TR2025009248A1 - FORMWORK SYSTEM FOR CONVENTIONAL REINFORCED CONCRETE BUILDING SLAB - Google Patents

Abstract

This invention relates to the molding system of beamed and or beamless slabs in reinforced concrete structures.

Description

DESCRIPTION FORMWORK SYSTEM FOR CONVENTIONAL REINFORCED CONCRETE SLAB TECHNICAL FIELD This invention is a formwork system for beamed and or non-beamed slabs in reinforced concrete structures. State of the Art Conventional slabs, together with their beams, are the horizontal load-bearing elements of the reinforced concrete frame structure system. In addition to being easily adaptable to contemporary architectural developments and requirements, their light weight and flexibility can reduce the total reinforced concrete construction cost by up to 45%. Reinforced concrete structure slabs are designed and implemented with or without beams on steel or reinforced concrete columns and shear walls, and even brick walls. Completing columns and walls to the base elevation of beams before slabs is widely preferred in practice. This preference helps shorten construction time, improve the quality of the concrete pour, and enhance the safety of the pour. However, construction time, quality, and cost-effectiveness are determined by the project and manufacturing system of the slabs. Perfectly completing reinforced concrete production in accordance with the project also improves the quality and reduces the cost of many other manufacturing processes, such as walls, plumbing, plaster, grout, paint, and ceramics. While formwork systems are known as plywood, PVC, fiberglass, or steel-coated "table formworks," modular steel or plywood panels, or "industrial aluminum systems that enable early slab formwork removal using the drop-head system," the "plywood + wood formwork" system, which requires inherited adze mastery, is still widely used for this purpose. The wonderful advantages of the conventional system are being wasted on unskilled but expensive labor, unpredictable molds and consumables, and delayed work schedules. Purpose of the Invention: Our country must create a safe, economical, high-quality "contemporary building stock" as quickly as possible, in line with seismic risk, general economic opportunities, and urgent needs. The "TUNNEL FORMWORK SYSTEM", widely known to the public, requires almost wasteful use of reinforced concrete material, can only meet limited architectural options, is contrary to the concept of contemporary building stocks, requires heavy construction machinery, high upfront investment costs, requires large organized expert teams, and is therefore rarely preferred in "multi-share, small-plot" URBAN TRANSFORMATION projects and elite architectural demands, but is generally "mandatorily preferred" in state tenders due to political and social pressures after natural disasters. Its sociological effects are debated. The urgent need is to reduce the safe installation and dismantling time of conventional reinforced concrete slab formwork. This period for our system is a maximum of 2 (two) days without concrete curing. This period is the same for the tunnel formwork system. With setting accelerators and heat curing, this time can be reduced to even one day. Plywood and similar imported consumables are minimized. The system elements are rated at an average of 6.5 or larger radii ("60 m"), reducing on-site crane mobilization costs. There are no system assembly and disassembly costs at the beginning and end of the project. The system consists of modular elements and does not require additional techniques and investments for different opening sizes and floor heights. Standard floor panels are covered with 3 mm steel sheet, and modular basement floor walls are also available. Figure 1: Our formwork system installed on a typical conventional reinforced concrete slab floor plan with beams, reference numbers, and dismantling directions. Figure 2: Reference numbers of formwork elements in the sections indicated in Figure 1. Figure 3: Figure 1, Sections A-A, unwound from corner formwork, BEAM WINGS folded at both ends and sides, lowered by tilting the formwork with a lowering trolley. Floor formwork in a position to be connected to the crane hook by pushing it directly to the working platform. (7.5x Figure 4: Typical assembled beam formwork elements and reference numbers. Figure 5: Images of standard floor and beam wing, early removable beam base and corner formwork panels. Figure 6: Typical concrete poured formwork, Section B-B Figure 7: Typical dismantling front view, Section B-B. Figure 8: Section A-A, Formwork system installation start, early removable beam base formwork and props. Figure 9: Some formwork accessories Figure 10: Section B-B, Structure frame with completed reinforced concrete fabrication. Explanation of References in Figures 1: Double jointed hinge lever is the key to the system. 2: Standard floor panel (10) inverted U hinge arm for widening and lengthening. 3: Inverted U profile (2), fixing to the floor board, eyebolt with brake stud (St: 75, conical tip) 4) Hinge lever (1) connecting to Beam Wing Mold (6) hanging and folding fixed pin : (1) and (6) installation position chain sink "joint lock and removal pin" and bearing 7: Standard (L=125 cm) floor board spine profile. 8: Puller arm for adjusting the plumb line of Beam Wing Mold (6). 9: Pin connection bearing of Floor board with Puller (8): Standard or special floor board (width=125 cm) 11: Beam wing mold (6) spine profile. 