US20070175146A1

US20070175146A1 - building formwork module

Info

Publication number: US20070175146A1
Application number: US11/565,437
Authority: US
Inventors: Geoffrey Carlisle
Original assignee: GreenGate Homes Ltd
Current assignee: GreenGate Homes Ltd
Priority date: 2005-12-23
Filing date: 2006-11-30
Publication date: 2007-08-02

Abstract

A building formwork module is described for use in a modular formwork system. The building formwork module comprises a body portion defining at least one elongate channel that extends through the building formwork module, the body portion having at least two sides. A first side is provided with a first distancing means that is arranged such when the first side is disposed in abutting relationship with a side of an adjacent building formwork module an elongate gap is defined between the first side and the side of the adjacent module. A settable material can be directed into the at least one elongate channel and the elongate gap between two adjacent modules.

Description

FIELD OF THE INVENTION

The present invention relates to a building formwork module and to modular formwork systems.

BACKGROUND

The present Applicant has previously developed building formwork modules for use in modular concrete formwork systems. Examples of such building formwork modules can be found in the Applicant's International PCT Application
The present invention is the result of further research into building formwork systems.

SUMMARY OF THE INVENTION

According to a first aspect of the present invention, there is provided a building formwork module for use in a modular formwork system, the building formwork module comprising:

- a body portion defining at least one elongate channel that extends through the building formwork module, the body portion having at least two sides;
  - a first side being provided with a first distancing means that is arranged such when the first side is disposed in abutting relationship with a side of an adjacent building formwork module an elongate gap is defined between the first side and the side of the adjacent module;
- wherein a settable material can be directed into the at least one elongate channel and the elongate gap between two adjacent modules.

According to a second aspect of the present invention, there is provided a modular formwork system comprising a plurality of building formwork modules according to the first aspect, the building formwork modules are arranged in abutting relationship such that the first distancing means of one building formwork module abuts the side of an adjacent building formwork module.
According to a third aspect of the present invention, there is provided a method of constructing a wall using a modular formwork system, comprising:

- providing a plurality of building formwork modules according to the first aspect;
- arranging the plurality of building formwork modules in abutting relationship such that the first distancing means of each building formwork module abuts a side of an adjacent building formwork module to form an elongate gap between adjacent building formwork modules;
- filling each of the at least one elongate channels and elongate gaps with a settable material;
- allowing the settable material to harden.

BRIEF DESCRIPTION OF THE DRAWINGS

In order that the invention may be more easily understood embodiments will now be described, by way of example only, with reference to the accompanying drawings, in which:
FIG. 1 is a perspective view of a building formwork module according to one embodiment of the present invention for use in a modular formwork system;
FIG. 2 is an end view of the building formwork module of FIG. 1;
FIG. 3 is an end view of a spacer module that can be used in combination with the building formwork module of FIG. 1;
FIG. 4 is an schematic end view of a wall formed of building formwork modules of FIG. 1;
FIG. 4 a is an enlarged view of region B in FIG. 4;
FIG. 4 b is an enlarged view of region C in FIG. 4;
FIG. 5 is a cross section view of a building formwork module, as seen along the line A-A in FIG. 2;
FIG. 6 is a side elevation view of the building formwork module of FIG. 1; and
FIG. 7 is a side elevation view of the spacing module of FIG. 3.

