US20230383558A1

US20230383558A1 - Formwork system and a method of forming a wall

Info

Publication number: US20230383558A1
Application number: US18/204,353
Authority: US
Inventors: Tony Russell JOHNSON
Original assignee: Earth House Holding Ltd
Current assignee: Earth House Holding Ltd
Priority date: 2022-05-31
Filing date: 2023-05-31
Publication date: 2023-11-30
Also published as: CA3201444A1

Abstract

A formwork system that is readily repositionable to facilitate casting of material is disclosed. A front panel and a rear panel are disposed opposite to each other to define a forming space therebetween to receive the material. The front and rear panels sheath the material so as to retain it in the forming space. A coupler extends over the forming space between the front and rear panels and is pivotably coupled thereto to allow rotation of the front and rear panels about the coupler. A tie is spaced apart from the coupler and extends over the forming space between the front and rear panels. The tie is selectively contractible to cause rotation of the front and rear panels away from each other to move the formwork system from a forming position to a release position to selectively engage and disengage with the front and rear panels with the material.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims the benefit of U.S. Provisional Application No. 63/347,450, filed on 31 May 2022.

TECHNICAL FIELD

The disclosure relates generally to rammed earth walls, and more particularly to formwork systems for such walls and methods of forming such walls.

BACKGROUND

There is a growing interest in rammed earth construction. Such construction involves ramming earth using forming systems. Walls made with such walls are environmentally friendly and are sought-after for their aesthetic appeal. Additionally, raw materials are relatively readily available and are relatively stable in cost. However, current systems and methods for constructing such walls lead to high costs, e.g. due to time-consuming methods of forming walls and use of expensive labor and goods. Furthermore, insulating such walls can prove challenging because they are formed in-place. For example, relatively lower performance rigid plastic-based insulation may need to be used.

SUMMARY

In some aspects disclosed herein, there is described a formwork system for casting of material for construction. The formwork system also includes a front panel; a rear panel disposed opposite to the front panel to define a forming space between the front and rear panels for receiving the material for casting, the front and rear panels being suitable to sheath the material so as to retain the material in the forming space; a coupler that extends across the forming space between the front and rear panels and is pivotably coupled to the front panel and to the rear panel to allow rotation of the front and rear panels about the coupler towards and away from each other; and a tie that extends across the forming space between the front and rear panels and that is spaced apart from the coupler, the tie being selectively contractible such that contracting the tie causes rotation of the front and rear panels away from each other to move the formwork system from a forming position, in which the front and rear panels are engaged with the material to retain the material in the forming space, to a release position, in which the front and rear panels are disengaged from the material to prevent the material from impeding movement of the front and rear panels.
In some aspects disclosed herein, there is described a method of assembling a formwork system that is readily repositionable to facilitate casting of material. The method also includes causing connection of a front panel to a rear panel disposed opposite to the front panel, via a tie extending between the front and rear panels, to define a forming space between the front and rear panels for receiving the material for casting, the front and rear panels being suitable to sheath the material so as to retain the material in the forming space, a coupler extending across the forming space between the front and rear panels and being pivotably coupled to the front panel and to the rear panel to allow rotation of the front and rear panels about the coupler towards and away from each other, the tie being selectively contractible such that contracting the tie causes rotation of the front and rear panels away from each other to move the formwork system from a forming position, in which the front and rear panels are engaged with the material to retain the material in the forming space, to a release position, in which the front and rear panels are disengaged from the material to prevent the material from impeding movement of the front and rear panels.
In some aspects disclosed herein, there is described a method of forming a wall using a formwork system. The method also includes receiving material, for casting, in a forming space defined between a front panel and a rear panel disposed opposite to the front panel, the front and rear panels being suitable to sheath the material so as to retain the material in the forming space and pivotably coupled to a coupler extending across the forming space between the front and panels to allow rotation of the front and rear panels about the coupler towards and away from each other; and after casting of the material, shortening a tie spaced apart from the coupler, coupled to the front and rear panels, and extending across the forming space to rotate the front and rear panels away from each other to move the formwork system from a forming position, in which the front and rear panels are engaged with the material to retain the material in the forming space, to a release position, in which the front and rear panels are disengaged from the material to prevent the material from impeding movement of the front and rear panels.
In some aspects disclosed herein, there is described a method of forming an insulated wall of rammed earth construction. The method also includes positioning a front panel relative to a rear panel to define a forming space therebetween; positioning two interior panels spaced apart from each other in the forming space to defining an insulation void therebetween; receiving earth in the forming space to fill the forming space and to facilitate ramming of the earth in the forming space to form rammed earth in the forming space; removing the front and rear panels, and the two interior panels; and receiving insulation material in the insulation void formed within the rammed earth.
In some aspects disclosed herein, there is described an insulated wall of rammed earth construction formed using a method of forming an insulated wall of rammed earth construction. The method also includes positioning a front panel relative to a rear panel to define a forming space therebetween; positioning two interior panels spaced apart from each other in the forming space to defining an insulation void therebetween; receiving earth in the forming space to fill the forming space and to facilitate ramming of the earth in the forming space to form rammed earth in the forming space; removing the front and rear panels, and the two interior panels; and receiving insulation material in the insulation void formed within the rammed earth.
Embodiments can include combinations of the above features.
Further details of these and other aspects of the subject matter of this application will be apparent from the detailed description included below and the drawings.

DESCRIPTION OF THE DRAWINGS

Reference is now made to the accompanying drawings, in which:

FIG. 1 is a perspective view of a building site with a plurality of formwork systems being used to form rammed earth walls, in accordance with an embodiment;

FIG. 2A is a perspective view of a step of assembling a formwork system, in accordance with an embodiment;

FIG. 2B is a perspective view of a later step of assembling the formwork system, in accordance with an embodiment;

FIG. 2C is a perspective view of a later step of assembling the formwork system, in accordance with an embodiment;

FIG. 2D is a perspective view of a later step of assembling the formwork system, in accordance with an embodiment;

FIG. 2E is a perspective view of a later step of assembling the formwork system, in accordance with an embodiment;

FIG. 2F is a perspective view of the formwork system, in accordance with an embodiment;

FIG. 3A is a schematic sectional view of a formwork system in a first condition of operation, in accordance with an embodiment;

FIG. 3B is a schematic sectional view of the formwork system in a second condition of operation, in accordance with an embodiment;

FIG. 3C is a schematic sectional view of the formwork system in a third condition of operation, in accordance with an embodiment;

FIG. 3D is a schematic sectional view of the formwork system in a fourth condition of operation, in accordance with an embodiment;

FIG. 3E is a schematic sectional view of the formwork system in a fifth condition of operation, in accordance with an embodiment;

FIG. 3F is a schematic sectional view of the formwork system in a sixth condition of operation, in accordance with an embodiment;

FIG. 3G is a schematic sectional view of the formwork system in a seventh condition of operation, in accordance with an embodiment;

FIG. 3H is a schematic sectional view of the formwork system in an eighth condition of operation, in accordance with an embodiment;

FIG. 3I is a schematic sectional view of the formwork system in a ninth condition of operation, in accordance with an embodiment;

FIG. 3J is a schematic sectional view of the formwork system in a tenth condition of operation, in accordance with an embodiment;

FIG. 3K is a schematic sectional view of the formwork system in an eleventh condition of operation, in accordance with an embodiment;

FIG. 3L is an enlarged view of region 3L in FIG. 3D;

FIG. 4A is a front elevation view with a partial section of a tie with an adjustable length, in accordance with an embodiment;

FIG. 4B is a top plan view of the tie, in accordance with an embodiment;

FIG. 4C is a side elevation view with of the tie, in accordance with an embodiment;

FIG. 5 is a top plan view of a coupler, in accordance with an embodiment;

FIG. 6 is a top plan view of an anchoring member, in accordance with an embodiment;

FIG. 7A is a perspective view of a system for forming an insulation void in a wall, in accordance with an embodiment;

FIG. 7B is a top plan view of the system for forming an insulation void in a wall, in accordance with an embodiment;

FIG. 8 is a perspective view of an insulated wall, in accordance with an embodiment;

FIG. 9 is a schematic view of a panel for forming an insulated wall;

FIG. 10 is a schematic flow chart of a method of forming a wall using a formwork system, in accordance with an embodiment; and

FIG. 11 is a schematic flow chart of a method of forming an insulated wall of rammed earth construction.

