Patent Application
20250059714
Described herein is formwork, matrices, concrete matrices and methods of manufacture. More specifically, a formwork is described configured to receive and retain concrete within an internal void space and which has a concrete free external void space. Matrices are described formed from the formwork. Also described is a concrete matrix formed using the formwork and related methods of manufacture of a formwork matrix and concrete matrix.
Structural cells may be provided for under hardscapes that support a compressive load. Art products are typically plastic mouldings using spaced apart legs and a base, top or other restraining structure to align the legs. The legs take up compressive loading on the structural cell allowing the void space inside the structural cell to be used for applications such as tree root growth in uncompacted soil or, water reservoir use where the void space is used to capture and retain storm water.
There can also be other uses for structural cells or matrices using the structural cells where void space is needed in order to fill a volume and, where some degree of structural strength and integrity is required. One example might be in the construction of roadside berms where structural cell matrices may provide an alternative to transporting and delivery of significant volumes of infill.
One drawback of existing designs may be complexity. Another drawback may be in cost. A further drawback may be in structural strength achieved from plastic. Another drawback may be a perceived lack of structural capability in civil and structural applications from a material like plastic. A further drawback may be that of plastic deflection whereby plastic art cells may move elastically when placed under load which is an issue when brittle or non-elastic materials are coupled with the cells and matrices.
WO2019/090397A1 presents one solution to the above describing a formwork used to form a matrix through which concrete may be poured and retained. The concrete sets to the matrix shape defined by the formwork. Concrete is a well-known and understood structural material hence, the formwork and resulting concrete cell provides an alternative means of providing a void space below a hardscape. The described formwork does however require multiple parts e.g. free sockets and separate plates leading to higher manufacturing cost and potentially slower assembly. Coupling cells is also reliant on separate parts like the described sockets or separate plates.
The formwork, matrices, concrete matrices and methods of manufacture described herein attempt to address at least some of the above drawbacks or at least provide the public with a choice.
Further aspects and advantages of the formwork, matrices, concrete matrices and methods of manufacture will become apparent from the ensuing description that is given by way of example only.
Formwork, matrices, concrete matrices and methods of manufacture are described. The formwork may be configured to receive and retain concrete within an internal void space and has a concrete free external void space. Also described is a concrete matrix formed using the formwork and related methods of manufacture of a formwork matrix and formwork. The formwork itself and matrices formed from the formwork may have a degree of compressive strength. With concrete poured and set into the formwork, the resulting concrete matrix has a very high compressive strength and forms a structural matrix on which a hardscape or load may be placed.
In a first aspect, there is provided a formwork configured to receive and retain concrete therein, the formwork may include a frame having lateral supports, each lateral support defining a volume within the lateral support, the volume defined by a base, sides and an at least partially open top. The formwork may further include at least four legs, each leg having a tapering wall structure defining a hollow interior. The formwork may further include a first end and a second end, both the first end and the second end opening to the hollow interior. The formwork may also include the leg first end having a first diameter opening tapering to a second diameter opening about the second terminal end, the first diameter opening being larger than the second diameter opening. The formwork may further include the legs connecting to the frame at the first end of each leg, the legs extending orthogonally away from the frame to the second ends of the legs. The formwork may include a vertical coupling, the vertical coupling may be configured to couple with a further vertical coupling located on a second end of a leg from a further formwork. The formwork may furthermore include the frame coupling the first end of the legs together via the lateral supports. The formwork may also define an external void space outside of the frame lateral supports and legs and an internal void space located inside the hollow interior of the legs and the volume within the lateral supports, the internal void space configured to receive concrete therein.
In a second aspect, there is provided a matrix including a plurality of formwork substantially as described above. The matrix may be aligned vertically with each said frame of the formwork alternating in orientation from a first matrix layer of the formwork in a frame located below the plurality of legs configuration to a second layer of the formwork in a frame located above the plurality of legs configuration. The matrix may further include the vertical coupling of each formwork coupling to the first matrix layer of formwork with the second matrix layer of further formwork.
