GB2056538A - Shuttering system - Google Patents

Abstract

In order to overcome problems with shuttering boards nailed to portions of a partly completed building structure for casting in situ columns, wall junction pillars, lintels etc., a shuttering system is used comprising mould members (80, 81, 90, 91) which are clamped to adjoining already built parts of the structure to define a mould for casting a concrete pillar or column. The mould members are clamped using tie members which are embedded in an adjoining wall portion during its construction and/or extend across the mould space and preferably the tie members are completely contained therein and have internally threaded opposite ends to received threaded bolts which pass through apertures in the mould members to clamp them in place. After the concrete has set the mould members and the bolts are removed leaving the tie members within the thickness of the building structure. <IMAGE>

Description

SPECIFICATION Shuttering system The invention relates to a shuttering system suitable for use in casting concrete during the construction of building structures to form, for example, free standing columns, T-shaped or other junctions between walls, pilasters in walls, corner joints between walls, and lintels and beams over windows and doors.

It is known to form moulds for casting in situ concrete wall junctions, pilasters, lintels etc., using wooded shuttering boards nailed directly to the already constructed neighbouring brick or concrete block wall portions. However, this method has certain disadvantages in requiring relatively skilful manipulation and also the possibility of cracking the neighbouring wall portions to which the shuttering boards are nailed. Moreover, in areas having extreme weather conditions the use of wooden boards is undesirable because they tend to warp, buckle or twist causing faults during usage and/or greatly limiting the working life thereof. The boards forming moulds for the concrete have to be supported using a multiplicity of struts and the erection procedure can be very lengthy.Moreover, it can be difficult or not practicable to erect such shuttering using struts in certain locations in a building structure, e.g. at elevated or relatively inaccessible locations in the structures. Therefore this technique has resulted in limitations in the design of the building structures.

According to the invention there is provided a method for forming a building member which is cast in situ in a building structure, which comprises positioning one or more mould members in a partly complete building structure to define a mould forthe building member generally with portions ofthe mould members overlying or resting on already built members of the structure adjacent the required position of the building member, the mould member(s) being located in position by releasable clamping means which include at least one tie member embedded within one of said already built members during its construction and/or at least one tie member extending across the mould space between a plurality of mould members, casting settable building material, e.g. concrete, into the mould and after the material has set releasing said clamping means and removing the mould elements.

At least a portion of the tie(s) of the clamping means will generally remain within the finished structure.

The invention also provides apparatus suitable for performing a method for forming a building member which is cast in situ in a building structure, which apparatus comprises mould elements for location in place in a partly constructed building to define a mould for the casting in situ of a support member and in most embodiments having edge portions overlying adjacent wall or other members of the structure, and clamping means adapted for cooperation with the mould elements including at least one tie for embedding in a wall or other member of the structure during construction thereof and/or at least one tie for extending across the mould space between the mould elements when in position to define the mould and releasable means for securing end portions of the tie(s) to the mould elements.

Advantages of the invention include the provision of a reusable, and lighter shuttering system for use in fabrication of building structures and one that does away with the need for supporting struts since the shuttering mould members and associated clamping devices provide a self-supporting system.

Moreover, the period for erection of the shuttering is considerably less, e.g. half the time, compared with that involved when conventional wooden board shuttering is used.

The mould members are preferably made of a flexible yet comparatively firm (semi-rigid) and cheap material, e.g. glass, reinforced fibre, so that a robust readily reusable system is achieved but they could also be made of metal e.g. steel/aluminium.

The mould members are generally provided with apertures for screw-threaded securing devices to pass therethrough, the apertures being located and designed to ensure that the pressures and forces likely to occur thereon during casting will not result in displacement of the mould member.

The clamping means in some embodiments comprise tie rods having internal threaded portions at opposite ends thereof. These rods may be embedded within a wall of the building, e.g. cast within respective concrete block wall portions or embedded in mortar between layers of bricks, whereby overlying parts of the mould elements can be clamped thereto by bolts passing through apertures in the mould elements and engaging in internally threaded ends of the ties. After casting the bolts are removed together with the mould elements while the ties remain within the structure. No further finishing work is required because the ties are contained completely within the thickness of the walls.

Such rods may also be used to locate mould members before concrete is cast into the mould.

After casting and setting of the concrete, the bolts can be removed, releasing the mould members with the tie rods left within the concrete mass formed within the mould.

When a free-standing column is constructed it may be cast in sections. One or more ties may be located adjacent the upper end of each section during casting thereof to provide a means for securing to the already formed column section a mould forthe casting of a further section thereabove.