DETAILED DESCRIPTION

The following disclosure relates to formwork systems for rammed earth walls and methods of forming such walls. In some embodiments, the systems and methods disclosed herein allow readily repositionable, and hence efficiently reusable, formwork systems that facilitate faster and more convenient casting of material for construction of walls and other structure. In some embodiments, such formwork may be particularly effective for construction of rammed earth walls, at least due to an ability to adjust a pressure (lateral compression) being applied to the material as it is being cast by ramming in a forming space. In some embodiments, the systems and methods disclosed herein allow formation of insulated rammed earth walls.
In various embodiments, there is described a forming apparatus for constructing a rammed earth wall, a method of erecting a rammed earth structural element having improved load bearing capabilities, a method of assembling formwork, an insulated rammed earth wall, and a method of forming an insulated rammed earth wall.
In various embodiments, there is described a formwork system. The formwork system may include front and rear panels. The front and rear panels may define a forming space therebetween. The front and rear panels may be rotatably coupled to each other to move the formwork system between a forming position and a release position. The forming position of the formwork system may be suitable for allowing ramming of earth in the forming space to form rammed earth. The release position may be suitable to release the formwork system from the rammed earth to allow repositioning of the formwork system.
In various embodiments, there is described a formwork system including front and rear panels. A front member may be attached to the front panel. A rear member may be attached to the rear panel. A coupler may extend between the front and rear member. The coupler may be rotatably coupled to the front member to allow rotation of the front panel about the coupler. The coupler may be rotatably coupled to the rear member to allow rotation of the rear panel about the coupler. A tie may be coupled to, and may extend between, the front and rear member. The tie may be spaced apart from the coupler. The tie may be adjustable to increase a distance between the front and rear member to pivot the front and rear members about the coupler to move the front panel and rear panel away from each other to move the formwork system from a forming position into a release position.
The front and/or the rear member may be vertical member(s). The front and/or rear members may be structural member(s). The front and/or the rear member may extend at least partially over, respectively, the front panel and rear panel. The front and/or the rear member may extend at least partially beyond, respectively, the front panel and rear panel. The front and/or rear member may be aligned parallel to the front and rear panel. The front and/or rear member may be coupled and/or engaged with the respective front and/or rear panels. The front and/or rear panels may be frictionally engaged with the respective front and or rear members. One or more, or a plurality, of engaging members may be disposed in-between the front (and/or rear) panel and the front (respectively, the rear) panel for causing engagement, e.g. frictional engagement, therebetween. The engaging members may be have width larger than the distance between a (front or rear) panel and a (respective, front or rear) member to thereby achieve an interference fit therebetween.
The coupler may be a horizontal member. The coupler may be structural member for providing structural support. The coupler may include a front slot for receiving the front member and a rear slot for receiving the rear member. The coupler may be rotatably coupled to the front and/or rear member via respective pin connections. The coupler may be rotatably coupled to the front and/or rear member for uniaxial rotation of the respective front and/or rear member about the coupler. The coupler may be rotatably coupled to the front and/or rear member at respective intermediate positions of the front and/or rear member. The coupler may extend between the front and rear panels above the front and rear panels.
The tie may be a horizontal member. The tie may be a structural member, such as an adjustable bar or beam. The tie may be adjustable under tension. The tie may be configurable to vary its length. The tie may extend between a front end and a rear end. The tie may include an intermediate connector configured to threadably engage with a threaded front extension at the front end and/or a threaded rear extension at the rear end. The engagement of the threaded front and/or rear extension with the intermediate being variable to change a length of the tie. The tie may include a chain hoist. The tie and the coupler may be coupled to each other using one or more, or a plurality of, coupling elements, e.g. chains.
A horizontal member may extend between the front and rear panels. The horizontal member may be disposed between the tie and the coupler. The horizontal member may include a front slot for receiving the front member and rear slot for receiving the rear member.
The front and rear panels may be coupled to side panels. A first side panel may be opposite a second side panel. The side panels may be lateral to the front and rear panels. The side panels may be defined by surfaces of corresponding structural members. Such structural members may include torsion boxes. Torsion boxes may include hollow cuboid structures elongated in a longitudinal (e.g. vertical) direction configured to withstand torsion. The torsion boxes may be coupled to the front and rear members via a formwork assembly. The formwork assembly may comprise a plurality of tubes, e.g. metal tubes, that are attached to each other and the torsion boxes. The formwork assembly may be rigidly attached to the torsion boxes and the front and rear members. The formwork assembly may include extensions extending outwardly away from the torsion boxes and the front and rear sheathing to allow pulling or repositioning of the formwork system by lifting the formwork system via the extensions.
A plurality of rigid ties or cross-wythe ties may extend in the forming space between the front panel and the rear panel. Earth may be intermingled with the rigid ties to form a wall. The cross-wythe ties may extend through the wythe.
In various embodiments, there is described a method of forming a wall. The method may include receiving a building material in a forming space defined between front and rear panels to fill the forming space and to set the building material in the forming space, the front and rear panels being rotatably coupled to each other. The method may include rotating the front and rear panels relative to each other to release the front and rear panels from the building material.
In various embodiments, there is described a method of forming a wall. The method may include rotatably coupling a front panel and a rear panel to a coupler extending between the front panel and the rear panel. The method may include rigidly coupling the front and rear panels to a tie that is adjustable to change a length thereof. The method may include receiving a building material in a forming space defined between the front and rear panels to fill the forming space and to set the building material in the forming space. The method may include adjusting the tie to change the length of the tie to rotate the front and rear panels about the coupler and relative to each other to release the front and rear panels from the building material. The method may include repositioning an assembly including the front and rear panels coupled to each other via the coupler and the tie by rigidly lifting the assembly away from the building material.
In various embodiments, there is described a method of forming an insulated wall. The method may include positioning a front panel relative to a rear panel to define a forming spacing therebetween. The method may include positioning two intermediate panels spaced apart from each other in the forming space to defining an insulation void therebetween. The method may include receiving building material in the forming spacing to fill the forming space and the set the building material in the forming spacing. The method may include removing the front and rear panels, and the two intermediate panels. The method may include receiving insulation material in the insulation void. In one aspect, there is disclosed an insulated wall formed using the method. The insulation void may be formed across a middle portion of the wythe.
Embodiments can include combinations of the above features.
Aspects of various embodiments are described in relation to the figures. To further improve clarity, in the figures, references numerals in particular drawings are omitted when that reference numeral is identified with its associated part(s) in other drawings and inclusion of the reference numeral would reduce clarity of the presentation.