DETAILED DESCRIPTION

FIGS. 1 and 2 show a building formwork module 10 according to one embodiment of the present invention. The formwork module 10 has a body portion consisting of two faces 12, 14, which are joined by first and second sides 16 and 18. A web 20 extends between the two faces 12, 14, the web 20 being substantially parallel with the first and second sides 16, 18. Two channels 22, 24 are formed by the faces 12, 14, the first and second sides 16, 18 and the web 20.
FIG. 4 shows a portion of a building formwork system 26 that has formwork modules 10 arranged in a series such that at least one of the sides 16, 18 of a formwork module 10 is disposed adjacent an adjacent module in the series.
The first side 16 is provided with first distancing means in the form of first fins 28. In the embodiment of FIG. 1 there are two first fins 28, although it will be appreciated that other arrangements are envisaged, the important aspect being that at least one first fin 28 is provided. The first fins 28 protrude in a generally normal direction with respect to the exterior surface of the first side 16, with each of the first fins 28 extending along an elongate edge of the first side 16. Similarly, the second side 18 is provided with second distancing means in the form of second fins 30. In the embodiment of FIG. 1 there are two second fins 30. The second fins 30 protrude in a generally normal direction with respect to the exterior surface of the second side 16. Each of the second fins 30 is positioned inwardly of an elongate edge of the second side 18.
As shown in FIGS. 4 and 4 a, two formwork modules 10 can be arranged adjacent one another such that the second fins 30 of a formwork module 10 abut the first side 16 of an adjacent formwork module 10. Similarly, the first fins 28 of a formwork module 10 abut the second side 18 of an adjacent formwork modules 10. As shown in FIG. 4 a, the second fins 30 are offset with respect to the first fins 28 in a direction perpendicular to the elongate direction of the formwork module 10.
A building formwork system 26 is formed by arranging a plurality of formwork modules 10 endwise relative to each other in abutting relationship. Each of the first and second fins 28, 30 protrude from the respective sides 16, 18 such that the first or second fins 28, 30 abut one of the first and second sides 16, 18 of an adjacent module 10. Accordingly, as shown in FIG. 4 a, a gap 32 is formed between adjacent formwork modules 10, with the first and second fins 28, 30 overlapping one another.
A settable material (not shown) is directed into the channels 22, 24 of the formwork modules 10. It will be appreciated that the settable material could be, for example, concrete. The settable material is also directed into the gaps 32 between adjacent formwork modules 10. In this embodiment, the thickness of the gap 32 is determined by the protruding dimension of the first and/or second fins 28, 30, which in this embodiment is approximately 3 mm. The protruding dimension of each of the first and second fins 28, 30 is indicated by dimension X in FIG. 2. Accordingly, the gap 32 formed is approximately 3 mm in thickness. However, it will be appreciated that the actual size of the gap 32 can be selected to accommodate the intended application. The selected size of the gap 32 may be influenced by the flow characteristics and the constituent products of the settable material.
Each of the first and second sides 16, 18 has at least one hole 34. Similarly, the web 20 is provided with at least one hole 34. The holes 34 facilitate the flow of settable material through the web 20 and through the first and second sides 16, 18.
As shown by the broken lines 36 a, 36 b in FIG. 5, the holes 34 in the first and second sides 16, 18 and the web 20 are aligned such that a reinforcing rod 60 can extend transversely through the formwork module 10. Each channel 22, 24 can be provided with a reinforcing rod 62 that extends in a generally longitudinal direction (as indicated by broken lines 36 c) through the respective channel 22, 24.
By alignment of the holes 34 in adjacent formwork modules 10 in a building formwork system 26, a reinforcing rod 60 can extend transversely through the holes 34 in two or more adjacent formwork modules 10. Furthermore, the alignment of holes 34 in adjacent formwork modules enhances the flow of settable material from a formwork module 10 to an adjacent formwork module 10.
It is to be appreciated that during construction of the building formwork system 26, the gaps 32 between adjacent formwork modules 10 are filled with settable material. This can be achieved by the settable material either being poured directly into the gaps 32 or being distributed through the holes 34 into the gaps 32. Hardened settable material within the gaps 32 inhibits the flow of water into and through the interface between adjacent formwork modules 10.
The first and second fins 28, 30 form a gap 32 that is sufficiently large that settable material can readily flow into the gaps 32. Accordingly, the protruding dimension of the first and second fins 28, 30, which determine the size of the gaps 32, is selected based on factors including the constituents of the settable material and/or its flow characteristics. It is to be appreciated that once settable material has filled the gaps 32 and has hardened, a solid body is provided between the two adjacent formwork modules 10 that form the gap. It is the presence of the hardened settable material that inhibits the flow of water and/or gas into and between the adjacent formwork modules 10. This is significant since minimising gaps in the wall minimises corrosion, transfer of sound through the wall, and in the event of a fire, prevents dangerous gases from passing through the wall.
Additionally, the overlap of the first and second fins 28, 30 of adjacent formwork modules 10, as shown in FIG. 4 a, further inhibits the ingress of water into the gaps 32.
As described in the Applicant's International PCT Application No. PCT/AU2004/001502 (the contents of which are incorporated herein by reference), the building formwork system 26 can include one or more spacer modules 38. An example of a spacer module 38 is shown in FIGS. 3 and 7. The spacer module 38 has a first side 40 and a second side 42. The first side 40 has an elongate cavity 44, while the second side 42 has an oppositely directed elongate cavity 46. Each cavity 44, 46 is shaped to receive one of the first and second sides 16, 18 of a formwork module 10. In this embodiment, each cavity 44, 46 is shaped to receive either the first or second side 16, 18 of a formwork module 10.
In this embodiment, the spacer module 38 has a web 48 that separates two primary flanges 50. The web 48 and primary flanges 50 form cavities 44, 46. As shown in FIG. 4 b, when arranged in the building formwork system, by virtue of the fins 30 on the formwork modules 10, a pair of gaps 54 are formed between the spacer module 38 and the adjacent formwork modules 10. Hardened settable material within the gaps 54 inhibits the flow of water between the spacer module 38 and the adjacent formwork modules 10.
Additionally, the overlap of the primary flanges 50 with the formwork modules 10 creates a tortuous path that inhibits the ingress of water into the gaps 54.
A pair of secondary flanges 52 are each generally parallel to and spaced from the primary flanges 50 by an extension 56. The secondary flanges 52 provide a mounting surface for substantially planar sheets (not shown) that form a façade or cladding (both internal and external). The planar sheets may be plasterboard, fibre cement sheeting, overlapping weather boards or the like.
As shown in FIG. 7, the web 48 of each spacer module 38 is provided with holes 58.
The size of the extensions 56 can be selected to provide the desirable spacing between the formwork modules 10 and the planar sheeting. For example, the size of the spacing may be chosen so as to be suitable for receiving insulation material, electrical wiring and/or plumbing. Typically, the spacing is within the range of 5 mm to 65 mm.
Some embodiments of the formwork modules and spacing modules can be formed by an extrusion process. For example, the formwork modules 10 can be formed by extruding continuous lengths of the section and then cutting to length. The holes 34 can be formed by any desired means, such as cutting, drilling, or ablating material.
It will be understood to persons skilled in the art of the invention that many modifications may be made without departing from the spirit and scope of the invention. For example, an alternative embodiment of the building formwork system may be provided in which the distancing means are formed by virtue of the formwork modules having a first side of male configuration and a second side of female configuration. In this alternative embodiment, the male side is received within the female side in an interference fit such that, while portions of the sides are in contact, a gap is formed therebetween. Similarly in respect of the gaps between a formwork module and a spacing module.
A further alternative embodiment may be arranged with distancing means provided on one side only, with the other side being substantially flat. For example, two or more fins may be provided on the one side. In such an embodiment the size of the gaps formed is determined by the dimensions of fins. It will be appreciated that the alignment of adjacent formwork modules of this alternative embodiment, in a direction normal to the wall surface, may need to be achieved by means other than the formwork modules 10 themselves.
It will be appreciated that the settable material can be any material that can harden to form a stone-like mass including, but not limited to, cement, concrete, mortar, and wet and dry grout.
In an alternative embodiment, the sides of a formwork module may be arranged on non-parallel surfaces of the formwork module such that the formwork module forms a corner between two non-parallel walls of the building formwork system. Similarly, a formwork module may be provided with distancing means on three or more sides to form a module of T-shape, for use at the junction of three walls, or a module of generally cross shape, for use at the junction of three or more walls.
In a further alternative embodiment, the faces of the module may be arranged to be non-planar, such that the module can be used to form a curved wall in a building formwork system.
In the claims of this application and in the description of the invention, except where the context requires otherwise due to express language or necessary implication, the words “comprise” or variations such as “comprises” or “comprising” are used in an inclusive sense, i.e. to specify the presence of the stated features but not to preclude the presence or addition of further features in various embodiments of the invention.
It is to be understood that prior art publications referred to herein do not constitute an admission that the publication forms a part of the common general knowledge in the art, in Australia or any other country.