12: Beam wing mold (6) Covering sheet (t=3mm) 13: The bearing of the extension arm (2), which is welded to the floor panel. 14: The upright and base jack of the twin beam base formwork (16) that can be easily dismantled. : The thick-toothed nuts to which the wing formworks that can adjust the different floor thicknesses "sliding within the omega profile" on the edges of the beam base formwork (16) are connected to the base formwork. (Figure 8) 16: The twin beam base formwork that can be easily dismantled. 17: The sliding plate to which the long nut (15) is welded. 18: The necessary plywood or pvc or wooden strip additional coating and the reinforcing metal or wooden rafter underneath, WHEN A SPECIFIC TO THE PROJECT FORMWORK IS NOT USED. 19: Conventional Reinforced Concrete Slab and Beam. (Figure, 2,6,7): Connection pin 21 of the floor panels (10,40) and the hydraulic lowering, tilting and transport trolley (37): Reinforcement cup welded to the backbone of the floor panel (10), containing the pin (20) and the holes for lifting the panel from the top with a crane. 22: Standard 2 V2 "(inch) pipe upright 23: Nut of upper jack (25) 24: 3-pronged sleeve supporting the floor board keel profile (7): Upper jack of floor board upright (22) 26: Hole group in keels (7) for side-by-side attachment of floor board (10) 28: Adapter square prism sleeve in the girder wing formwork keel (11). 29: Column clamp (Figure 9) for connecting the Beam base formworks (16) on the poured column tops. flags. 36: Standard safety net system uprights and supports (Figure 10). between the installed standard floor uprights (22) and the beam base uprights (14). width and length (100 cm x 110 cm), includes multi-stage hydraulic lift system, moves by manually pushing, has a 3 ton lifting capacity. Extra long floor panels (L: 375, 500., 625 cm) Figure : 9, Extra long hinge arm (2). Connection adapter of corner formwork (53) and beam wing formwork (6) (Figure 4). Working Platform in Disassembly or Assembly position. Work safety network system (36) and floor mounting bolt and washer of the working platform (44). Adjustable post of the assembly platform (44). Platform guardrail. Horizontal and diagonal 2" pipe connections of floor and beam posts. Connection bolt and hole of column clamp (29) to the column. Cast reinforced concrete column. Connection bearings and bolts to the twins of early dismantling twin beam base formwork (16). (Figure 8) Extra long floor panel (40) reinforcement. Standard 10 cm x 10 cm floor corner formwork (Figure 1, 4). 55: 'Kikir' (it is an 8 cm high guide concrete cast on the slab to determine the axes of columns and walls) frame angle formwork for columns and walls, creates an 8 cm high threshold, forms the basis for the establishment of upper floor column and wall formwork. 56: Kicker cone bolt 57: 'Kiker' cone foot. 58: Special corner formwork (t=10 mm, 10x10 cm top sheet metal) 59: Beam outer formwork assembly and dismantling console Figure 6, (It is also used in external curtains with adapter bolts) 60: Outer formwork path Figure 6, (Expanded sheet metal cladding) 61: Special beam base formwork post (14). 62: Wheeled bench (sipa) that allows the floor panels to be lowered and moved by the trolley (37) by placing them under the floor panels (10,40) that are dismantled and tilted, and to be pushed to the working platform (44), or to be kept in the place where they are lowered without changing their position. 63: Lifting holes of floor panels. 65: Profile reservation for extending the standard beam wing formwork panel (6). 66: Standard Beam Wing Formwork with Extension PFOF. (Figure 4) Description of the Invention The invention is a study to develop and disseminate the formwork system necessary to solve the "Urban Transformation" problem of "Industrial Mass Housing" technology with reinforced concrete design, which we define as the "Conventional" construction style. Conventional floor plans contain similar geometric elements with different dimensions (Figure 1); floor plans are fundamentally determined by the topographic application of columns and shear walls. After the column and wall fabrications, column clamps (29) are connected to the column tops with connection bolts (49), the "early removable twin base formworks" (16) of the beams are fixed between the columns and walls with bolts (30) Figure 8, the base level of the beam base formwork uprights (14) is adjusted, the connection bolts (51) and earrings (34) of (16) are connected, there are independent sliding long nut plates (15, 17) for the connections to the beam wing formwork (16) on both sides. When the two adjacent beams from the beam base formworks are ready, standard floor uprights (22) are connected to the beam base formwork uprights (14). The floor is adjusted with the beam wing formworks connected, the standard square corner panels (36) are placed on the uprights (24) with a crane, if necessary, additional uprights are placed, the floor height is adjusted (25), the closing bolts (38) are tightened through the adapters (28) to the connection nuts (15) pre-designed according to the floor thickness. Figure 4. The process is repeated according to the gap remaining parallel to the first floor panel placed, the lengths of the telescopic hinge arms (2) of the "last panel" are adjusted and the brake studs (3) are tightened, the gap formed in the corner of the beam wing formwork and the floor is covered with plywood strip (18, 41) when the floor panel is placed, the existing reservations for the extension of the wing formwork The profile placed (65) provides this solution. Figure 1. The wing formwork (6) is aligned with the side sliding plate (17) (16) and screwed with the thick-toothed connection bolt (38), the plumb puller (8) is adjusted. The other parallel floor panels and other floor sections are placed with the same method, final adjustments are made, the side and diagonal reinforcements of the formwork posts and all work safety precautions are completed, the beam wing outer formworks (54) are screwed to the beam base formwork (16) in the same way on the outer formwork path (60) (38), the puller (8) pins are installed, the plumb is adjusted, the floor formwork is ready for the iron reinforcement. 