AU2005239713B2 - Formwork panel - Google Patents

Description

P/00/011 Regulation 3.2 AUSTRALIA Patents Act 1990 ORIGINAL COMPLETE SPECIFICATION STANDARD PATENT Invention Title: FORMWORK PANEL Applicant: STRAMIT CORPORATION PTY LIMITED The following statement is a full description of this invention, including the best method of performing it known to me: 1 1A FORMWORK PANEL The present invention relates to a panel. More particularly, the present invention relates to a panel for use as formwork in the building and construction industries 5 and will be herein described generally in that context. However, it is to be appreciated that the invention has broader application and is not limited to that particular use. Existing concrete structures, such as concrete slabs are generally fabricated on 10 site. The fabrication of such structures is a time consuming, labour intensive and therefore costly exercise. Fabrication of, for example, a concrete slab on site firstly requires the fabrication site to be cleared and other building and construction activities in the immediate area to be suspended. The required formwork that ultimately defines the shape of the concrete slab is positioned 15 and secured. Reinforcement bars, wires and the like are then placed in position and secured in place and concrete is then poured through the open upper end of the formwork. Following this, the concrete is agitated and sufficient time is then allowed for the concrete to set prior to removal of the formwork and recommencement of other building and construction activities on and around 20 the newly fabricated concrete slab. Such a slab fabrication process is complicated even further when a slab is to be fabricated at a height above ground level, such as required when fabricating the floor slabs for each level above ground level in a multi-storey building. This is 25 because formwork and a suitable supporting structure, including propping frames, support bearers and joists, must also be provided on the underside of the slab to be fabricated. Accordingly, slab fabrication is a very time consuming and labour intensive task, 30 especially when constructing large and/or multi-storey buildings incorporating a large number of concrete slabs. It would therefore be desirable to simplify existing concrete slab fabrication techniques. Y:\Ulie\Davin\Provisional\StramitFORMWORKSHEETING-CAP.do 2 According to a broad aspect of the present invention, there is provided a panel for use in forming concrete structures. The panel includes a panel surface having a plurality of ribs, a first female connector and a second female connector. 'The second female connector is spaced on the surface of the panel 5 relative to the first female connector, and the first and second female connectors extend in a longitudinal direction proximate to a first edge of the panel. The panel also includes a male connector extending in a longitudinal direction proximate a second edge of the panel. The male connector is adapted to connect to a female connector of a first adjacent panel, and the first and 10 second female connectors are adapted to connect the panel to a male connector of a second adjacent panel. It is to be appreciated that the panel is adapted for connection to like panel(s) to create an overall formwork panel structure. The formwork panel has been 15 especially, but not exclusively, designed for use in forming concrete slabs. The panel is preferably generally rectangular or square. Further, the first and second panel edges are preferably generally oppositely disposed and parallel. It is to be appreciated, however, that the panel may adopt other shapes including 20 both regular and irregular shapes. The male connector is configured for receiving in (or mating with) one of a first female connector and a second female connector of the first adjacent panel; while the first and second female connectors are adapted to receive (or mate 25 with) a male connector of the second adjacent panel. The first female connector being spaced relative to the second female connecter enables a formwork installer to select the desired effective width of a formwork panel structure when connecting together a number of formwork 30 panels. This is achieved, at least in part, by the installer selecting either of the first and second female connectors to receive the male connector of the second adjacent panel. This feature is advantageous because it substantially reduces (or even obviates) the need for on-site cutting of formwork panels to a size suitable for a particular application. Y:Vuie\Davin\Provisionals\SiramitFORMWORKSHEETNG-CAP.doc 3 Preferably, the male connector is releasably received in, at the installer's discretion, one of the first and second female connectors of the first adjacent panel. Likewise, at the installer's discretion, one of the first and second female connectors preferably releasably receives the male connector of the second 5 adjacent panel. This enables the formwork installer to adjust the formwork arrangement as required prior to the reinforcement laying and concrete pouring stages. Preferably, the