FIG. 1 is a perspective view of a building site with a plurality of formwork systems 100 being used to form rammed earth walls, in accordance with an embodiment.
FIGS. 2A-2E show various stages in assembling a formwork system 100, in accordance with an embodiment. FIG. 2F shows the finished formwork system 100.
FIG. 2A is a perspective view of a step of assembling the formwork system 100, in accordance with an embodiment.
The formwork system 100 may be used to form a rammed earth wall. The rammed earth wall may be formed by ramming earth over a footing 102 in a constrained space, called the forming space 104 herein. The formwork of the formwork system 100 is used to form the forming space 104. The embodiments in FIGS. 2A-2E have concrete footings 102 onto which the formwork is set.
Such formwork may also be used to form poured concrete walls. However, the stresses against the formwork by the building material may be higher in the case of rammed earth, compared stresses in formwork being used to form a forming space for a poured concrete wall, due to the need to compress or ram the earth as it fills the forming space. This compression causes the wall to exert outward forces on internal surfaces of the formwork of the formwork system 100 as the wall is formed by ramming or compression of earth in the forming space 104. Various embodiments disclosed herein may facilitate application of side pressure onto the material, which may facilitate ramming of earth.
In the embodiment of FIG. 2A, a plurality of reinforcing bars 106 are set in the concrete. The reinforcing bars 106 are made of steel and are suitable for use in forming rammed earth walls.
FIG. 2B is a perspective view of a later step of assembling the formwork system 100, in accordance with an embodiment, and which shows installation of plumb members to support ends of the wall to be constructed. These plumb members take the form of a pair of torsion boxes 108 attached to the concrete footing 102. In FIG. 2B, the torsion boxes 108 are fastened using concrete nails to the footing 102. The inside surfaces of the torsion boxes 108 are suitable for serving as side panels of the formwork. Outer surfaces of the torsion boxes 108 may have attached thereto a scaffolding tubing (aluminum tubing), to form a scaffold assembly. Each of the torsion boxes 108 has a pair of tubes of such tubing attached thereto. Each of the pairs of tubes may be attached to the respective torsion box 108 by one or more retaining brackets. One or more extensions 112 may be attached to the torsion boxes 108 and may extend outwardly therefrom for allowing handling, e.g. repositioning, of the torsion boxes 108. As an example, the tubes may have a circular cross-section of diameter about 48 mm.
The pair of torsion boxes 108 define a front side 114A and a rear side 114B. The front and rear sides 114A, 114B may be defined such that each side extends from the pair of torsion boxes 108.
Each torsion box 108 may include two layers of material or skins sandwiching therebetween a core. The core may be lightweight. The torsion box 108 may be suitable for resisting torsion under an applied load.
In some embodiments, the torsion box 108 may be constructed of 0.75 inch plywood, such as formply or G1S plywood. Joints of the torsion box 108 may be glued with exterior grade wood glue.
FIG. 2C is a perspective view of a later step of assembling the formwork system 100, in accordance with an embodiment, and which shows temporary supports locating and setting the coupler 120 and the strongbacks.
Front and rear walers 116A, 116B (or bars) extend between the torsion boxes 108 at the respective front and rear sides 114A, 114B to couple the torsion boxes 108 to each other. The front and rear walers 116A, 116B may provide rigidity.
A pair of front members 118A extend vertically at the front waler 116A. A pair of rear members 118B extend vertically at the rear waler 116B. The two front and the two rear members 118A, 118B extend from the concrete footing 102 vertically upward. The two front and the two rear members 118A, 118B are substantially parallel to (a longitudinal or elongation direction) the torsion boxes 108.
Each front member 118A is coupled to a corresponding rear member. Each rear member 118B is coupled to a corresponding front member. The front and rear members 118A, 118B are coupled using couplers 120. A pair of couplers 120 couple the front members 118A to the rear members 118B. Each coupler 120 couples a front member 118A and a rear member 118B.
Each coupler 120 may be rotatably coupled to a front member 118A and a rear member. The couplers 120 may be so coupled by pin connections.
FIG. 2D is a perspective view of a later step of assembling the formwork system 100, in accordance with an embodiment, and which shows a frame 122 of the formwork system 100.
As shown in FIG. 2D, the frame 122 rests on a stationary base in the form of the concrete footing 102. It is understood that, in various embodiments, the stationary base may take the form of other stationary supporting surfaces.
As shown in FIG. 2D, the frame 122 comprises support tubing and clamp scaffolding. Tubes extending laterally between the torsion boxes 108 may be coupled to the tubes on the torsion boxes 108, and may provide bracing of the formwork system 100. Such tubes are coupled to tubes extend vertically adjacent to the front and rear members 118A, 118B. In various embodiments, other types of supporting/framing structures may be used instead of, or in addition to, the tubing as shown and described.
As illustrated in FIG. 2D, each of the couplers 120 may be selectively engageable with the frame 122 to selectively hold it in-place relative to the frame 122. Advantageously, the front and rear members 118A, 118B may be held fixed to the stationary base via the coupler 120. In various embodiments, couplers 120 may be engaged or fastened to the frame 122 via a frictional connection, e.g. via a clamp, or via a threadable fastener, or via a dog. When engaged with the frame 122 in such a manner, the coupler(s) are held fixed thereto. When disengaged with the frame 122, the coupler(s) may be moved relative to the frame 122. As such, advantageously, any components attached to the frame 122 (such as the front and rear members 118A, 118B, and components attached thereto) may be moved, e.g. translated vertically, by movement of the coupler 120.
Advantageous, such type of selectively removable connections between the coupler 120 and the frame 122 may allow rapid repositioning of the formwork system 100.
FIG. 2E is a perspective view of a later step of assembling the formwork system 100, in accordance with an embodiment, and which shows anchoring members 124 and the coupler 120 installed.
Each of the anchoring members 124 is selectively engageable with the frame 122 to selectively hold that anchoring member 124 in-place relative to the frame 122 and to selectively allow that anchoring member 124 to move relative to the frame 122.
In the embodiment of FIG. 2E, anchoring members 124 couple the front and rear members 118A, 118B. The anchoring members 124 are vertically spaced apart from corresponding couplers 120. In various embodiments, the anchoring member 124 is disposed between the tie 128 and the coupler 120.
A hoist 126 connects the coupler 120 to the anchoring member 124. When the anchoring member 124 is engaged with the frame 122 to be held in-place relative to the frame 122 and the coupler 120 is disengaged with the frame 122 to allow movement of the coupler 120 relative to the frame 122, the hoist 126 enables the anchoring member 124 to support the coupler 120 and to allow lifting of the coupler 120 relative to the anchoring member 124. This may be particularly advantageous for efficient repositioning of the formwork system 100, e.g. from one vertical location to another adjacent vertical location. For example, the hoist 126 may include a pulley (see pulley 152 of the tie 128 in FIGS. 4A-4C).
In various embodiments, the tie 128 may be coupled to the anchoring member 124 by one or more of the chains 127. A pulley of the hoist 126 connected to such one of the chains 127 may be attached to the tie 128, e.g. at a middle portion thereof.
For example, the anchoring member 124 may be coupled to the coupler 120 by means of chains 127 extending from the anchoring member 124 to the coupler 120. Such chains 127 between the anchoring member 124 and the coupler 120 may non-operable hoisting chains suitable to be tension, in suitable circumstances, by operation of the pulley of the tie 128. A plurality of chains 127 may be used for coupling the anchoring member 124 and the coupler 120. Each anchoring member 124 may be coupled to a corresponding coupler 120 by means of two chains 127 to prevent rocking of the coupler 120 when supported by the chains 127.
