AU2014265077B2

AU2014265077B2 - A Building Element

Info

Publication number: AU2014265077B2
Application number: AU2014265077A
Authority: AU
Inventors: Kevin SAUNDERS
Original assignee: Knew Pod Systems Pty Ltd
Current assignee: Knew Pod Systems Pty Ltd
Priority date: 2014-11-20
Filing date: 2014-11-20
Publication date: 2017-03-02
Anticipated expiration: 2034-11-20
Also published as: AU2014265077A1

Abstract

A building element for forming a slab or a foundation with a settable material includes a body having an upper surface, a bottom, and a sidewall extending from the upper surface to the bottom. At least one rib-forming channel extends across the upper surface. At least one upright channel is in the sidewall, the upright channel extending from the bottom of the body to the rib-forming channel to be continuous with the rib-forming channel. Figure 13 4t UL" --so ------------- -XXX.: ,xxxx Ki -NNN.". X, -- -------- Figure 14

Description

2014265077 06 Feb 2017 1 A Building Element

FIELD

[0001] Various exemplary embodiments of building elements for forming a slab or foundation are described in this specification. The building elements are commonly referred to as cavity formers or pods.

SUMMARY

[0002] Various exemplary embodiments of a building element for forming a slab or a foundation with a settable material include a body having an upper surface, a bottom, and a sidewall extending from the upper surface to the bottom; a hole defined in the body, the hole being an aperture which extends completely through the body from the upper surface to the bottom, wherein the bottom of the body around the hole is configured to rest against the ground, in operation; at least one rib-forming channel which extends across the upper surface; and at least one upright channel in the sidewall, the upright channel extending from the bottom of the body to the rib-forming channel to be continuous with the ribforming channel.

[0003] The body may have a central aperture which extends through the body from the upper surface to the bottom. The central aperture may be configured to receive a pile. The rib forming channel(s) may intersect the central aperture.

[0004] The body may be generally rectangular in top plan view, and the sidewall may extend along the perimeter of the body.

[0005] The rib-forming channel(s) may extend diagonally across the upper surface from corner to corner, and the upright channel(s) may be at the corners of the body.

[0006] The rib-forming channel(s) may extend from side to side, with the upright channel(s) at the sides of the body.

[0007] Two upright channels and the rib-forming channel may together form one continuous channel. 2014265077 06 Feb 2017 2 [0008] Various exemplary embodiments of a building element system may include two or more of the building elements as described above placed side by side so that an upright channel of one of the building elements is in register with an upright channel of the adjacent building element.

[0009] Various exemplary embodiments of a foundation are formed using the building elements of any one of the preceding claims, the foundation including: a generally flat slab portion formed on the upper surfaces of the bodies of the building elements; a number of reinforcement ribs on the underside of the slab portion which is suspended above the surface on which the foundation is formed, the reinforcement ribs being formed in the rib-forming channels; and a number of feet extending downwardly from the underside of the slab portion past the reinforcement ribs, the feet formed in the upright channels.

[0010] The foundation may include an edge beam depending downwardly from the slab portion, the edge beam having a void or cavity formed in a foot of the edge beam where the edge beam is supported on the surface on which the foundation is formed.

[0011] Various exemplary embodiments of a method of forming a foundation include the steps of: positioning a number of building elements, as described above, on a substrate to form the building element system; displacing a settable material onto the building element system so that at least the upright channels and rib-forming channels are at least partially filled with the settable material; and allowing the settable material to harden.

[0012] Reinforcing elements may be positioned in the rib-forming channels prior to displacing the settable material. Reinforcing elements may also be positioned in the upright channels prior to displacing the settable material.

[0013] Piles may be driven through the central apertures.

[0014] The reinforcing elements that are positioned in the upright channels may be tied to the piles prior to displacing the settable material. 2014265077 06 Feb 2017 3

DESCRIPTION OF THE DRAWINGS

[0015] Figure 1 shows a top perspective view of an exemplary embodiment of a building element in the form of a pod.

[0016] Figure 2 shows a bottom perspective view of the pod of figure 1.

[0017] Figure 3 shows a side perspective view, from below, of the pod of figure 1.

[0018] Figure 4 shows a side view of the pod of figure 1.

[0019] Figure 5 shows a plan view of a number of pods of figure 1 arranged side by side to form part of a building element system.

[0020] Figure 6 shows a top view of another exemplary embodiment of a building element in the form of a pod.

[0021] Figure 7 shows a bottom view of the pod of figure 7.