connectors retain connected adjacent panels in a substantially 10 common plane. This reduces the opportunity for dirt and debris to penetrate the gap between panels, an effect that could lead to concrete seepage, partial release between the panels after concrete curing or an unsightly finish. The panel may be provided in any practical size. The panel length may be 15 selected to correspond to the length of a concrete slab to be created. In this respect, the panel may be manufactured in a continuous length, and contemporously or subsequently cut to size during the manufacturing process for a specific formwork application. This provides considerable benefit over existing formwork arrangements, which are generally constructed from a 20 plurality of standard short length plywood panels. The panel may be re-useable as formwork for forming two or more separate concrete structures. More preferably, however, the panel is configured for single use. In this respect, the panel may include a means for permanently securing 25 the panel to a cured concrete slab, such that once the concrete slab has cured the panel remains permanently connected to the surface of the concrete slab. Preferably, the ribs are aligned in a substantially parallel manner on the panel surface. Each of the ribs may include any practical profile. One or more of the 30 ribs may include an upwardly and/or outwardly facing generally planar surface to accommodate, for example, pedestrian traffic there over. The generally planar surface may include grooves, knurling, non-slip paint or the like to minimise the potential for pedestrians slipping when walking on the panel. Y:ulie\Davin\Provisionals\StrmhFORMWORKSHEETING-CAP.do 4 The provision of ribs potentially provides considerable advantage, in that a stronger and more robust panel is provided when compared to existing plywood formwork panels. This improved strength and robustness may obviate the need for supporting joists in the formwork structures of some formwork applications. 5 It will be convenient to hereinafter describe a preferred embodiment of the invention with reference to the accompanying drawings. The particularity of the drawings is to be understood as not limiting the preceding broad description of the invention. 10 In the drawings: Figure 1 is an upper perspective view of a panel in accordance with one aspect of the present invention; Figure 2 is an end view of the panel illustrated in Figure 1. 15 Referring to the drawings, there is provided a panel 10 for use in forming concrete structures, especially concrete slabs. The panel 10 is adapted for connection to like panel(s) to create an overall formwork panel structure. 20 The panel is manufactured from galvanised steel, although it is to be appreciated that the panel 10 may be manufactured from any other suitable material. The panel 10 includes a first edge 12, an oppositely disposed second edge 14, 25 an outer, visible surface 16 and a inner, concrete contact surface 18 . The first edge 12 and the second edge 14 are parallel. For safe handling, the edges 12,14 are of a flattened C-shape. A plurality of ribs 20,22,24,26,28,30 extends longitudinally along the panel 10 30 parallel to the edges 12,14. The ribs 20,22,24,26,28,30 are separated by longitudinally extending channels 32,34,36,38,40. The ribs 20,22,24,26,28,30 potentially provide a stronger and more robust panel when compared to existing plywood formwork panels. This improved strength and robustness may obviate Y:\Julic\Davin\Provisionals\StmitFORMWORKSHEETNG-CAP.do 5 the need for supporting joists in the formwork structures of some formwork applications. The longitudinally extending centre lines AA of the ribs 20,22,24,26,28,30 are 5 spaced 100mm apart. This assists in the placement of concrete reinforcement that typically is spaced at increments of 100mm. A longitudinally extending first female connector is provided proximate the first panel edge 12, in the form of a channel 42. A second female connector is also 10 provided proximate the panel edge 12 in the form of channel 32. It is to be appreciated that the channels 42 and 32 are parallel and include substantially identical cross-sections. The respective longitudinally extending centre lines XX and YY of the channels 15 42,32 are spaced at a distance of 100mm. The panel 10 also includes a longitudinally extending channel-shaped male connector 44 proximate the second panel edge 14. The male connector 44 includes an integrally formed longitudinally extending lip 58. 20 The longitudinally extending centre line ZZ of the male connector 44 is spaced at a distance of 600mm from the centre line XX of channel 42 and 500mm from the centre line YY of channel 32. 25 The male connector 44 is adapted to connect to either of the first or second female connectors of a substantially identical first adjacent panel (not illustrated). More specifically, the male connector 44 is adapted to overlap and be received in (or mate with) one of the channels 32 or 42 of a first adjacent panel overlapping the panel edge 14. 