A tie 128 couples the front and rear members 118A, 118B and is adjustable to vary its length. The tie 128 is selectively contractible and/or extendible to change its length. The tie 128 is spaced apart from the coupler 120. The tie 128 may be disposed over or positioned vertically above the anchoring member 124 and/or the coupler 120.
Each anchoring member 124 has a front anchor slot 130A and a rear anchor slot 130B for receiving the front and rear members 118A, 118B, respectively, therein to constrain their respective horizontal movements. Furthermore, each of the anchoring members 124 may be fastened, e.g. by connection pins, to prevent relative motion between the front and rear members 118A, 118B and the anchoring member 124. Each anchoring member 124 may be releasable from the corresponding front and rear members 118A, 118B to allow sliding of the anchoring member 124 relative to the front and rear members 118A, 118B via the front and rear anchor slots 130A, 130B of the anchoring member 124. The front and rear anchor slots 130A, 130B can be most clearly seen in FIG. 6 .
The coupler 120 may also have a corresponding front slot 132A and a corresponding rear slot 132B for receiving the front and rear members 118A, 118B, respectively, therein. The front and rear slots 132A, 132B can be most clearly seen in FIG. 5 . The coupler 120 may be fastened, e.g. by connection pins, to prevent relative motion between the front members 118A and rear members 118B and the coupler 120. The front members 118A may each be revolutely joined to their corresponding front slot 132A to facilitate uniaxial rotation of the front members 118A about the corresponding couplers 120. Similarly, rear members 118B may each be revolutely joined to their corresponding rear slot 132B to facilitate uniaxial rotation of the rear members 118B about the corresponding couplers 120. The coupler 120 may be releasable from the front and rear members 118A, 118B to allow sliding of the coupler 120 relative to the front and rear members 118A, 118B via the front and rear slots 132B of the coupler 120. Revolute joining may include joining via a revolute joint such as a one degree of freedom pin connection.
In various embodiments, the anchoring member 124 may be referred to as a first yoke or an upper yoke (in the particular embodiments where it is vertically higher than the coupler) while the coupler 120 may be referred to as a second yoke or a lower yoke (in the particular embodiments where it is vertically lower than the anchoring member).
FIG. 2F is a perspective view of the formwork system 100, in accordance with an embodiment, and which shows the panels, walers 116A, 116B, and an installed insulation void 134.
In the embodiment of FIG. 2F, a front panel 140A and a rear panel 140B are disposed opposite to each other to define the forming space 104 therebetween for receiving the material for casting. The front and rear panels 140A, 140B are suitable to sheath the material so as to retain the material in the forming space 104. The ties 128 and the couplers 120 extend over this forming space 104 between the front and rear panels 140A, 140B. In various embodiments, the ties 128, the couplers 120, and the anchoring members 124 extend substantially only horizontally or at least partially horizontally over the forming space 104. The front and rear panels 140A, 140B extend between the pair of torsion boxes 108 defining opposing ends of the forming space 104 lateral to the front and rear panels 140A, 140B.
In various embodiments, the front and rear panels 140A, 140B may be disposed at opposed ends of the torsion box. In various embodiments, the front and rear panels 140A, 140B may be made of or may include formply. As shown, the front and rear panels 140A, 140B extend between a pair of torsion boxes 108 defining opposing ends of the forming space 104 lateral to the front and rear panels 140A, 140B.
An insulation void 134 is formed between the front and rear panels 140A, 140B. The insulation void 134 is formed by means of spaced apart interior panels 136 (first and second interior panels 136 relatively proximal to, respectively, the front and rear sides) disposed between the front and rear panels 140A, 140B. A plurality of spacers 137 (see FIG. 3L for a representation of such spacers) are disposed in the insulation void 134 to maintain spacing between the first and second panels. The insulation void 134 advantageously at least partially thermal breaks (or provides a thermal break for) the resulting wall, e.g. rammed earth wall.
The front and rear members 118A, 118B are attached, respectively, to the front and rear panels 140A, 140B. As shown in FIG. 2F, a plurality of members 138 (planks) are disposed between the front members 118A and the front panel 140A and may be frictionally engaged therewith to couple the front panel 140A to the plurality of members 138. Similarly, a plurality of members 138 (planks) are disposed between the rear members 118B and the rear panel 140B and may be frictionally engaged therewith to couple the rear panel 140B to the plurality of members 138. Six or more planks may be provided at each of the front and rear sides, three of which (at each side) extend to the formwork tubing. In various embodiments, the plurality of members 138 may be clamped or integrally coupled to the front and rear panels 140A, 140B, e.g. via one or fasteners. In some embodiments, reinforcing gussets are provided between waler locations.
In various embodiments, the front and rear panels 140A, 140B are configured and assembled to provide a rigid structure to reduce deformation, such as bending, when earth is rammed into the forming space 104.
In various embodiments, during operation of the formwork system 100, the frame 122 or scaffold assembly may remain relatively stationary while the coupler, adjustable tie 128, and front and rear panels 140A, 140B are moved relative to the scaffold assembly during construction of the rammed earth wall.
As shown in FIG. 2F, each of the couplers 120 is pivotably coupled to the front panel 140A and to the rear panel 140B via, respectively, the front member 118A and rear member 118B. In particular, each of the front members 118A is pivotably coupled to the coupler 120 to rotate around a corresponding front pivot axis 142A (illustrated in FIG. 3C), and each of the rear members 118B is pivotably coupled to the coupler 120 to rotate around a corresponding rear pivot axis 142B (illustrated in FIG. 3C). However, it is understood that, in some embodiments, one or more of the couplers 120 may be coupled directly to the front panel 140A and/or the rear panel 140B. Alternatively, in some embodiments, components additional to the front member 118A and/or rear member 118B may be provided in the pivotable connection between the front and rear panels 140A, 140B and the couplers 120. Such (direct or indirect) coupling of the front and rear panels 140A, 140B to the coupler(s) allows rotation of the front and rear panels 140A, 140B about the coupler 120 towards and away from each other. Advantageously, coupling the front and rear panels via the respective front and rear members may allow the front and rear panels to be manipulated (e.g. moved about) from a distant location. For example, obstruction of the forming space may be achieved by forming revolute joints (e.g. see front revolute joint 148A and rear revolute joint 148B in FIG. 3L) between the front and rear members and the coupler at distant locations from the forming space. In various embodiments, the couplers, revolute joints, and the tie may be positioned vertically above the forming space to a sufficient degree so as to facilitate operations in the forming space, e.g. ramming of earth using equipment positioned in or over the forming space. Advantageously, the members may be of a separate construction compared to the panels, e.g. the members may be taller, narrow, thicker, and/or structurally stronger or made of a stronger material.
Contracting or extending the tie 128 causes rotation of the front and rear panels 140A, 140B away from each other due to varying of the length of the tie 128, e.g. via the front and rear members 118A, 118B, to move the formwork system 100 from a forming position to a release position. For example, the front and rear members 118A, 118B may be rotated (or pivoted) about the coupler, where they are rotatably coupled.
As will be further discussed later, in the forming position, the front and rear panels 140A, 140B are engaged with the material in the forming space 104 to retain it therein. In the release position, the front and rear panels 140A, 140B are disengaged from the material to prevent the material from impeding movement of the front and rear panels 140A, 140B. Such frictional disengagement may facilitate repositioning of the formwork system 100.