[0022] Figure 8 shows a perspective view of the bottom of the pod of figure 7.

[0023] Figure 9 shows a perspective view of the top of the pod of figure 7.

[0024] Figure 10 shows a side view of the pod of figure 7.

[0025] Figure 11 shows a top plan view of a number of pods of figure 7 arranged side by side to form part of a building element system.

[0026] Figure 12 shows a perspective view of two of the pods of figure 7 arranged side by side.

[0027] Figure 13 shows a top plan view of a number of the pods of figure 7 arranged side by side and including reinforcement bars located in the rib-forming panels of the pods to form a building element system.

[0028] Figure 14 shows a top plan view of a number of the pods of figure 7 arranged side by side and including a reinforcement mesh located on top of the pods to form a building element system.

[0029] Figure 15 shows a sectional view of a foundation formed by pouring concrete on the pods of figure 1. 2014265077 06 Feb 2017 4

DESCRIPTION OF THE EMBODIMENTS

[0030] In figures 1 to 5 of the drawings, reference numeral 10 generally indicates an exemplary embodiment of a building element. The building element is a pod, also known as cavity or void former.

[0031] The pod 10 is a space filling element when pouring wet concrete to form a slab or foundation. Reference in this specification to a “foundation” includes reference to a “slab” and vice versa. The pod 10 is configured to not be removed once the concrete has set. However, the inventor envisages that, in certain applications, the pod 10 could be removed once the concrete has set.

[0032] A number of pods are placed side by side in a pattern over an area where the concrete for the foundation is to be poured. The pod 10 has features and design elements for forming a novel and useful foundation as described in the following paragraphs. Reference is made in the specification to “concrete”. However, it is to be appreciated that other settable materials suitable for forming foundations or slabs can also be used with the pods. Also, the term “concrete” is to be understood as including various forms of cementitious material that are suitable for construction. Apart from the traditional or conventional concrete, this material could include fibre-reinforced cementitious material, and other lightweight materials that are used in specialised fabrication.

[0033] The pod 10 comprises a body 12 having an upper surface 14, a bottom 16, and a sidewall 18 extending from the upper surface 14 to the bottom 16. The pod 10 is generally rectangular, more specifically square, in top plan view. The upper surface 14 and the bottom 16 are generally parallel to each other.

[0034] The sidewall 18 has four sides 20.1, 20.2, 20.3 and 20.4 depending from the periphery of the upper surface 14. The sides 20 can be between 800mm and 1500mm long, for example 1145mm long. The sidewall 18 can be between 200mm and 400mm high, for example 300mm high. The distance from the upper surface 14 to the bottom 16 of the body 12 can thus be between 200mm and 400mm, for example 300mm. The body 12 may be of any suitable material, including polystyrene, recycled cardboard, plastic, rubber, metal, saw dust or other suitable material. The body 12 can also be fabricated in 2014265077 06 Feb 2017 5 a number of different ways. For example, the body 12 can be moulded, milled, folded from sheet material, such as metal sheeting, and in other suitable ways.

[0035] The inventor envisages that the pod 10 can be infinitely variable in dimensions, to suit ground conditions and any other environments and applications in which the pod 10 is to be used.

[0036] A central aperture in the form of a pile-receiving hole 22 extends through the body 12 from the upper surface 14 to the bottom 16. The hole 22 is generally cylindrical. The hole 22 is at the centre of the body 12. The hole 22 has a bore that is the same or slightly larger than the width of a floor 28 of rib-forming channels 26 in the upper surface 14. The inventor envisages that the hole 22 need not always be used for receiving a pile.

[0037] The rib-forming channels 26 extend across the upper surface 14 from side 20 to opposite side 20. The channels 26 intersect the holes 22 where the channels 26 cross. The channels 26 are orthogonal relative to each other. The channels 26 break the upper surface 14 of the body into four quadrants.

[0038] The rib-forming channels 26 have sides 27 and a floor 28. The sides 27 diverge from the floor 28 to the upper surface 14, as can be seen in figure 4. The ribforming channels 26 thus narrow from top to bottom. The width of the floor 28 of the ribforming channels 26 may be between 70mm and 130mm, for example 100mm. The distance between the sides 27 of the forming channels 26 at the upper surface 14 may be a multiple of between 1.2 and twice the width of the floor 28, for example a multiple of 1.6. The inventor envisages that the channels could be significantly larger when used for heavy industrial applications, such as airport runways, bridges, railway lines, heavy industry factories, and the like.