'Kiker' bolts and cones (56, 57) are tightened to the standard corner moulds (36) where the column and curtain 'kiker' angles (55) will be placed, and when the iron reinforcement is completed, the kiker frames (55) are connected, thus creating perfect column or curtain foundations, and in the expert's words, 'piles' are hammered. The next day after the concrete pouring, without touching the lower jack of any pillar, only the horizontal scaffold connections (48) under the floor panel to be dismantled are loosened, the panel transport trolley (37) is driven under the first floor panel (10,40) to be dismantled and the tower is lifted up. Figure 6, the connection pins (20) are easily fitted to the bearings in the connection cup (21) (the arms of the tower are secured by lifting the vehicle). The floor panel (10,40) is secured. The dismantling of the beam wing formworks (6) will begin. THE LEVER HANDLE LOCK PINS (5) ARE REMOVED, (28) ARE REMOVED FROM INSIDE (38), THE CORNER PANEL CONNECTION PINS (43) ARE REMOVED, FIRST THE OPPOSITE END WINGS The end wings are suspended by tightening the pullers (8) and folded inside, Figure 2,3,7, then the side wings are suspended in the same way. The formwork group with folded and suspended side forms is ready to be lowered from the ceiling with a gap of 100 millimeters on each end and a gap of 40 millimeters on the side. The three-pronged sleeves (24) on the standard panel uprights (22) are lowered 2"3 centimeters and turned 90 degrees, thus securing the floor panel group on the sides to be removed later. While the transport trolley (37) tower is shortened, the connected floor panel (10,40) is automatically lowered to the side by its own weight and the physics of the center of gravity. By lying down (Figure 7), and reducing the profile width, it is LOWERED BEAM LEVEL between the untouched floor studs (22), the dismantled stud horizontal connections (48) are reconnected, additional studs are placed in the bare concrete where necessary. The panel (10, 40) is first cleaned and then driven directly onto the platform (44) with the trolley (37), or placed on the transport slats (62) at minimum height where it is, and pinned to wait for their turn to be transferred by crane. Then, by pushing it onto the working platform (44), with the help of the lifting apparatus and holes (63) (Figure (2, 4, 5, 10); the columns, spare beam base formworks and studs will be moved to their new position, and the cycle will begin again. When the two adjacent floor section panels are dismantled and lowered; the column clamp The bolts (29,30,49) will be removed, the upper jack nut (23) of the beam base uprights (14) will be loosened and the "early removable twin beam base formworks (16)" will be removed (Figure 2). It will be installed in its new place with the dismantled column clamp and "spare" uprights (14). Perfect column and wall foundations, ceiling and beam surfaces will be obtained, only primer and paint will be applied. Application of the Invention to Industry URBAN TRANSFORMATION As long as it is one of the most vital problems of our country, we need to apply its solution in the safest, highest quality and most economical way. How we can reduce the REINFORCED CONCRETE COST of Housing Projects with our system is explained below with a few figures. If the number of formworks used in Mass Housing projects is over 80, "project-specific sizes of slab, beam wing and beam base formworks", installation and dismantling are carried out with the least possible number of formwork pieces. The plan shown in Figure 1 is 60 M2, 21 formwork groups (including beam bases) require the use of a crane (max = 1050 (kg), under average construction site conditions; 21 piece formwork x 5 Cranes (60 minutes X 8 hours): and when casting is done at most every two days; 3 sets, even 4 sets of floor props and beam base props are required continuously, this requirement is often overlooked in our country. Including "4 sets of beam bases and floor props", the average WEIGHT of our system is 230 KG/M2 PLAN. In mass housing projects, this figure is reduced to 200kg/m2 plan. It can be reused at least 500 times. USD/KG, cost 1.1 USD/m2. Mold Cost + Mold Labor + Reinforcement Labor ("14 USD/m2 plan) = 19.5 USD/m2 PLAN. Today, the real cost of conventional mold and rebar labor is at least 32 USD/m2 plan. In short, rough labor costs are reduced by 40%, manufacturing speed increases by at least threefold, and the conventional system already reduces steel and concrete costs by 35%. Time and investment cost profitability have not been calculated either. Contemporary building stocks will be created with contemporary architectural plans, plywood and lumber use will almost disappear, and imported materials will be minimized. TR