30 The channels 32,42 are adapted to connect the panel 10 to a male connector of a substantially identical second adjacent panel (not illustrated). More specifically, the channels 32,42 are adapted to receive (or mate with) a male connector of a second adjacent panel overlapping the panel edge 12. Y:Wil\Davin\Provisionals\StramitFORMWORKSHEETING-CAP.dc 6 It is to be appreciated that the cross-sectional shape of the channels 32,42 differs from that of channels 34,36,38,40. This prevents the male connector of the second adjacent panel being received in any channel other than one of channels 32,42. 5 The effective width of the panel 10 may be reduced by 100mm from 600mm to 500mm by an installer inserting the male connector of the second adjacent panel into channel 32, rather than channel 42. Thus five such panels may be combined in one formwork arrangement to provide an effective formwork width 10 of 2500mm, or may be combined in another arrangement to provide an effective width of 3000mm. It is to be appreciated that effective widths of between 2500mm and 3000mm in 100mm increments are also possible. This feature minimises the need for on site cutting of panels to the required widths for a specific application. 15 The panel 10 is designed to be single use, such that the panel 10 remains permanently secured to the cured concrete structure. In this respect, a means for permanently securing the panel 10 to the cured concrete slab is provided in the form of channel flanges 46,48,50,52,54,56, which securely interlock the 20 panel 10 to the surface of the cured concrete slab. The top planar surfaces of the ribs 20,22,24,26,28,30 include longitudinally extending grooves 43 (only some of which have been labelled). The grooves are particularly useful prior to the placement of reinforcement and concrete 25 pouring, because they minimise the potential for pedestrians slipping when walking on the panel 10. The top surfaces of the ribs 20,22,24,26,28,30 are spaced approximately 40mm apart in order to minimise the risk of a worker turning an ankle or otherwise sustaining an injury whilst walking on the panel surface. 30 Interconnection of two (or more) such panels is simply achieved. The male connector 44 of one panel is inserted into either channel 32,42 of an adjacent channel. It is to be appreciated that the adjacent panels must be angled slightly to one another to enable this to occur. Once the male connector 44 is inserted Y:\hdie\Davin\Provisioals\SrmitFORMWORKSHEETING-CAP.do 7 into the desired channel 32,42, the panels are rotated relative to one another about their connection point until a generally planar (or other desired) panel configuration is achieved. Once in this position, the male connector 44 remains robustly secured within either channel 32,42 of the adjacent panel by the 5 interaction of the lip 58 with and either of the lips 60,62. That is, the lip 58 of the male connector 44 locates behind and is retained in position by either of the lips 60,62 of the channel 32,42. It is to be appreciated that while the cross-sectional shape of the male 10 connector 44 illustrated is preferred, the male connector 44 (and channels 32,42 for that matter) may be manufactured in any other suitable cross sectional shape. Once connected together, adjacent panels are retained in a substantially 15 common plane. This advantageously reduces the opportunity for dirt and debris to penetrate the gap between panels, an effect that could lead to concrete seepage, partial release between the panels after concrete curing or an unsightly finish. 20 It is envisaged that the panel 10 will be manufactured in a continuous length and cut to the required length for a particular formwork application. C-shaped cappings (not illustrated) are fitted to panel ends 64,66 once the panel is cut to the required length or during installation. The C-shaped cappings 25 assist in the safe handling of the panels. More particularly, the C-shaped cappings reduce the risk of injury from accidental contact; such as in the event of a fall or other mishap once the panel is installed. It is envisaged that the C shaped cappings would also assist in preventing concrete seepage. The cappings may be securely connected to the panel 10 by any suitable means, 30 including by riveting or threaded fasteners. The cappings may also be used in conjunction with foam or tape to further minimise concrete seepage. The panel 10 of the present invention is simple and effective to use, in that it advantageously enables the simple interconnection of like-panels to create a Y.ulie\Davin\Provisionals\.tramiLFORMWORKSHEETING-CAP.doc 8 formwork structure of any practical size. The unique connecting arrangement for connecting adjacent panels is also desirably capable of withstanding significant load during use, and prevents dirt, debris and wet concrete entering between interconnected panels. 5 Finally, it is to be understood that various alterations, modifications and/or additions may be introduced into the construction and arrangement of the parts previously described without departing from the spirit or ambit of this invention. 10 Y:ulic\Davin\Provisioals\SrmitPORMWORKSHEETING-CAP.do