[0039] The floor 28 is spaced from the bottom 16 of the body 12. The spacing, or thickness of the body 12, between the bottom 16 of the body 12 and the floor 28 of the rib-forming channels 26 may be between 40mm to 100mm, for example 70mm. In the example wherein the sidewall is 300mm high and the spacing between the bottom 16 of the body 12 and the floor 28 of the rib-forming channels 26 is 70mm, the rib-forming channels 26 are 230mm deep measured from the upper surface 14.

[0040] The body 12 has an upright channel 30 formed in each side 20 of the pod 10. The upright channels 30 have a generally U-shaped profile. The upright channels 30 are 2014265077 06 Feb 2017 6 open to the rib-forming channels 26. The upright channels 30 are continuous with the rib forming channels 30. Each rib-forming channel 26 terminates at an upright channel 30 at its respective ends. The upright channels 30 are depressions in the respective sidewalls 18. The upright channels 30 are located midway along each of the sides 20.

[0041] The bottom 16 of the body 12 is generally planar. Four cavities 34 are formed in the bottom 16 of the body 12. Strengthening ribs 36 extend across the cavities 34.

[0042] The pods 10 are arranged side by side with respective sides 20 of adjacent pods 10 in abutment with each other, in use. Figure 5 shows a pod system 48 comprising three pods 10 placed side by side. It will be appreciated that a number of pods 10 are placed side by side to cover the area between the perimeter footing or edge beams of the foundation.

[0043] The sides 20 of the pods 10 abut in a manner wherein the upright channel 30 of one pod 10 is in register with the upright channel 30 of an adjacent pod 10. The upright channels 30 of adjacent pods align to together form a foot cavity 40 extending from the joint upper surfaces 14 to the joint bottom 16 of adjacent pods.

[0044] In figures 6 to 12, reference numeral 100 generally indicates another exemplary embodiment of a building element in the form of a pod. With reference to the preceding drawings, like reference numerals refer to like parts, unless otherwise specified. The use of common reference numerals is intended to be for convenience only and should not be regarded as limiting. It is to be appreciated that characteristics, such as dimensions and materials of fabrication or manufacture that are described with reference to the pod 10, are equally applicable to the pod 100, where possible and appropriate.

[0045] The pod 100 has crosswise rib-forming channels 126 which extend between corners 102 of the body 112 of the pod 100. The rib-forming channels 126 are the same as, or similar to, the rib-forming channels 26 of the pod 10. Each rib-forming channel 126 extends from one corner 102 to an opposite corner 102. The rib-forming channels 126 intersect at the pile-receiving hole 22. 2014265077 06 Feb 2017 7 [0046] Upright channels 130 of the pod 100 are formed at the corners 102 of the body 112. The upright channels 130 are defined by a semi-circular wall or depression. The upright channels 130 have a quarter circular profile.

[0047] Figure 11 shows a pod system 108 comprising four pods 100 placed side by side. A cylindrical foot cavity 140 is formed where the four corners 102 of the pods 100 meet. Figure 12 shows half a foot cavity 140 where two corners 102 of adjacent pods 100 meet. The upright channels 130 are complementary to each other to form the foot cavity 140.

[0048] The pods 10, 100 are arranged in-situ with their bottoms 16 resting on the ground or surface on which the foundation or slab is to be formed. The floor 28 of the rib-forming channels 26, 126 are elevated above the ground or surface. When wet concrete is poured on the pods 10, elevated ribs or beams are formed in the rib-forming channels 26, 126. The formed ribs may be supported relative to the ground by piles received in the central holes 22 and the foot cavity 140.

[0049] The formed ribs are also supported relative to the ground by feet or pillars formed in the foot cavities 40, 140. The foot cavities 40, 140 fill with concrete as the concrete is poured into the rib-forming channels 26. The feet formed in the foot cavities 40, 140 extend from the ground to the ribs formed in the rib forming channels 26, 126.

[0050] Piles or piers (not shown) may be driven into the ground to support the foundation. The piles may extend through the pile-receiving hole 22. The piles may also extend through the foot cavities 40, 140. The concrete poured into the rib-forming channels 26, 126 flows into the pile-receiving holes 22 and/or the foot cavities 40, 140 to form a support collar around the pile.

[0051] Figure 13 shows a side-by-side arrangement of pods 100. A number of reinforcement bars 104 are placed in the rib-forming channels 126. The reinforcement bars 104 may be supported in the channels 126 at a height above the floor 28.