Embodiments of the invention will now be described by way of example and with reference to the accompanying drawings, in which: Figure lisa perspective view of part of a building in which elements of the structure are made by methods according to the invention, Figures 2 to 4 show perspective views of mould members usedforforming building members in accordance with the invention, Figures 5 and 6 show perspective views of mould members for use in casting a free standing column, Figures 7 and 8 show plan views of co-operating mould members for forming circular and hexagonal columns respectively in accordance with the invention, Figure 9 is a perspective view of a building structure having a circular column and wall cornered joint formed in accordance with the invention, Figures 10 and 11 are respectively a perspective view of a support element for use in forming a square section column in accordance with the invention, and a perspective view of such a column being so formed, Figure 12 is a detail in cross-section ofthe device of Figure 10, Figures 13 to 20 show cross-sections of respective mould member assemblies in accordance with the invention for forming a column integral in a wall structure (Figures 13 and 14), a pilaster (Figures 15 and 16), a T-junction (Figures 17 and 17A), a wall corner section (Figure 18), a beam (Figure 19), and a cross-shaped wall junction member (Figure 20), Figure 21 shows diagrammatically details of the moulds used to make the column of Figure 18, Figures 22 and 23 are respectively a plan view and a vertical sectional view of a method in accordance with the invention for forming a wall corner member using a hopper, Figure 24 is a front elevation showing the manufacture of a window lintel in accordance with the invention, Figure 25 is a perspective detail of apparatus for forming another building member in accordance with the invention, Figure 26 is a perspective view of an external staircase showing the formation of an end wall member using a mould trough member as shown in Figure 4, Figure 27 shows a cross-section through a further mould apparatus in accordance with the invention, Figure 28 shows a perspective view of a washerfor use with mould members shown in Figures 2 and 3, Figure 29 shows a pair of mould members for use in constructing a beam or lintel in accordance with the invention, Figure 30 shows a perspective view of three mould members which can be secured together in order to form a lintel or beam mould member of a required size, Figure 31 is a detail of a centering bolt for use with apparatus in accordance with the invention, Figure 32 is a plane view of a lintel manufactured using rolled members as shown in Figure 29, Figure 33 and 33A are details of two releasable clamping means for use in securing mould members.

for performing a method according to the invention, Figure 34 shows another form oftie-rod for use in securingtogetherthe mould members, Figure 35 shows a yet further type of tie-rod and, Figure 36 shows a margin bolt for use in securing the mould members.

Figure 1 shows a building structure having a cast concrete foundation 10 and one or more floors 11 and walls formed of superimposed brick layers or layers 12 formed of pre-cast concrete blocks. Pillars are formed at the corner junctions of the walls and at an intermediate location in the walls by a method in accordance with the invention. Furthermore, window lintels and a cast free-standing circular col umn 13 are also formed in the building structure by a method in accordance with the invention As described in more detail below the moulds for these members are formed using glass reinforced fibre mould members which are clamped in position prior to casting. In the case ofthe corner pillar, a pair of angle mould members are used, the external member 15 being sown in Figure 1.In the case of the integral pillar 1 pair of generally flat mould members are used for each portion of the pillar, the external members 17 and 1!8of each pair being shown in Figure 1. In the caseofthe lintels, a further pair of flat elongate mould members are used, external members 19 and:20 of each pair being shown in Figure 1. Finally, in these ofthe column 13a pair of semi-circular mouldmembers are used, one of which is shown in Figure 7 and has the reference numeral 21.

Figure 2 shows an internal anglemember and Figure 3 shows an external angle mernber for use in forming a corner pillar as shown in Figures 1 and 22.

Both the internal member 1 5A and the external member 15 have elongate slots 20 for securing bolts for securing the members to the adjacent portions of the wall members, and circularapertures 21 for a securing ties which extends directly between the members 15 and 1 5A across the mould space defined thereby. The members may also have apertures 21A, typically at 3 in. centre distances (3" c/s) to provide a securing against sliding of the members. The bolts to be used, e.g. when using the securing ties of Figures 33 and 33A, and indeed the location stud and bolt of Figure 31 are desirably plastics material, e.g. Nylon.

Referring to Figure 22, a tie-member30 preferably as shown in Figure 33 or33A, is embedded in the mortar layer between the layers of bricks (Figure 1) during the construction of the adjoining wall portions and the mould elements 15 and 15Awhich overlie areas of those adjoining wall portions are bolted directly to those ties using bolts 31 which pass through the elongate apertures 20 in the mould members and engage in the internally threaded end portions ofthe tie 30 embedded in the wall. Finally, the mould members are bolted:together using a further tie 34 which may be of the type shown in Figure33, together with a washer 35, shown in greater detail in Figure 28, having aV-shaped internal surface for engagingU the apex of the angle mould members. This tie serves to prevent splaying of the angle membersduringcasting. With the mould members in position casting can then take place using a hopper as shown in Figures 22 and 23.