In a third aspect, there is provided a concrete matrix which may include a plurality of formwork substantially as described above and concrete within the internal void space of the formwork in the matrix.
In a fourth aspect, there is provided a method of forming a matrix which may include pouring concrete therein, by selecting a plurality of formwork substantially as described above. The method may further include forming a first matrix layer by placing, on a substrate, multiple formwork, the multiple formwork orientated in a configuration with the formwork frame located below the second ends of the legs. The method may also include forming a second matrix layer, over the first matrix layer, by vertically coupling the second ends of the legs of each formwork in the second matrix layer to the second ends of the legs in the first matrix layer, the formwork of the second matrix layer orientated in a configuration with the formwork frame located above the second ends of the legs.
In a fifth aspect, there is provided a method of forming a concrete matrix which may include selecting a plurality of formwork substantially as described above and forming a first matrix layer by placing, on a substrate, multiple formwork, the multiple formwork orientated in a configuration with the formwork frame located below the second ends of the legs. The method may also include forming a second matrix layer, over the first matrix layer, by vertically coupling the second ends of the legs of each formwork in the second matrix layer to the second ends of the legs in the first matrix layer, the formwork of the second matrix layer orientated in a configuration with the formwork frame located above the second ends of the legs. The method may furthermore include pouring concrete into the internal volume of the plurality of formwork and allowing the poured concrete to cure and harden in the internal void space of the plurality of formwork.
The formwork itself and matrices formed from the formwork may have a degree of compressive strength. With concrete poured and set into the formwork, the resulting concrete matrix has a very high compressive strength and form a structural matrix on which a hardscape or load may be placed.
Further aspects of the formwork, matrices, concrete matrices and methods of manufacture will become apparent from the following description that is given by way of example only and with reference to the accompanying drawings in which:
As noted above, formwork, matrices, concrete matrices and methods of manufacture are described. The formwork may be configured to receive and retain concrete within an internal void space and has a concrete free external void space. Also described is a concrete matrix formed using the formwork and related methods of manufacture of a formwork matrix and formwork. The formwork itself and matrices formed from the formwork may have a degree of compressive strength. With concrete poured and set into the formwork, the resulting concrete matrix has a very high compressive strength and forms a structural matrix on which a hardscape or load may be placed.
For the purposes of this specification, the term ‘about’ or ‘approximately’ and grammatical variations thereof mean a quantity, level, degree, value, number, frequency, percentage, dimension, size, amount, weight or length that varies by as much as 30, 25, 20, 15, 10, 9, 8, 7, 6, 5, 4, 3, 2, or 1% to a reference quantity, level, degree, value, number, frequency, percentage, dimension, size, amount, weight or length.
The term ‘substantially’ or grammatical variations thereof refers to at least about 50%, for example 75%, 85%, 95% or 98%.
The term ‘comprise’ and grammatical variations thereof shall have an inclusive meaning—i.e. that it will be taken to mean an inclusion of not only the listed components it directly references, but also other non-specified components or elements.
In a first aspect, there is provided a formwork configured to receive and retain concrete therein, the formwork may include a frame comprising lateral supports, each lateral support defining a volume within the lateral support, the volume defined by a base, sides and an at least partially open top. The formwork may further include at least four legs, each leg comprising a tapering wall structure defining a hollow interior, a first end and a second end, both the first end and the second end opening to the hollow interior. The formwork may also include the leg first end having a first diameter opening tapering to a second diameter opening about the second terminal end, the first diameter opening being larger than the second diameter opening. The formwork may further include the legs connected to the frame at the first end of each leg, the legs extending orthogonally away from the frame to the second ends of the legs. The formwork may also include the second end of the legs comprising a vertical coupling, the vertical coupling configured to couple with a further vertical coupling located on a second end of a leg from a further formwork. The formwork may further include the frame coupling the first end of the legs together via the lateral supports. The formwork may define an external void space outside of the frame lateral supports and legs and, an internal void space located inside the hollow interior of the legs and the volume within the lateral supports, the internal void space configured to receive concrete therein.
