Figure 2.
In this embodlment the inner wall panel 10 includes the same C-
15 shaped receptades 26 but is fomved only from a single sheet of plastics
material as
Indicated at 50: In this embodiment the single wall 50 inctudes two female
receptacies 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 supporfing wall portion 54. Thus the C-shaped receptacies 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 receptat:les 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 68 which is identical in cross sectiun to the
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 hallow 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
walls 50 and 56. Thus the whole of ths stnicti,re is filled with concxete up
to the wall
50 and the additional wall 56 and the support wall 54 are present merely to
provide
support for the wa1150 during instailation.
Tuming now to Fgure 4, there Is shown a further : altemative
arrangement which uses the same inside watl panel 50 and connecting walls 19
as
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 connecting wall 19.
In this embodiment, the support 30 is provided by an additionai support
wall 60 which is identicai in crass sec#lon to the connecting walls 19 and
extends
thus across the full width of the ceil from the side wall 50 to the outside
wall panel
15A. Thus the outside panel 15A is modified relative to that of tlae previous
embodiment by the addition of "haped receptacles 51 A and 52A ! identical in
evnstructPon to the receptacles 51 and 52 on the panel 50. Thus the T-shaped
male
connectQrs on the edge of the support wall are engaged Into the receptade
defined
CA 02594374 2007-08-01
17
by the receptade portions 51A and 52A and at the same time the mala connectors
on the other edge of the wall 60 are engaged into the receptacles 51 arid 52.
Thus
the support wall bridges the whole width of the cell and comrrwnicates 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 efFectiva
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 deparHng 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.