In various embodiments, the front members 118A extend, lateral to the front pivot axis 142A and opposite to the forming space 104, across the front panel 140A to support the front panel 140A. Similarly, the rear members 118B extend, lateral to the rear pivot axis 142B and opposite to the forming space 104, across the rear panel 140B to support the rear panel 140B. Advantageously, such extension may improve structural rigidity of the formwork system 100 and mitigate bowing, buckling, or other undesirable deformation of the front and rear panels 140A, 140B. Such mitigation is particularly important when the front and rear panels 140A, 140B are under stress due to ramming of building material (e.g. earth) in the forming space 104 and/or lengthening of the tie 128 during casting, i.e. after the building material is already disposed in the forming space 104.
As mentioned earlier, the couplers 120 may be selectively engageable with the frame 122 to selectively hold the coupler 120 in-place relative to the frame 122. This may facilitate holding the front and rear panels 140A, 140B, the front and rear members 118A, 118B, and the ties 128 in-place relative to the frame 122 while the formwork system 100 is in the forming position. Furthermore, advantageously, this may allow each of the couplers 120 to move relative to the frame 122 to move the front and rear panels 140A, 140B, the front and rear members 118A, 118B, and the ties 128 relative to the frame 122 while the formwork system 100 in the release position.
FIGS. 3A-3K schematically illustrate the formwork system 100 in various conditions or stages of operation. FIGS. 3A-3B, FIGS. 3G-3H, and FIG. 3K show the formwork system 100 positioned or configured in the forming position while FIGS. 3C-3F, and FIGS. 3I-3J show the formwork system 100 positioned or configured in the release position.
FIG. 3A-3B show the formwork system 100 positioned in the forming position to form a first portion of a wall structure, e.g. a rammed earth wall. FIGS. 3G-3H show the formwork system 100 position in the forming position to form a second portion of the wall structure. The second portion is adjacent to the first portion and vertically contiguous with the first portion to form a substantially continuous wall structure.
FIG. 3A is a schematic sectional view of a formwork system 100 in a first condition of operation, in accordance with an embodiment, and which shows form work ready to receive ramming material thereinto.
In the first condition of operation, the formwork system 100 (or forming system) is installed over a concrete footing 102 and is ready to receive earth therein to form a rammed earth wall.
In the embodiment of FIG. 3A, the insulation void 134 has spacers positioned at six vertical heights.
In the embodiment of FIG. 3A, the forming space 104 has wythe ties (or cross-wythe ties) at three vertical heights herein. The wythe ties may be spaced 24 inches apart.
The coupler 120 is coupled to the front and rear members 118A, 118B (strongbacks) by pinned connections.
The adjustable tie 128 is adjusted so that its length fixes the rotation of the front and rear members 118A, 118B at an angle such that the front and rear panels 140A, 140B are configured to suitably define the front and rear ends of a wall to be constructed. For example, for parallel walls, the length of the adjustable tie 128 is varied such that the front and rear panels 140A, 140B are substantially parallel to each other.
In various embodiments details of corners, windows, control joints, and other components of the wall to be constructed are set off (e.g. masked) prior to insertion of earth in the forming space 104.
In some embodiments, crystalline waterproofing is disposed or installed on the footing 102 and/or reinforcement bars. The panels defining the insulation void 134 are attached and secured to the bottom (footing).
The plumb line defining an upper end of the wall is specified.
Once the formwork system 100 is configured to achieve the desired wall structure, each anchoring member 124 may be engaged with corresponding front and rear members 118A, 118B and the frame 122 to hold the anchoring member 124 and front and rear members 118A, 118B in-place relative to the frame 122. For example, the anchoring member 124 may be secured to the front and rear members 118A, 118B and the frame 122 by means of securing pins and clamps, such as half clamps. Furthermore, each coupler 120 may be fixedly engaged with corresponding front and rear members 118A, 118B and the frame 122 to hold the coupler 120 and front and rear members 118A, 118B in-place relative to the frame 122. For example, the coupler 120 may be secured to the front and rear members 118A, 118B and the frame 122 by means of securing pins and clamps, such as half clamps.
FIG. 3B is a schematic sectional view of the formwork system 100 in a second condition of operation, in accordance with an embodiment, and which shows rammed earth filled in.
In the embodiment of FIG. 3B, in the second condition of operation, earth is filled in the forming space 104 up to the plumb line. Earth is shown in with wave lines in FIG. 3B. In various embodiments, up to 96″ (of height of the forming space 104) of earth may be mixed, delivered, and rammed to form a finished 72″ of compacted wall height. For example, the earth may be delivered in 12 separate lifts. Compacting of rammed earth may be carefully controlled to avoid over-compacting. The insulation void 134 is substantially free of earth. In various embodiments, earth is compacted or rammed in the forming space 104. For example, earth may be compacted by hand or be use of power tools.
The tie 128 is suitable to be lengthened so as to support the material in the forming space 104 and to apply pressure onto the material to facilitate ramming. The front and rear panels 140A, 140B are suitable for withstanding stresses arising due to ramming of earth in the forming space 104 and lengthening of the tie 128, e.g. by reducing deformation (such as bending) enough to maintain dimensions and geometry of a resulting wall within target tolerances.
FIG. 3C is a schematic sectional view of the formwork system 100 in a third condition of operation, in accordance with an embodiment, and which shows the formwork opened, e.g. by use of the coupler 120 and adjustable tie 128.
In the third condition of operation, the front and rear panels 140A, 140B are disengaged with outer surfaces of the rammed earth wall after setting of the rammed earth wall in the forming space 104. The front and rear panels 140A, 140B are rotated relative to each other and away from the rammed earth walls by reducing a length of the adjustable tie 128. The front and rear panels 140A, 140B are pivoted about separate pivoting locations. The pivoting locations are, respectively, defined by front and rear connections of the coupler, and are situated below the adjustable tie 128.
In some embodiments, the length of the adjustable tie 128 is varied to achieve rotations of the front and rear panels 140A, 140B of about 3° about the respective pivot locations. In some embodiments, the rotation is at least 3°.
In the release position of FIG. 3C, the anchoring member 124 is secured to the front and rear members 118A, 118B (and/or the frame 122) by means of securing pins and clamps, such as half clamps, to prevent vertical movement of the anchoring member as the front and rear members are vertically moved. The insulation void assembly may be configured to allow vertical movement thereof, e.g. panels thereof may be released. At the same time, the coupler 120 is released from the front and rear members 118A, 118B (and/or the frame 122) by removing pins and clamps to allow vertical movement of the coupler 120. In some embodiments, positional holes are used to facilitate movement of the front and rear panels 140A, 140B vertically to preset or predetermined positions.
FIG. 3D is a schematic sectional view of the formwork system 100 in a fourth condition of operation, in accordance with an embodiment, and which shows the formwork lifted.
FIG. 3L is an enlarged view of region 3L in FIG. 3D.
In the fourth condition of operation, the upper end of the formwork system 100 (including the adjustable tie 128) is lifted up. This repositioning allows forming a subsequent portion of the rammed earth wall. The lifting may be lifting by 36 inches or by 72 inches.
In various embodiments, the front and rear members 118A, 118B are lifted by chains or by a telehandler, and/or by hoisting by the chains 127 coupling the anchoring member 124 and the coupler 120. Lifting of the front and rear members 118A, 118B lifts the coupler 120. The anchoring member 124 is not lifted since it is disengaged from the front and rear members 118A, 118B while remaining engaged and fixed to the frame 122. The anchoring member 124 and the coupler 120 are brought closer to each other. The chains 127 coupling the anchoring member 124 and the coupler 120 are shortened when the anchoring member 124 and the coupler 120 are brought closer to each other. The chains may allow hoisting of the coupler 120 relative to the anchoring member 124. During lifting, the front and rear slots 132A, 132B of the coupler 120 slide relative to the respective front and rear members 118A, 118B.