Claims (25)

1. A panel for use in forming concrete structures, the panel including: a panel surface having a plurality of ribs, a first female connector, and 5 a second female connector, the second female connector being spaced on the surface of the panel relative to the first female connector, and the first and second female connectors extending in a longitudinal direction proximate to a first edge of the panel, the panel also including a male connector extending in a longitudinal direction io proximate a second edge of the panel, wherein the male connector is adapted to connect to a female connector of a first adjacent panel, and the first and second female connectors are adapted to connect the panel to a male connector of a second adjacent panel. 15

2. A panel according to claim 1, wherein the panel is generally rectangular or square.

3. A panel according to claim 1 or 2, wherein the first and second panel edges are generally oppositely disposed and parallel. 20

4. A panel according to any one of the preceding claims, wherein the male connector is adapted to mate with one of a first female connector and a second female connector of the first adjacent panel. 25

5. A panel according to any one of the preceding claims, wherein the first and second female connectors are adapted to mate with a male connector of the second adjacent panel.

6. A panel according to any one of the preceding claims, when manufactured in a 30 continuous length, and contemporously or subsequently cut to size for a specific formwork application.

7. A panel according to any one of the preceding claims, wherein the ribs are aligned in a substantially parallel manner on the panel surface. SPCC-760551 doc 10

8. A panel according to claim 7, when directly or indirectly dependent on claim 3, wherein each of the ribs are generally parallel to each of the first and second edges.

9. A panel according to any one of the preceding claims, wherein one or more of 5 the ribs include a generally planar surface defining a pedestrian walking surface on one side of the panel, and wherein the pedestrian walking surface preferably includes at least one of grooves, knurling and non-slip paint.

10. A panel according to any one of the preceding claims, when manufactured 10 from steel, preferably galvanised steel.

11. A panel according to any one of the preceding claims, wherein each of the first and second edges is, in profile, a generally flattened C-shape. 15

12. A panel according to any one of the preceding claims, wherein each rib extends along a longitudinally extending centreline, with adjacent centrelines being spaced approximately 100 mm apart.

13. A panel according to any one of the preceding claims, wherein at least one of: 20 the first female connector is in the form of a first channel, and the second female connector is in the form of a second channel.

14. A panel according to claim 13, wherein each of the first and second channels extend along longitudinally extending centrelines spaced approximately 100mm apart. 25

15. A panel according to any one of claims 13 or 14, wherein the male connector is in the form of a third channel, and wherein the third channel preferably includes an integrally formed longitudinally extending lip. 30

16. A panel according to claim 15, wherein the third channel extends along a longitudinally extending centreline spaced approximately 600 mm from the centreline of the first channel and approximately 500 mm from the centreline of the second channel. SPEC-760551 d- 11

17. A panel according to any one of claims 13 to 16, wherein each of the ribs are separated by separating channels, with the cross-sectional shape of each of the separating channels differing from the cross-sectional shapes of each of the first and second channels. 5

18. A panel according to any one of claims 13 to 17, wherein the cross-sectional shape of the first and second channels is substantially the same.

19. A panel according to claim 17, including a means for securing the panel to a lo cured concrete structure, and wherein the means for permanently securing the panel to a cured concrete slab preferably includes a longitudinally extending flange provided on at least one of the first, second, third and separating channels.

20. A panel according to claim 9, or any one of claims 10 to 19 when directly or 15 indirectly dependent on claim 9, wherein the generally planar surfaces of the ribs are spaced approximately 40 mm apart.

21. A panel according to any one of the preceding claims, including oppositely disposed ends having generally C-shaped cappings fitted to the ends. 20

22. A plurality of panels according to any one of the preceding claims, when connected together to create an overall formwork panel structure, and wherein the plurality of panels are preferably connected together in a substantially common plane. 25

23. A panel according to any one of claims 1 to 21, when used to form a concrete slab.

24. A method of connecting a plurality of panels together, each of the panels according to any one of claims 1 to 21, the method including the steps of: 30 -angling two panels to be connected together relative to one another -inserting the male connector of one panel into either of the first or second female connectors of the other panel, -rotating the connected panels into a generally common plane. SPEC-760551 do 12

25. A panel substantially as herein described and illustrated. 5 SPEC-760551.doc