As noted above, the formwork may be configured to receive and retain concrete therein. The formwork design such as the shape the lateral supports and the legs may describe an internal void space as described that may receive concrete therein.
In one example, the formwork may be used without concrete. That is, the formwork or matrices formed using the described formwork may be used alone without concrete to support a hardscape or structure thereon. Soil may be placed in the external void space e.g. uncompacted soil for tree growth. Soil or other particulate materials may be placed in the internal void space instead of concrete. The internal and external void spaces of the formwork may be left empty with a structure on the top of the formwork. In view of these alternative uses, the use of the formwork to receive and retain concrete in the internal void space should not be seen as limiting.
The formwork may define a generally cuboid volume. The formwork frame may define a generally square cross-section shape in a horizontal plane. The lateral supports may extend orthogonally from the leg in four directions spaced at 90 degrees to each other.
The formwork may comprise four legs.
The formwork may have a height from 5 to 30 inches.
The plurality of legs may be arranged relative to each other to collectively spread a compressive load placed thereon.
The diameter of the first end of the leg may be at least 85 mm and the diameter of the second end of the leg may be at least 80 mm
Each lateral support may have a generally U-shaped cross-section in a vertical plane formed by the lateral support base and sides and open top.
The formwork may comprise internal and external lateral supports. The internal lateral supports may extend from one leg first end to another leg first end. The external lateral supports may extend partly from a leg first end outside an envelope defined by the legs and internal lateral supports. The external lateral supports may extend coincident with the orientation of the internal lateral supports. The external lateral support length may be substantially half that of the length of an internal lateral support.
The vertical coupling may comprise elongated tabs extending from the second end of the legs. The elongated tabs may be configured to nest and snug fit into a second end of a leg of a further formwork.
Each elongated tab may be generally flat and shaped to nest with the interior wall or a part thereof of the further formwork leg second terminal end.
The vertical coupling may comprise empty regions where no elongated tabs are present. The empty regions may be located intermediate the elongated tabs. The empty regions may be configured to receive elongated tabs from a second end of a leg of a further formwork.
The elongated tabs may act as a male coupling fitting into the leg terminal end which may act as a female portion of the coupling.
The coupling may be configured to provide a smooth interior face between the leg terminal ends so as to facilitate concrete flow from one leg to a further leg.
The second end of the legs may comprise a return shape forming a hook cross section shape. The elongated tab may comprise a resilient member. When the formwork and the further formwork are coupled together vertically via the second ends of the legs, the resilient member may snap fit over the return shape of the second end of the legs to couple the formwork and further formwork together.
Each of the lateral supports may comprise a horizontal coupling. The horizontal coupling may be configured to couple together one formwork lateral support to a further formwork lateral support. Horizontal coupling may be about a horizontal plane.
The frame may comprise internal lateral supports between the legs. The frame may comprise external lateral supports extending from the legs. The internal lateral supports may be of a uniform length and link each of the legs together. The external lateral supports may be of a uniform length. The external lateral supports uniform length may be substantially half the length of the internal lateral supports. The external lateral supports may extend from the legs in a direction parallel to and coincident with, the direction of an adjoining internal lateral support.
Each external lateral support may comprise a first end about the formwork leg first end and a second end distal to the first end of the leg.
The second end of each external lateral support may comprise a horizontal coupling. The horizontal coupling may be configured to allow the formwork and a further formwork to be coupled together in a horizontal alignment.
The second end of each external lateral support may comprise a male or a female fitting.
The external lateral support ends of a formwork may comprise alternating male and female fittings on each side of a formwork. These fittings may be configured to allow alternating formwork coupling about a horizontal plane.
The first end of the leg may be configured to receive a grill or a blank over the opening to the hollow interior of the leg.
The leg first frame end may comprise a recess and shoulder adapted to nestingly receive a grill or blank therein.