After lifting, the coupler 120 is engaged with the front and rear members 118A, 118B (and/or the scaffold assembly) by using engaging pins and half clamps. The chains 127 coupling the anchoring member 124 are disconnected, e.g. chain hoist hooks are released from the coupler 120.
In various embodiments, braces and safety rails are lifted into 36 inches or higher positions for clearance while maintaining regulation railing heights. In various embodiments, scaffold braces are added every 36 inches.
FIG. 3E is a schematic sectional view of the formwork system 100 in a fifth condition of operation, in accordance with an embodiment, and which shows the lifting process.
In the fifth condition of operation, the anchoring member 124 is released and lifted. Thereafter, the anchoring member 124 is engaged with the front and rear members 118A, 118B (and/or the scaffold assembly) to prevent vertical movement of anchoring member 124 relative to the front and rear members 118A, 118B. For example, the coupler 120 is engaged with pins and half-clamps. The chains 127 are engaged with the coupler 120 and then made taut. The coupler 120 is then disengaged from the front and rear members 118A, 118B to allow vertical movement of the coupler 120.
FIG. 3F is a schematic sectional view of the formwork system 100 in a sixth condition of operation, in accordance with an embodiment, and which shows the lifting process.
In the sixth condition of operation, all four chain hoists 126 are used to lift the front and rear members 118A, 118B, and other components attached thereto. The coupler 120 moves vertically upwards as it is disengaged with the front and rear members 118A, 118B. The anchoring member 124 remains in-place. The anchoring member 124 and the coupler 120 are brought closer to each other.
FIG. 3G is a schematic sectional view of the formwork system 100 in a seventh condition of operation, in accordance with an embodiment, and which shows the formwork closed and the insulation void 134 installed in the next position (after removal from an earlier location).
In the seventh condition of operation, the formwork system 100 is in position for forming another vertical portion of the wall. The anchoring member 124 is lifted by 36″ and locked in-place relative to the front and rear members 118A, 118B. The front and rear panels 140A, 140B are rotated back into a closed or forming position to form a forming space 104 for receiving and ramming earth, by changing of a length of the adjustable tie 128. A lower portion of the front and rear panels 140A, 140B may be engaged with an upper portion of the previously set portion of the rammed earth wall. The length of the adjustable tie 128 is reduced until the lower portion of the wall exerts a forcing against the front and rear sheathing portions. Advantageously, this allows formation of a substantially continuous and aligned wall.
FIG. 3H is a schematic sectional view of the formwork system 100 in an eighth condition of operation, in accordance with an embodiment, and which shows the formwork filled with material and rammed.
In the eighth condition of operation, earth is filled in the forming space 104 and rammed to form the vertical portion of the rammed earth wall.
FIG. 3I is a schematic sectional view of the formwork system 100 in a ninth condition of operation, in accordance with an embodiment. Here, the formwork is opened and ready to be lifted for higher walls (e.g. repeating FIGS. 3C-3I) or be lifted by machinery to a next wall position, i.e. lifted to a new wall height or removed to a new or next wall position. As shown in FIG. 3I, the formwork system 100 may be aerially suspended by hoisting of the coupler 120. The insulation void 134 form is removed for the next wall position (FIG. 3J).
In the ninth condition of operation, a roof bracket above the adjustable tie 128 is removed. The front and rear panels 140A, 140B are disengaged from the rammed earth wall.
The front and/or rear panels may be wheeled to facilitate, while the formwork system 100 is in the release position, wheeled movement of the front panel 140A and/or rear panel, respectively, along the wall structure formed by casting of the material in the forming space 104. In various embodiments, the entire formwork system 100 may be translatable along the structure by the wheeled movement of the front and/or panels while the formwork system 100 in the release position. Advantageously, this may permit rapid and accurate repositioning of the formwork system 100 to continue forming of the wall structure by casting of the material in spatially sequential forming space 104. In some embodiments, wheels or casters (e.g. 4″ gate spring casters) are attached to the front and rear panels 140A, 140B to allow rolling of the front and rear panels 140A, 140B on the rammed earth wall.
The chains 127 may be wrapped around the anchoring member 124. The scaffold system, including tubes and braces, are disassembled and/or removed.
In FIG. 3I, a lifting beam or spreader bar is coupled to the coupler, e.g. chain hooks on the coupler, for lifting the coupler 120. For example, in some embodiments, the lifting bar may have 8000 lb capacity. Lifting may be achieved by a telehandler. In various embodiments, the jerking motion of the crane or telehandler may be used to release tow connectors and insulation void bolts so that the formwork system 100 can be lifted carefully to a next wall ramming position.
FIG. 3J is a schematic sectional view of the formwork system 100 in a tenth condition of operation, in accordance with an embodiment, and which shows the form in a new position and ready to re-install scaffolding and void formwork.
FIG. 3K is a schematic sectional view of the formwork system 100 in an eleventh condition of operation, in accordance with an embodiment, and which shows the form in a condition to allow repetition of (or at least parts of) the process described above.
In the tenth condition of operation, the formwork system 100 is moved to a second wall different than the first wall. In the eleventh condition of operation, the scaffold system is installed, and the front and rear panels 140A, 140B are rotated in position to form a second forming space 104 for the second wall.
FIG. 4A is a front elevation view with a partial section of a variable or adjustable tie 128, in accordance with an embodiment.
FIG. 4B is a top plan view of the tie 128, in accordance with an embodiment.
FIG. 4C is a side elevation view with of the tie 128, in accordance with an embodiment.
The tie 128 defines a front end 144A and a rear end 144B connected to each other via an intermediate connector 146. The intermediate connector 146 is threadably engaged with the front end 144A and, separately, with the rear end 144B to allow lengthening of the tie 128. Such lengthening of the tie 128 facilitates supporting of the material in the forming space 104. Additionally, a predetermined or desired pressure may be applied onto the material in the forming space 104 by lengthening the tie 128 and/or otherwise varying threadable engagement of the front and/or second ends 144A, 144B with the intermediate connector 146.
The intermediate connector 146 may be an intermediate cylinder that receives bolts at opposed ends thereof. The bolts may be engaged with nuts in the cylinder for fastening.
The front and/or rear ends 144A, 144B may be U-shaped, e.g. these may be U-shaped brackets. The U-shaped front end 144A may be suitable to receive and to frictionally engage with the front member 118A while the U-shaped rear end 144B may be suitable to receive and frictionally engage with the rear member 118B. The U-shaped ends 144A, 144B may have open distal ends to facilitate quick engagement. The U-shaped ends 144A, 144B may be closed proximal ends (opposite the open distal ends) and sides, which define grasping surfaces that frictionally engage with the front and rear members 118A, 118B to maintain the tie 128 in-place. The ends 144A, 144B may be clamping ends.
In various embodiments, the tie 128 may be a Double Acting Acme cylinder and may be constructed of steel and/or iron.
In various embodiments, a pulley 152 may be used to hoist one or more of the coupler 120, anchoring member 124, and/or front and rear members 118A, 118B towards the tie 128.
FIG. 5 is a top plan view of the coupler 120, in accordance with an embodiment.
The coupler 120 defines two slots 132A, 132B at opposite ends thereof. The two slots 132A, 132B may be formed by U-shaped ends of the coupler 120. For example, such ends may be clamping ends.
FIG. 6 is a top plan view of the anchoring member 124, in accordance with an embodiment.
The anchoring member 124 defines two anchor slots 130A, 130B at opposite ends thereof. The two anchor slots 130A, 130B may be formed by U-shaped ends of the anchoring member 124. For example, such ends may be clamping ends.