After the concrete has set the bolts 31 are removed so that the mould members can also be removed to leave the finished product. The tie members 30 and 34 remain within the building structure and no further finishing operation is required since these ties are completely contained within the thickness of the walls and the cast pillar therebetween. As indicated in Figures 2 and 3, the mould members may have at respective ends projecting tongues 40 and grooves (not shown) whereby several such members can be located with respect to one another in an end-to-end relationship to provide a mould of any desired modular length.

Figures 5, 6,7 and 8 illustrate mould members for forming free-standing columns of different crosssectional shape. Figures 5 and 6 illustrate mould membes for rectangular columns, Figure 5 shows a kicker tray 47 for casting a column base portion. The tray 47 is placed on a floor of the building with the two parts A and B held together by at least one tie and bolt device, e.g. as shown in Figures 33 and 33A, with the tie extending across the mould space. When the concrete is cast in the mould the bolts and the mould parts A and B are removed leaving the tie embedding in the concrete for use in securing together mould parts as described below with reference to Figures 1 to 12, Figure 7 is a mould for a circular column and Figure 8 for hexagonal column.

The forming of a circular column is also illustrated in Figure 9. Each mould is formed of two parts A and B which are held together by ties and bolts as indicated in Figure 33 or 33A which passes through the elongate slots 50 as illustrated in Figure 6. Once again these mould members can have tongue and groove connections for providing pillars of any required height in accordance with the modular size of the mould members.

Figures 10, 11 and 12 illustrate a means of casting an upper portion on a lower column portion 60 already constructed. Atwo-part hinged rectangular frame 65 as shown in Figure 10 is closed around the column and a peg 67 passes through aligned holes 68 in the frame in order to hold it in a closed position.

The frame has internal webs 69 which bite into the columns 60 when the frame is secured around it.

Mould members as shown in Figures 5 and 6 are then located on the frame for a further casting operation. The mould members are secured again by ties as shown in Figures 33 or 33A. During the formation of each section of the column 60 one or more such ties remain embedded therein at the upper end of the section 60. The frame 65 is clamped at a position spaced from the upper end of the portion 60so that when the mould members are located thereon the ties cast within column 60 at its upper end can be used for securing the mould members located on the frame.

Figures 13 and 14 show pairs of flat mould members used for casting an integral pillar, for example a pillar 16 as shown in Figure 1. In Figure 13 the mould members are clamped using bolts which engage in ties embedded in the adjoining wall portions, whereas in Figure 14 the mould members are clamped by a single tie extending through the mould space defined by the members which firmly embrace the edges of the adjoining wall portions.

Figures 15 and 16 show mould members for casting a pilaster. In Figure 15, the members are clamped by a single tie which extends between a top-hat shaped mould member 80 and a flat mould member 81, with a pair of centering bolts as shown in Figure 31, provided through the arms of the top-hat section mould member and engaging in the adjoining wall portions in order to assist in preventing splaying of the member 80 during casting. The centering bolts may possibly be set into the mortar of the wall and instead of the construction shown in Figure 31 may comprises base part 82 without the projecting stud.

The part 82 then has a tapped hole to receive a bolt which passes through the arms of the member 80.

The centering device is preferably made of plastics material. In Figure 16 the members 81 and 82 are secured by bolts to tie members embedded in the adjoining wall portions.

Figure 17 shows a mould for a T-section pillar adjoining three wall portions. In this case, a flat mould member 85 and two angle members 86 and 87 are used. The mould members are bolted to tie members embedded in the three adjoining wall portions. Figure 17A shows an alternative clamping arrangement.

Figure 18 shows mould members for making a corner section similar to that described above in connection with Figures 2, 3, 22 and 23. However, the inner angle mould member has two perpendicular flanges 91 and 92 which are bolted to tie members 30 embedded in the adjoining wall portions.

Figure 19 shows an arrangement for forming a beam or lintel for example, an arrangement for forming a lintel over a window as illustrated in Figure 24. For this construction beam members as shown in Figures 29, 30 and 32 are used together with securing ties 30 and bolts 31 clamping the mould members together. The members shown in Figure 30 enable different lengths of mould to be produced by using mould members 99 arranged end-to-end and having tongue and groove connectors therebetween. The members are held together by plates 100 using bolts passing through apertures adjacent the ends of the individual members 99.

Figure 20 shows a construction for forming a pillar where four walls meet. The mould members are four angle sections 110.