The lateral supports may comprise a recess and shoulder adapted to also nestingly receive part of a grill or blank therein.
The grills may connect to/interact with the legs and lateral supports.
The internal void space may be continuous and not segmented.
The internal void space may be formed as one integral moulded volume. The legs and lateral supports may be integral and may not be separate parts. The legs and lateral supports are moulded together.
The free void space may comprise 75-90% of a volume of the formwork.
The internal void space may comprise 1-25% of the volume of said formwork.
The balance of the volume of a formwork may be the volume of the frame or plurality of legs themselves.
The formwork without concrete located in the formwork, may have a compression strength in excess of 100 kPa.
Without concrete therein, the formwork may resist elastic deformation up to a point 5-20% below a final compressive strength of the formwork when plastic deformation occurs.
In a second aspect, there is provided a matrix which may include a plurality of formwork substantially as described above. The matrix may be aligned vertically with each said frame of the formwork alternating in orientation from a first matrix layer of the formwork in a frame located below the plurality of legs configuration to, a second layer of the formwork in a frame located above the plurality of legs configuration. The matrix may further include the vertical coupling of each formwork couples the first matrix layer of formwork with the second matrix layer of further formwork.
In the above aspect, two formwork are used stacked in an alternating manner on top of each other to form the matrix, each formwork coupling to another formwork via the legs.
A multi-layered matrix may include multiple layers of three or more formwork which may include a first matrix layer of the formwork in a frame located below the plurality of legs configuration to, a second layer of the formwork in a frame located above the plurality of legs configuration, and a third layer of the formwork located on the second layer of the formwork in a frame located below the plurality of legs configuration. The multi-layered matrix may, optionally, include a further layer of the formwork located on the third layer of the formwork in a frame located above the plurality of legs configuration. The multi-layered matrix may further include layers which may be added beyond a third (or further layer) described above.
The layers of the matrix may alternate in a manner from leg to leg vertical coupling to frame to frame vertical coupling in the above example.
Vertical coupling of the formwork frames may be achieved via male female fittings, slots and extensions, or simply via friction.
The matrix may comprise a top, a bottom, and sides. At least one side panel may be fitted to the side or sides of the matrix.
The side panels may be fixed to the matrix by attachment to a formwork or multiple formwork of the matrix. The side panels may snap fit onto the matrix or formwork sides.
Side panels may be used to prevent ingress of backfill into the matrix once assembled.
In a third aspect, there is provided a concrete matrix which may include a matrix comprising a plurality of formwork substantially as described above, and concrete within the internal void space of the formwork in the matrix.
In a fourth aspect, there is provided a method for forming a matrix by pouring of concrete therein, which may include selecting a plurality of formwork substantially as described above. The method may further include forming a first matrix layer by placing, on a substrate, multiple formwork, the multiple formwork orientated in a configuration with the formwork frame located below the second ends of the legs. The method may also include forming a second matrix layer, over the first matrix layer, by vertically coupling the second ends of the legs of each formwork in the second matrix layer to the second ends of the legs in the first matrix layer, the formwork of the second matrix layer orientated in a configuration with the formwork frame located above the second ends of the legs.
Optionally a multi-layered matrix may be formed by forming a third or further layer on the second layer by coupling the formwork frame of the second matrix layer to a third matrix layer and, optionally, via the third formwork and further formwork legs, forming a further layer.
The method may comprise a further step of coupling the formwork of the first matrix layer, or the second matrix layer, or both the formwork of the first or the second matrix layer, together in a horizontal plane.
In a fifth aspect, there is provided a method of forming a concrete matrix which may include selecting a plurality of formwork substantially as described above. The method may also include forming a first matrix layer by placing, on a substrate, multiple formwork, the multiple formwork orientated in a configuration with the formwork frame located below the second ends of the legs. The method may further include forming a second matrix layer, over the first matrix layer, by vertically coupling the second ends of the legs of each formwork in the second matrix layer to the second ends of the legs in the first matrix layer, the formwork of the second matrix layer orientated in a configuration with the formwork frame located above the second ends of the legs. The method may also include pouring concrete into the internal volume of the plurality of formwork and allowing the poured concrete to cure and harden in the internal void space of the plurality of formwork.