[0052] Figure 14 shows the arrangement of pods 100 including the reinforcement bars and further including a reinforcement mesh 106 placed on top of the pods. The reinforcement mesh 106 may be elevated above the upper surface 14 of the pods 100 by spacers such as chairs or saddles. The reinforcement mesh 106 strengthens the foundation formed by pouring wet concrete on the pods 100. 2014265077 06 Feb 2017 8 [0053] Figure 15 shows a foundation 200 formed by pouring concrete on the pods 10. One of the pods 10 is adjacent formwork to form a perimeter footing or edge beam 208 of the foundation 200. The concrete for the edge beam is poured at the same time as pouring the concrete on top of the pods 10, 100 to form a foundation with an integral edge beam and suspended rib beams.

[0054] The foundation 200 comprises a generally flat slab portion 202 formed on the upper surfaces 14 of the pods 10. A number of criss-crossing reinforcement ribs 204 extend downwardly from the underside 203 of the slab portion 202. The reinforcement ribs 204 are is suspended above the ground surface 206 on which the foundation 200 is formed. The reinforcement ribs 204 are formed in the rib-forming channels 16 of the pods 10. The reinforcement ribs 204 are elevated above the ground surface 206 due to the spacing between the floor 28 of the rib-forming channels 26 and the bottom of the pods 10, 100.

[0055] A number of feet 212 extend downwardly from the underside 203 of the slab portion 202. The feet 212 extend past the lowest point of the reinforcement ribs 204 to be supported on the ground surface 206. The feet 212 are formed in the central apertures 22 and upright channels 30, 130 of the pods 10, 100.

[0056] The reinforcement ribs 204 are supported relative to the ground by the edge beams 208 and the concrete formed feet 212 in the central holes 22 and the foot cavities 40, 140. The concrete formed feet 212 may include piles extending upwardly from the ground and into the central holes 22 and/or the foot cavities 40, 140.

[0057] The edge beam 208 depends downwardly from the slab portion 202. The edge beam has a void or cavity 210 formed in the foot 212 of the edge beam 208 where the edge beam 208 is supported on the ground surface 206. The cavity 210 is formed by placing a void or cavity former 214 on the ground surface where the edge beam is to be formed before pouring the concrete. The cavity former 214 is generally elongate and triangular in cross-section. The cavity former extends to the same height as the floor of the rib forming channel 28.

[0058] The foundation 200 has a number of benefits over traditional waffle foundations. A traditional waffle foundation is formed by placing cavity formers spaced from each other. Crisscrossing internal beams or strip footings on the underside of the 2014265077 06 Feb 2017 9 foundation slab thus extend all the way from the slab portion of the foundation down to the ground along the whole length of the strip footings. When the ground on which the foundation is supported rises or falls, forces are transmitted through the strip footings to the slab and may lead to weakening or cracking of the slab.

[0059] The feet 212 of the foundation 200 accommodate the rising of ground around a foot 212 rather than transferring the upward load onto the reinforcement rib 204 and slab portion 202. The ground can rise to a height at which the reinforcement ribs 204 are suspended above the ground.

[0060] Although the rib-forming channels 26, 126 and upright channels 30, 130 are shown to meet each other at a right angles, there may be a curved transition between the upright channels 30, 130 and the rib forming channels 26, 126. In one embodiment, the upright channels 30, 130 and the rib forming channels 26, 126 may together form one continuous curved channel. This can optimise the strength of the junction between the feet formed in the channels 30, 130 and the reinforcement ribs 204.

[0061] The pods 10, 100 can have any number of uses. These uses can range from application in domestic housing right up to heavy duty applications such as airport runways, and the like, as described above. In addition, the uses can include use as a flotation device with the pods 10, 100 providing the necessary buoyancy where they are fabricated of a material such as polystyrene, or any other expanded plastics material.

For example, the pods 10, 100 could also be fabricated so that they define internal closed volumes. In that embodiment, the pods 10, 100 could define buoyancy chambers so that the slab formed with the points 10, 100 may float. In that application, structures could be formed or built on the resultant slab so that the structures can float.

[0062] The pods 10, 100, can also be used for forming slabs in multi-storey buildings. In that application, suitable support structures could be provided to support the feet 212.