Figure 33 shows a securing tie device comprising a tube of high tensile steel having threaded end portions for fixing bolts 31. Figure 33A shows a similar device comprising 2 in. galvanized pipe sections 32 threaded to take 2 in. bolts. The device is made from 2 in. dia galvanized pipe having a diametral slot 32A cut th rough between the end sections 32.

Figures 34,35 and 36, show other possible forms of tie devices for securing the mould members. The type of tie 30 and 32 shown in Figures 33 and 33A is the preferred construction because is can be accommodated completely within the thickness of a wall when the mould members and the bolts 31 are removed so that no finishing operations are required. If the tie shown in Figure 34 is used, then after removal of the mould members and the nuts provided on the threaded ends of the tie member, the projecting end portions ofthetie are removed by severing them at the weakened neck joints with the main body of the tie which remains within the wall.

The tie of Figure 36 is used in conjunction with mould 160 used for forming border sections as shown in Figure 26. The splayed head of this tie is embedded in the wall and the threaded end pass through apertures in the base of the mould member 160. In other embodiments the end ofthe tie may be internally threaded, instead of having the projecting threaded stud as shown in Figure 36, to receive a bolt. This will allow the tie to remain completely embedded in the cast concrete so that no finishing work is required.

Figure 27 illustrates a further tie construction which by using a hammer and plunger device as shown can be knocked out of the cast pillar after the concrete has set, and when the mould members are removed.

Figure 25 shows a variation of an external angle mould member having a flange 120 adjacent its lower end, providing a step for engaging the corner portion of a concrete base on which a wall section is erected. In other embodiments the flange 120 may be replaced by centering bolt device as described above with reference to Figure 31, which passes through an aperture in the mould member and projects therefrom to locate on the floor 11. One or more centering bolts 82 may be used to locate reinforcement provided in the mould.

Figure 26 shows the construction of an external staircase wherein cast end portions 130 are provided along the edges of the wall sections and they are formed by a trough-shaped mould 160 as shown in Figure 4, which is bolted to ties embedded in the wall section during their construction by bolts which pass through elongate apertures in the edges of the trough member as seen in Figure 4. Once again several such trough members can be placed in endto-end relation and located with respect to one another by tongue and groove connections in the end surfaces of the members.

Claims (12)

1. Amethodforforminga building member which is cast in situ in a building structure, which comprises positioning one or more mould members in a partly complete building structure to define together with already built parts of the building structure, a mould for the building member, the mould member(s) being located in position by releasable clamping means which include at least one tie member at least partly embedded within one of said already built parts during its construction and/or at least one tie member extending across the space defined by the mould, casting settable building material and after the material has set, releasing said clamping means and removing the mould members.

2. A method as claimed in claim 1, wherein at least a portion of the tie member(s) remains within parts of the finished building structure.

3. A method as claimed in claim 2, wherein the tie member(s) is sized to be completely contained within said one already built part of the building structure and/or the mould in which said building member is to be formed, with ends of the tie member(s) being exposed for connection thereto of securing members which pass through apertures in the mould members and which are removed together with the mould members after casting.

4. A method as claimed in any preceding claim for casting a column standing on an already built part ofthe building structure, wherein the column is cast in sections, with one or more of said tie members cast in one section towards the upper end thereof to provide a means for securing to that section mould members forming a mould for casting of the next section on top of said one section.

5. Shuttering apparatus suitable for performing a method forforrning a building memberwhich is cast in situ in a building structure, which apparatus comprises at least one mould member for location in place in a partly constructed building to define together with already built parts of the building structure, a mouldforthecasting in situ of a building member, and clamping means adapted for cooperation with the mould elements and including at least one tie memberfor embedding in a wall or other already built part of the building structure during construction thereofiand/or at least one tie member for extending across the mould space when the mould member(s) are in position to define the mould and releasable means for securing end portions of the tie member(s) to the mould elements.

6. Shuttering apparatus as claimed in claim 5, wherein the mould members are made of a plastics material.

7. Shuttering apparatus as claimed in claim 6, wherein the mould members are made of glass, reinforced fibre.

8. Shuttering apparatus as claimed in claim 5, wherein the mould members are made of metal.

9. Shuttering apparatus as claimed in any of claims 5 to 8, wherein the mould members are provided with aperturesforscrew-threaded parts ofthe clamping means to pass therethrough.

10. Shuttering apparatus as claimed in claim 9, wherein said clamping means comprise tie rods having internally threaded portions at opposite ends thereof and screw-threaded securing members for passing through the apertures in the mould members to engage in the internally threaded ends ofthe tie rods.

11. A method for forming a building member which is cast in situ in a building structure substantially as hereinbefore described with reference to the accompanying drawings.

12. Shuttering apparatus substantially as hereinbefore describedwith; reference to, and as illustrated in, the accompanying drawings.