FIG. 7A is a perspective view of a system for forming an insulation void 134 in a wall, in accordance with an embodiment.
FIG. 7B is a top plan view of the system for forming an insulation void 134 in a wall 150 formed in accordance with an embodiment.
The system includes two opposed interior panels 136 with spacers 137 disposed therebetween to maintain a spacing between the two opposed interior panels 136, referred to as the insulation void 134. Advantageously, the insulation void 134 allows receiving non-rigid insulation, e.g. rock wool insulation, mineral wool batt insulation, or blown insulation, which may be more effective than rigid insulation. The opposed interior panels 136 may form apertures for receiving cross-wythe ties. A plurality of panels may be disposed on opposite sides of the insulation void 134.
FIG. 8 is a perspective view of the wall 150 provided with insulation to form an insulated wall, in accordance with an embodiment.
Once the rammed earth wall 150 is formed, the interior panels 136 and spacers 137 are removed to form the insulation void 134, which may be formed between spaced apart, structurally rigid portions of the rammed earth wall 150. As shown in FIG. 6 , non-rigid insulation may be disposed inside the insulation void 134 to achieve high performance insulation.
FIG. 9 is a schematic view of interior panels 136 for forming an insulated wall, in accordance with an embodiment.
In various embodiments, the interior panels 136 may be made of or may include 1″ (25 mm) plywood or Oriented Strand Board (OSB). The interior panels 136 may have dimensions of 24 inches by 77.5 inches. The interior panels 136 may be notched to support the wythe ties. The notches are formed at edges of the panels such that notches from adjacent panels are brought together to form an aperture for receiving the wythe ties. The panels are releasable from the wythe ties. Separation of the adjacent interior panels releases the panels from the wythe ties. The panels are releasable from the wythe ties.
FIG. 10 is a schematic flow chart of a method 1000 of forming a wall using a formwork system, in accordance with an embodiment.
Step 1002 of the method 1000 includes receiving material, for casting, in a forming space defined between a front panel and a rear panel disposed opposite to the front panel, the front and rear panels being suitable to sheath the material so as to retain the material in the forming space and pivotably coupled to a coupler extending across the forming space between the front and panels to allow rotation of the front and rear panels about the coupler towards and away from each other.
Step 1004 of the method 1000 includes after casting of the material, shortening a tie spaced apart from the coupler, coupled to the front and rear panels, and extending over the forming space to rotate the front and rear panels away from each other to move the formwork system from a forming position, in which the front and rear panels are engaged with the material to retain the material in the forming space, to a release position, in which the front and rear panels are disengaged from the material to prevent the material from impeding movement of the front and rear panels.
In some embodiments of the method 1000, the front panel is pivotably coupled to the coupler via a front member attached to the front panel, and the rear panel is pivotably coupled to the coupler via a rear member attached to the rear panel, the coupler being selectively engageable with a frame resting on a stationary base to selectively hold the coupler in-place relative to the frame to hold the front and rear panels, the front and rear members, and the tie in-place relative to the frame while the formwork system is in the forming position and to allow the coupler to move relative to the frame to move the front and rear panels, the front and rear members, and the tie relative to the frame while the formwork system is in the release position.
Some embodiments of the method 1000 may further comprise repositioning the front and rear panels by hoisting the coupler vertically up to an anchoring member that is held fixed to the frame while the coupler is disengaged with the frame, the coupler and the anchoring member extending horizontally over the forming space.
In a method of assembling a formwork system that is readily repositionable to facilitate casting of material, a step may include causing connection of a front panel to a rear panel disposed opposite to the front panel, via a tie extending between the front and rear panels, to define a forming space between the front and rear panels for receiving the material for casting, the front and rear panels being suitable to sheath the material so as to retain the material in the forming space, a coupler extending across the forming space between the front and rear panels and being pivotably coupled to the front panel and to the rear panel to allow rotation of the front and rear panels about the coupler towards and away from each other, the tie being selectively contractible such that contracting the tie causes rotation of the front and rear panels away from each other to move the formwork system from a forming position, in which the front and rear panels are engaged with the material to retain the material in the forming space, to a release position, in which the front and rear panels are disengaged from the material to prevent the material from impeding movement of the front and rear panels.
Some embodiments of such a method may further comprise forming a front revolute joint between the coupler and a front member that is attached to the front panel, the front revolute joint being spaced apart from the forming space to prevent obstruction of the forming space; and forming a rear revolute joint between the coupler and a rear member that is attached to the rear panel, the rear revolute joint being spaced apart from the forming space to prevent obstruction of the forming space.
In such a method, the front panel may be pivotably coupled to the coupler via a front member attached to the front panel, and the rear panel may be pivotably coupled to the coupler via a rear member attached to the rear panel, the coupler being selectively engageable with a frame resting on a stationary base to selectively hold the coupler in-place relative to the frame to hold the front and rear panels, the front and rear members, and the tie in-place relative to the frame while the formwork system is in the forming position and to allow the coupler to move relative to the frame to move the front and rear panels, the front and rear members, and the tie relative to the frame while the formwork system is in the release position.
Some embodiments of such a method may include repositioning the front and rear panels by hoisting the coupler vertically up to an anchoring member that is held fixed to the frame while the coupler is disengaged with the frame, the coupler and the anchoring member extending horizontally over the forming space.
FIG. 11 is a schematic flow chart of a method 1100 of forming an insulated wall of rammed earth construction.
Step 1102 of the method 1100 includes positioning a front panel relative to a rear panel to define a forming space therebetween.
Step 1104 of the method 1100 includes positioning two interior panels spaced apart from each other in the forming space to defining an insulation void therebetween;
Step 1106 of the method 1100 includes receiving earth in the forming space to fill the forming space and to facilitate ramming of the earth in the forming space to form rammed earth in the forming space;
Step 1108 of the method 1100 includes removing the front and rear panels, and the two interior panels; and
Step 1110 of the method 1100 includes receiving insulation material in the insulation void formed within the rammed earth.
An insulated wall of rammed earth construction formed may be formed using the method 1100.
As can be understood, the examples described above and illustrated are intended to be exemplary only.
The embodiments described in this document provide non-limiting examples of possible implementations of the present technology. Upon review of the present disclosure, a person of ordinary skill in the art will recognize that changes may be made to the embodiments described herein without departing from the scope of the present technology. For example, the formwork system may be used to form a concrete wall. Yet further modifications could be implemented by a person of ordinary skill in the art in view of the present disclosure, which modifications would be within the scope of the present technology.
The term “connected” or “coupled to” may include both direct coupling (in which two elements that are coupled to each other contact each other) and indirect coupling (in which at least one additional element is located between the two elements).