[0063] In use, a number of the pods 10, 100 are positioned on a substrate, such as the ground to form a building element system such that the upright channels 30, 130 of at least one of the pods 10, 100 are in register with the upright channels 30, 130 so that an upright passage is formed. Also, the rib forming channels 26, 126 can be in register with each other to form elongate channels intersecting with the upright passages. 2014265077 06 Feb 2017 10 [0064] Reinforcing elements such as the reinforcement bars 104, or the like, are positioned in the elongate channels, as shown in figures 13 and 14. It is optional that further reinforcing elements such as reinforcing bars, or the like, also positioned in the upright passages. Those could be tied to the reinforcing elements in the channels.

[0065] Piles can be driven through the central apertures. The reinforcing elements could be tied to the piles.

[0066] Concrete is then displaced or poured onto the building element system so that the upright passages and the elongate channels are filled with concrete with the concrete extending above the pods 10, 100. The concrete can then be finished in a conventional manner to form the foundation.

[0067] It is to be understood that the terminology employed above is for the purpose of description and should not be regarded as limiting. The described embodiments are intended to be illustrative of the invention, without limiting the scope thereof. The invention is capable of being practised with various modifications and additions as will readily occur to those skilled in the art.

[0068] Variations, modifications and/or enhancements of one or more embodiments described herein might become apparent to those of ordinary skill in the art upon reading this application. Such variations are therefore to be considered as covered by the appended claims. Moreover, every combination of the various combinations described in this specification are, where practical, covered by the attached claims.

[0069] The use of words that indicate orientation or direction of travel is not to be considered limiting. Thus, words such as “front”, “back”, “rear”, “side”, “up”, “upright”, “down”, “upper”, “lower”, “top”, “bottom”, “forwards”, “backwards”, “towards”, “distal”, “proximal”, “in”, “out” and synonyms, antonyms and derivatives thereof have been selected for convenience only, unless the context indicates otherwise. The inventor envisages that various exemplary embodiments of the claimed subject matter can be supplied in any particular orientation and the claimed subject matter is intended to include such orientations.

[0070] When any number or range is described herein, unless clearly stated otherwise, that number or range is approximate. Recitation of ranges of values herein are merely intended to serve as a shorthand method of referring individually to each 2014265077 06 Feb 2017 11 separate value falling within the range, unless otherwise indicated herein, and each separate value and each separate sub range defined by such separate values is incorporated into the specification as if it were individually recited herein. For example, if a range of 1 to 10 is described, that range includes all intermediate values, for example, 1.1,2.5, 3.335, 5, 6.179, 8.9999, etc., and includes all subrings there between, such as for example, 1 to 3.65, 2.8 to 8.14, 1.93 to 9, etc.

Claims

1. A building element for forming a slab or a foundation with a settable material includes a body having an upper surface, a bottom, and a sidewall extending from the upper surface to the bottom; a hole defined in the body, the hole being an aperture which extends completely through the body from the upper surface to the bottom, wherein the bottom of the body around the hole is configured to rest against the ground, in operation; at least one rib-forming channel which extends across the upper surface; and at least one upright channel in the sidewall, the upright channel extending from the bottom of the body to the rib-forming channel to be continuous with the ribforming channel.

2. The building element as claimed in claim 1, wherein the body is generally rectangular in top plan view, and the sidewall extends along the perimeter of the body.

3. The building element as claimed in claim 2, wherein the rib-forming channel(s) extend diagonally across the upper surface from corner to corner, and the upright channel(s) are at the corners of the body.

4. The building element as claimed in claim 2, wherein the rib-forming channel(s) extend from side to side, with the upright channel(s) at the sides of the body.

5. The building element as claimed in any one of the preceding claims wherein two upright channels and the rib-forming channel together form one continuous channel.

6. A building element system comprising two or more of the building elements as claimed in any one of claims 1 to 5 placed side by side so that an upright channel of one of the building elements is in register with the upright channel of the adjacent building element.

7. A method of forming a foundation, the method including the steps of: positioning a number of building elements, as claimed in any one of claims 1 to 5, on a substrate to form a building element system as claimed in claim 6; displacing a settable material onto the building element system so that at least the upright channels and rib-forming channels are at least partially filled with the settable material; and allowing the settable material to harden.

8. The method as claimed in claim 7, in which reinforcing elements are positioned in the rib-forming channels prior to displacing the settable material.

9. The method as claimed in claim 8, in which reinforcing elements are positioned in the upright channels prior to displacing the settable material.

10. The method as claimed in any one of claims 7 to 9, inclusive, in which piles are driven through central apertures defined in the building elements.

11. The method as claimed in claim 10, in which the reinforcing elements that are positioned in the upright channels are tied to the piles prior to displacing the settable material.