Claims

1. A building formwork module for use in a modular formwork system, the building formwork module comprising:

a body portion defining at least one elongate channel that extends through the building formwork module, the body portion having at least two sides;

a first side being provided with a first distancing means that is arranged such when the first side is disposed in abutting relationship with a side of an adjacent building formwork module an elongate gap is defined between the first side and the side of the adjacent module;

wherein a settable material can be directed into the at least one elongate channel and the elongate gap between two adjacent modules.

2. A building formwork module according to claim 1, further comprising a second distancing means provided on a second of the at least two sides.

3. A building formwork module according to claim 1, wherein the first distancing means comprises one or more first fins that protrude from the first side.

4. A building formwork module according to claim 3, wherein the second distancing means comprises one or more second fins that protrude from the second side and are offset with respect to the first fins in a direction perpendicular to the elongate direction of the module.

5. A building formwork module according to claim 4, wherein the protruding dimension of the second fins is substantially equal to the protruding dimension of the first fins.

6. A building formwork module according to claim 4, wherein the elongate gap is bounded by the first and second sides and one or both of the first and second fins.

7. A building formwork module according to claim 1, wherein each of the at least two sides is provided with at least one hole through which settable material can pass.

8. A building formwork module according to claim 7, wherein the plurality of holes in the sides are aligned such that a reinforcing rod can pass transversely through the building formwork module.

9. A building formwork module according to claim 1, further comprising at least one web that is connected to the first and second faces, the at least one web bounding adjacent elongate channels extending through the module.

10. A building formwork module according to claim 9, wherein each of the at least one web is provided with at least one hole through which settable material can pass.

11. A modular formwork system comprising a plurality of building formwork modules according to claim 1, wherein the building formwork modules are arranged in abutting relationship such that the first distancing means of one building formwork module abuts the side of an adjacent building formwork module.

12. A method of constructing a wall using a modular formwork system, comprising:

providing a plurality of building formwork modules according to claim 1;

arranging the plurality of building formwork modules in abutting relationship such that the first distancing means of each building formwork module abuts a side of an adjacent building formwork module to form an elongate gap between adjacent building formwork modules;

filling each of the at least one elongate channels and elongate gaps with a settable material;

allowing the settable material to harden.