Claims

What is claimed is:

1. A formwork system for casting of material for construction, comprising:

a front panel;

a rear panel disposed opposite to the front panel to define a forming space between the front and rear panels for receiving the material for casting, the front and rear panels being suitable to sheath the material so as to retain the material in the forming space;

a coupler that extends across the forming space between the front and rear panels and is pivotably coupled to the front panel and to the rear panel to allow rotation of the front and rear panels about the coupler towards and away from each other; and

a tie that extends across the forming space between the front and rear panels and that is spaced apart from the coupler, the tie being selectively contractible such that contracting the tie causes rotation of the front and rear panels away from each other to move the formwork system from a forming position, in which the front and rear panels are engaged with the material to retain the material in the forming space, to a release position, in which the front and rear panels are disengaged from the material to prevent the material from impeding movement of the front and rear panels.

2. The formwork system of claim 1, wherein the material is earth that is cast by ramming into the forming space, the tie being suitable to be lengthened so as to support the material in the forming space and to apply pressure onto the material to facilitate ramming while the formwork system is in the forming position.

3. The formwork system of claim 1, wherein the tie defines a front end and a rear end connected to each other via an intermediate connector threadably engaged with the front end and threadably engaged with the rear end to allow lengthening of the tie so as to support the material in the forming space and apply pressure onto the material in the forming space.

4. The formwork system of claim 1, wherein the front panel is wheeled to facilitate, while the formwork system is in the release position, wheeled movement of the front panel along a structure formed by casting of the material in the forming space.

5. The formwork system of claim 4, wherein the formwork system is aerially suspended and is translatable along the structure by wheeled movement of the front panel while the formwork system is in the release position.

6. The formwork system of claim 1, wherein the front panel is pivotably coupled to the coupler via a front member that is attached to the front panel and is pivotably coupled to the coupler to rotate around a front pivot axis, and the rear panel is pivotably coupled to the coupler via a rear member that is attached to the rear panel and is pivotably coupled to the coupler to rotate around a rear pivot axis, the front member extending across the front panel opposite to the forming space lateral to the front pivot axis to support the front panel, the rear member extending across the rear panel opposite to the forming space lateral to the rear pivot axis to support the rear panel.

7. The formwork system of claim 1, wherein the front panel is pivotably coupled to the coupler via a front member that is attached to the front panel, and the rear panel is pivotably coupled to the coupler via a rear member that is attached to the rear panel, the front member being received through a front slot of the coupler and being revolutely joined to the front slot to facilitate uniaxial rotation of the front member about the coupler, the rear member being received through a rear slot of the coupler and being revolutely joined to the rear slot to facilitate uniaxial rotation of the rear member about the coupler.

8. The formwork system of claim 1, wherein the front panel is pivotably coupled to the coupler via a front member that is attached to the front panel and is pivotably coupled to the coupler, and the rear panel is pivotably coupled to the coupler via a rear member that is attached to the rear panel and is pivotably coupled to the coupler, the tie defining a U-shaped front end suitable to receive and to frictionally engage with the front member, the tie further defining a U-shaped rear end opposite to the front end suitable to receive and frictionally engage with the rear member.

9. The formwork system of claim 1, further comprising:

a front member attached to the front panel and pivotably coupled to the coupler;

a rear member attached to the rear panel and pivotably coupled to the coupler; and

a frame resting on a stationary base, the coupler being selectively engageable with the frame to selectively hold the coupler in-place relative to the frame to hold the front and rear panels, the front and rear members, and the tie in-place relative to the frame while the formwork system is in the forming position and to allow the coupler to move relative to the frame to move the front and rear panels, the front and rear members, and the tie relative to the frame while the formwork system is in the release position.

10. The formwork system of claim 9, wherein the coupler extends horizontally over the forming space, the formwork system further comprising:

an anchoring member extending horizontally over the forming space and vertically spaced apart from the coupler, the anchoring member being selectively engageable with the frame to selectively hold the anchoring member in-place relative to the frame and to allow the anchoring member to move relative to the frame; and

a hoist connecting the coupler to the anchoring member to support the coupler and to allow lifting of the coupler relative to the anchoring member while the anchoring member is engaged with the frame to be held in-place relative to the frame and the coupler is disengaged with the frame to allow movement of the coupler relative to the frame.

11. The formwork of claim 10, wherein the anchoring member is disposed between the tie and the coupler, the anchoring member defining a front anchor slot for receiving the front member to constrain horizontal movement of the front member and a rear anchor slot for receiving the rear member to constrain horizontal movement of the rear member.

12. The formwork system of claim 1, wherein the formwork system is aerially suspended by hoisting of the coupler.

13. The formwork system of claim 1, wherein the front and rear panels extend between a pair of torsion boxes defining opposing ends of the forming space lateral to the front and rear panels.

14. A method of assembling a formwork system that is readily repositionable to facilitate casting of material, comprising:

causing connection of a front panel to a rear panel disposed opposite to the front panel, via a tie extending between the front and rear panels, to define a forming space between the front and rear panels for receiving the material for casting, the front and rear panels being suitable to sheath the material so as to retain the material in the forming space, a coupler extending across the forming space between the front and rear panels and being pivotably coupled to the front panel and to the rear panel to allow rotation of the front and rear panels about the coupler towards and away from each other, the tie being selectively contractible such that contracting the tie causes rotation of the front and rear panels away from each other to move the formwork system from a forming position, in which the front and rear panels are engaged with the material to retain the material in the forming space, to a release position, in which the front and rear panels are disengaged from the material to prevent the material from impeding movement of the front and rear panels.

15. The method of claim 14, further comprising:

forming a front revolute joint between the coupler and a front member that is attached to the front panel, the front revolute joint being spaced apart from the forming space to prevent obstruction of the forming space; and

forming a rear revolute joint between the coupler and a rear member that is attached to the rear panel, the rear revolute joint being spaced apart from the forming space to prevent obstruction of the forming space.

16. The method of claim 14, wherein the front panel is pivotably coupled to the coupler via a front member attached to the front panel, and the rear panel is pivotably coupled to the coupler via a rear member attached to the rear panel, the coupler being selectively engageable with a frame resting on a stationary base to selectively hold the coupler in-place relative to the frame to hold the front and rear panels, the front and rear members, and the tie in-place relative to the frame while the formwork system is in the forming position and to allow the coupler to move relative to the frame to move the front and rear panels, the front and rear members, and the tie relative to the frame while the formwork system is in the release position.

17. The method of claim 16, further comprising:

repositioning the front and rear panels by hoisting the coupler vertically up to an anchoring member that is held fixed to the frame while the coupler is disengaged with the frame, the coupler and the anchoring member extending horizontally over the forming space.

18. A method of forming a wall using a formwork system, comprising:

receiving material, for casting, in a forming space defined between a front panel and a rear panel disposed opposite to the front panel, the front and rear panels being suitable to sheath the material so as to retain the material in the forming space and pivotably coupled to a coupler extending across the forming space between the front and panels to allow rotation of the front and rear panels about the coupler towards and away from each other; and

after casting of the material, shortening a tie spaced apart from the coupler, coupled to the front and rear panels, and extending across the forming space to rotate the front and rear panels away from each other to move the formwork system from a forming position, in which the front and rear panels are engaged with the material to retain the material in the forming space, to a release position, in which the front and rear panels are disengaged from the material to prevent the material from impeding movement of the front and rear panels.

19. The method of claim 18, wherein the front panel is pivotably coupled to the coupler via a front member attached to the front panel, and the rear panel is pivotably coupled to the coupler via a rear member attached to the rear panel, the coupler being selectively engageable with a frame resting on a stationary base to selectively hold the coupler in-place relative to the frame to hold the front and rear panels, the front and rear members, and the tie in-place relative to the frame while the formwork system is in the forming position and to allow the coupler to move relative to the frame to move the front and rear panels, the front and rear members, and the tie relative to the frame while the formwork system is in the release position, the method further comprising: