WO2010082812A2

WO2010082812A2 - Fast-track wall system

Info

Publication number: WO2010082812A2
Application number: PCT/MY2010/000012
Authority: WO
Inventors: Muhd Zaimi Abd Majid; Rosli Mohamad Zin; Siti Hamisah Tapsir; Abdul Rahim Abdul Hamid; Abdul Karim Mirasa; Arham Abdullah; Jee Hock Lim; Mohd Nur Asmawisham Alel; Mohd Warid Hussin; Mohamad Ibrahim Mohamad; Shaiful Amri Mansur; Norazlin Nordin; Jamiah Md Saalleh
Original assignee: Universiti Teknologi Malaysia (UTM)
Current assignee: Universiti Teknologi Malaysia (UTM)
Priority date: 2009-01-15
Filing date: 2010-01-14
Publication date: 2010-07-22
Anticipated expiration: 2011-07-15
Also published as: WO2010082812A3; MY149121A

Abstract

The present invention provides a formwork system (40) of forming concrete wall for a building comprising, site clearing and leveling, forming a foundation (10) which includes a beam (12) and ground slab (14), thereafter forming concrete wall (30) by setting up form works on top of the foundation (10) characterized in that the formwork system (40).

Description

FAST-TRACK WALL SYSTEM

FIELD OF INVENTION

The present invention generally relates to a formwork system and more particularly relates to a fast-track forming system for concrete or mortar wall.

BACKGROUND OF INVENTION

Concrete walls are usually constructed by erecting form panels in parallel spaced apart and then pouring concrete in the space between the forms. Most common method of erecting concrete walls involves form panels of plywood and wood forming. If reinforcement is needed, rebar or other kinds of metal reinforcement is installed in the space between the forms. In some installations, metal reinforcement is installed prior to structural forms. After the space is filled with concrete, the wooden forms are removed.

This type of construction method of forming up and pouring concrete wall in- situ is cumbersome. The wood itself is relatively expensive and provision of wooden form is labour intensive. Skilled labours are needed to erect the wooden forms and the wooden forms need to be removed after poured concrete is set. Accordingly, erection operation for such construction method is time consuming and required considerable expensive skilled labours for eraction. Moreover, a large proposition of form components or materials is non-reusable after the wooden forms are removed.

Although conventional building methods are well established and are generally effective for constructing traditional building structure, there is still a need in the art for a system for constructing a building structure which is cost effective to implement and can be quickly and easily utilized so as to construct a desired building structure. Accordingly, there is still substantial need in the art for an affordable yet effective low cost building construction system that not only can be transported to an installation site in a compact and convenient manner, but which can also be erected efficiently, effectively and rapidly without skilled labours. SUMMARY OF INVENTION

Accordingly, there is provided a formwork system of forming concrete wall for a building comprising, site cleaning and leveling, forming a foundation which includes a beam and ground slab, thereafter forming concrete wall by setting up formworks on top of the foundation characterized in that the formwork system (40) includes an L-shaped cornering formwork with standardized components, an predetermined intermediate formwork, a sectional form panel securely mounted to one surface of the formworks, whereby the standardized components of L-shaped cornering formwork is used, in combination and/or incorporating with the predetermined intermediate formwork to form T-shaped and/or Cross-shaped cornering formworks, wherein said standardized components of L-shaped cornering formwork includes an inner frame and outer frame, which are characteristically formed by L-section frames, configured in offset, spaced apart to each other forming the L-shaped cornering formwork, wherein T-shaped cornering formworks is formed by two opposed, spaced apart inner frames of L-section, and the predetermined intermediate formwork is spaced apart disposed at opposite of corresponding faces of two opposed, spaced apart inner frames, wherein Cross-shaped formwork is formed by four opposed, spaced apart inner frames of L-section, said inner frames are arraying in circular arrangement about predetermined centre axis, wherein an opening frame is provided at predetermined position of the intermediate formwork to prevent concrete from being poured in area of the window opening and wherein the L-, T- and/or Cross-shaped cornering formworks are incorporated with parallel, opposed, spaced apart predetermined intermediate formwork to form concrete wall to suit variations in distances of wall lengths by connecting means.

BRIEF DESCRIPTION OF DRAWINGS

The drawings constitute part of this specification and include an exemplary or preferred embodiment of the invention, which may be embodied in various forms. It should be understood, however, the disclosed preferred embodiments are merely exemplary of the invention. Therefore, the figures (not to scale) disclosed herein are not to be interpreted as limiting, but merely as the basis for the claim and for teaching one skilled in the art of the invention.

In the appended drawings: FIG. 1a - 1b illustrate steps of forming a beam and slab raft foundation of a building in accordance with preferred embodiment of present invention;

FIG. 2a illustrates a cross-section view A - A of the beam and slab raft foundation of

FIG. 1 ;

FIG. 2b illustrates an enlarged view, partially in cross-section of the beam and slab raft foundation of FIG. 2a;

FIG. 3 illustrates a perspective view of a formwork system for constructing building wall in accordance with preferred embodiment of present invention;

FIGS. 4a - 4c illustrate perspective view of L-, T- and Cross-shaped cornering formworks in accordance with preferred embodiments of present invention; FIGS. 5a - 5b illustrate enlarged perspective view of a clamping bracket and a supporting or clasping bracket for connecting two adjacent coplanar formworks;

FIGS. 6a - 6b illustrate a perspective view of building wall constructed by formwork system and a roof structure in accordance with preferred embodiment of present invention; FIGS. 7a - 7b illustrate a partly perspective view of a formwork system for window opening construction, providing window or like opening frame in accordance with preferred embodiment of present invention.

FIG. 8 illustrates the cross-sectional view of FIG. 1b taken along the lines 1 -1.

DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS

Detailed descriptions of preferred embodiments of the invention are disclosed herein. It should be understood, however, that the embodiments are merely exemplary of the invention, which may be embodied in various forms. Therefore, the details disclosed herein are not to be interpreted as limiting, but merely as the basis for the claim and for teaching one skilled in the art of the invention. The numerals in the diagrams refer to features of the same description in different embodiments, although the features may vary in configuration.

FIGS. 1a - 1b generally show a primary approach of forming a building foundation (10) wherein beam (12) and ground slab (14) is initially formed. For better understanding of these drawings, FIG. 8 is provided to illustrate the cross-sectional view of FIG. 1 b taken along the lines 1-1. Cleaning and leveling of site is required and to be completed prior to excavation for foundation. Accordingly, before any trenching for footings, building site for entire project is first cleaned and then leveled to engineering specification. Sufficient rock, gravel and aggregate may be introduced to meet soil standard. Next is to make an excavation on the ground with appropriate depth for the beam (12). By way of example and not by way of limitation, the beam excavation is generally at about 0.4m in depth x 0.4m in width. Forms may be set at all around excavated beam channel to provide lateral support and to prevent soil from falling into excavated beam channel. Preferably, the form used may be plywood with a thickness of about 0.006m.

It will be appreciated that rebar or reinforcing steel is set up within the beam channel. Preferably, the rebar or reinforcing steel includes elongated bars (16) extending entire length of the footings. The elongated bars (16) are circumscribed by a mild steel stirrup (18) (FIGS. 2a - 2b). Upstanding starter bars (20) are introduced and sited at predetermined locations extending upwardly from the mild steel stirrup

(18) where concrete wall to be formed on the beam (12) will terminate. It will be appreciated that a reinforcing mesh (22) is then introduced on top of the mild steel stirrup (18) and is laying throughout the area bounded by excavated area. Said reinforcing mesh (22) is used as reinforcement for the foundation or ground slab

(14). Once all reinforcement works are done for the beam (12) and ground slab (14), concrete is poured and allowed it to set. Concrete walls (30) are then formed by formworks setup on top of the foundation (10). Accordingly, the concrete walls (30) are formed by formwork system (40) as shown in FIG. 3. As refer to FIG. 3, the formwork system (40) generally comprises an L-shaped cornering formwork (42) and T-shaped cornering formwork (44). It is important to note that system components of L-shaped cornering formwork (42) are standardized and can be utilized, in combination and incorporating with predetermined intermediate formwork (48) to form T-shaped cornering formwork (44). Cross-shaped cornering formwork (46) may also be formed by system components of L-shaped cornering formwork (42). Accordingly, system components of L-shaped cornering formwork (42) is adapted to be reconfigured and/or incorporated with appropriate intermediate formwork (48) to form desired T- and/or Cross-shaped wall corners.

Referring to FIG. 4a - 4c, illustrate more detailed of cornering formworks (42, 44, 46) in accordance with preferred embodiments of the present invention. In FIG.

4a, the L-shaped cornering formwork (42) includes an inner frame (42a) and outer frame (42b) configured in offset, spaced apart to each other. Said inner and outer frames (42a, 42b) are characteristically formed by L-section frames (43). Preferably, the L-section frames (43) are made of hollow metal bars and are structured to include a plurality of horizontal and vertical bars to form a lattice structure (52). It will be appreciated that the lattice structure (52) is sufficiently strong to resist forces of hydrostatic pressure from poured concrete. Preferably, the lattice structure (46) formed by means of welding.

A form panel (50) is introduced and securely mounted to one surface of the inner and outer frames (42a, 42b). Accordingly, the form panel (50) securely attached at outer surface of the inner frame (42a) and inner surface of the outer frame (42b). Preferably, the form panel (50) is made of, but not limited to reusable plastic board. It will be appreciated that the form panel (50) is of predetermined sectional piece to suit difference wall length and is adaptable to be securely attached to the formwork frame by means of, but not limited to self-tapping screws.

By way of example and not by way of limitation, FIG. 4b shows the T-shaped cornering formwork (44) which is constructed by two opposed, spaced apart inner frames (42a) formed by L-section frames (43), and a predetermined intermediate formwork (48) is spaced apart disposed at opposite of corresponding faces of two opposed, spaced apart inner frames (42a). The predetermined intermediate formwork (48) includes plurality of horizontal and vertical bars defined lattice structure (52) sufficiently strong to resist forces of hydrostatic pressure from poured concrete. The form panel (50) is introduced and securely mounted to appropriate inner surfaces of the T-shaped cornering formwork (44) by the self-tapping screws. It will be appreciated that the predetermined intermediate formwork (48) can be of different standardized dimensions to suit various wall lengths.

FIG. 4b shows the Cross-shaped cornering formwork (46) which is constructed by four opposed, spaced apart inner frames (42a) that formed by L- section frames (43). Accordingly, the Cross-shaped cornering formwork (46) is erected by four inner frames (42a) arraying in circular arrangement about predetermined centre axis. Similarly, the form panel (50) is introduced and securely mounted to appropriate inner surfaces of the Cross-shaped cornering formwork (46) by the self-tapping screws.

It will be appreciated that the L-, T- and/or Cross-shaped cornering formworks (42, 44, 46) enable to form wall corners of substantially right angle depending upon geometries of building and rooms (FIG. 3). Said L-, T- and/or Cross-shaped cornering formworks (42, 44, 46) can also be incorporated with parallel, opposed, spaced apart predetermined intermediate formwork (48) to form concrete wall to suit variations in distances of wall lengths by suitable connecting means (60).

By way of example and not by way of limitation, the connecting means (60) can be in a clamping bracket (61) to securely connect two adjacent coplanar formworks. Said clamping bracket (60) is preferably a standard C-channel that comprises a web portion (62) with two equal size flanges (64) at substantially right angle extending from edges web portion (62). The flanges (64) are disposed with aperture (66) to receive a fastening means (68). Preferably, the fastening means (68) can be of, but not limited to a bolt shaft (68a) and nut (68b) (FIG. 5a). The clamping bracket (61) enables to be matingly engaged with the two adjacent coplanar formworks and securely fastened by the fastening means (68). It will be appreciated that numerous different variation to the connecting means (60) will become apparent to person skilled in the art, and such variations should be considered to be within the scope of the present invention.

A supporting or clasping bracket (70) is provided on top of each adjacent coplanar formwork to further secure the formworks and form panels (50).

Accordingly, the supporting or clasping bracket (70) is of standard C-channel without fastening aperture. In particular, said supporting or clasping bracket (70) is adapted to be securely rest seated on top of each adjacent coplanar formwork frames.

It is important to note that combination of L-, T- and/or Cross-shaped cornering formworks incorporate with the parallel, opposed, spaced apart predetermined intermediate formwork (48) permit rapid forming of concrete walls (30) (FIG. 6a). Window opening (90) or the like is also provided. Further details for constructing a window opening (90) on the formwork system is shown in FIGS. 7a - 7b, and will be described hereinafter.

It will be appreciated that the L-, T- and/or Cross-shaped cornering formworks (42, 44, 46) can be simultaneously constructed with parallel, opposed, spaced apart predetermined intermediate formworks (48) and concretes are then poured at same time with a steel mesh to allow the concrete to set together. Once the concrete is set, the cornering formworks (42, 44, 46) and the predetermined intermediate formworks (48) are removed. The formwork system (40) are preferably raised by conventional supports and are prefabricated of more than one type to provides various size for different wall lengths and door openings. However, the formwork system (40) is standardized and identical with respect to overall height.

Referring now to FIGS. 7a - 7b, illustrate more detailed of formwork system for window opening (90) construction in accordance with preferred embodiments of the present invention. The window opening (90) is provided at intermediate wall portions by provision an opening frame (92) to prevent concrete from being poured in area of the window opening (90). Said opening frame (92) may be configured at appropriately predetermined position of the intermediate formworks (48) and may be in various lengths depending upon the size of the window opening to be constructed. Appropriate connecting means, such as clamps and wedges may be utilized to secure the opening frame (92) into position. There are provided supporting bars or bracings (95) engageable to the formwork system for supporting or stabilizing the parallel opposed, spaced apart predetermined intermediate formworks and the cornering formworks.

A final stage of building construction is to construct a roof structure (80) (FIG.

6b). By way of example and not by way of limitation, the roof structure (80) can be of, for example, beams/trusses constructed either in horizontal or raked. The beams /trusses give added stability and strength to the top of building structure, and to support the roof and ceiling materials. It will be obvious to person skills in the art that windows, doors, roofs, roofs finishes, ceiling materials, painting and other features such as M&E and architectural works, for example, installation of wiring, piping, plumping, architectural fittings, and electrical fittings may be added in accordance with normal building construction practices.

It is to be found that by employing the formwork system of the present invention, a single story house with two or three bed rooms can be completed within 20 days to 25 days respectively. The formwork system of the present invention provides standard system components which can be transported to an installation site in a compact and convenient manner and also can be erected efficiently, effectively and rapidly without skilled labours. Moreover, the system components of the present invention are reusable; consequently reduce costs and materials wastage.

While embodiments of the invention have been illustrated and described, it is not intended that these embodiments illustrate and describe all possible forms of the invention. Rather, the words used in the specification are words of description rather than limitation and various changes may be made without departing from the scope of the invention.

Claims

CLAIM

1. A formwork system (40) of forming concrete wall for a building comprising, site cleaning and leveling, forming a foundation (10) which includes a beam (12) and ground slab (14), thereafter forming concrete wall (30) by setting up formworks on top of the foundation (10) characterized in that the formwork system (40) includes: a) an L-shaped cornering formwork (42) with standardized components; b) an predetermined intermediate formwork (48); c) a sectional form panel (50) securely mounted to one surface of the formworks; whereby the standardized components of L-shaped cornering formwork (42) is used, in combination and/or incorporating with the predetermined intermediate formwork (48) to form T-shaped and/or Cross-shaped cornering formworks (44, 46); wherein said standardized components of L-shaped cornering formwork (42) include an inner frame (42a) and outer frame (42b), which are characteristically formed by L-section frames (43), configured in offset, spaced apart to each other forming the L-shaped cornering formwork (42); wherein T-shaped cornering formworks (44) is formed by two opposed, spaced apart inner frames (42a) of L-section, and the predetermined intermediate formwork (48) is spaced apart disposed at opposite of corresponding faces of two opposed, spaced apart inner frames (42a); wherein Cross-shaped formwork (46) is formed by four opposed, spaced apart inner frames (42a) of L-section, said inner frames (42a) are arraying in circular arrangement about predetermined centre axis; wherein an opening frame (92) is provided at predetermined position of the intermediate formwork (48) to prevent concrete from being poured in area of the window opening (90); and wherein the L-, T- and/or Cross-shaped cornering formworks (42, 44, 46) are incorporated with parallel, opposed, spaced apart predetermined intermediate formwork (48) to form concrete wall to suit variations in distances of wall lengths by connecting means (60).