As described above, additional third or further layers may be used to form a multi-layered matrix of formwork. The above method of forming a concrete matrix may also be adapted by the addition of further formwork layers and then pouring concrete in the internal volume of the multi-layered formwork matrix.
Advantages of the above formwork, matrices, and methods may comprise one or more of the following:
No separate plate is needed in this revised design to retain the legs together. A separate plate is however an option to facilitate stacking of formwork particularly those under particularly heavy loads but this is not essential;
The embodiments described above may also be said broadly to consist in the parts, elements and features referred to or indicated in the specification of the application, individually or collectively, and any or all combinations of any two or more said parts, elements or features.
Further, where specific integers are mentioned herein which have known equivalents in the art to which the embodiments relate, such known equivalents are deemed to be incorporated herein as if individually set forth.
The above described formwork, matrices, concrete matrices and methods of manufacture are now described by reference to specific examples and with reference to the following items and item numbering:
In this example, a formwork 1 is described.
As shown in
The lateral supports 3 define a volume 4 within the lateral supports 3, defined by a base 5, sides 6 and an open top 7.
The formwork 1 as shown has four spaced part legs 8. Each leg 8 has a first end 9 that is open and a second end 10 that is also open.
The leg first end 9 has a first diameter opening tapering to a smaller second diameter opening about the leg second end 10.
The legs 8 are connected to the frame 2 at the first end 9 of each leg 8. The legs 8 extend orthogonally away from the frame 2 to the leg second ends 10.
The frame 2 comprising the lateral supports 3 and leg 8 first ends 9 forms a generally planar flat surface across and outer edge of the lateral supports 3 and leg 8 first ends 9.
The formwork 1 defines an external void space 17 outside of the frame 2 lateral supports 3 and legs 8. The formwork 1 also defines an internal void space 18 located inside the plurality of legs 8 and the volume 4 within the lateral supports 3. The internal void space 18 of the formwork 1 is configured to receive and retain concrete (not shown) therein.
The second end 10 of the legs 8 comprises a vertical coupling 11. The vertical coupling 11 is configured to couple with a further tabs 52 located on a second terminal end 51 of a leg 58 from a further formwork 50.
Each elongated tab 12 may be generally flat and shaped to nest with the interior of the leg 8 wall structure 15 or a part thereof.
The vertical coupling 11 may further comprise regions 19 where no elongated tabs 12 are present 19. These regions 19 may be located intermediate the elongated tabs 12 and configured to receive elongated tabs 52 from the further formwork 50 leg 58 second end 51. As may be appreciated, the elongated tabs 12, 52 may act as a male coupling fitting into the non-elongated tab 12 regions 19 in the second end 10 of the legs 8 which act as a female portion of the vertical coupling 11.
The vertical coupling 11 may be configured to provide a smooth interior face 21 between the second ends 10 of the legs 8 so as to facilitate concrete flow from one leg 8 to a further leg 58.
The leg 8 second end 10 may further comprise a retention feature 23 forming a hook cross section shape 24. In this example, the elongated tab 12 may be shaped as a resilient member. When two formwork 1, 50 are coupled together vertically via the leg 8 second ends 12, the resilient member elongated tab 12 may have a barb/hook 25 configured to snap fit over the return shape 24 of the leg 8 second end 10 to lock the formwork 1, 50 together.
A horizontal coupling 30 may also be used shown in
The external lateral supports 3b may extend from the legs 8 in a direction parallel to the direction of an adjoining internal lateral support 3a. Each external lateral support 3b may comprise a first end 31 about the formwork 1 leg 8 and a second end 32 distal to the leg 8. The second end 32 of each external lateral support 3b comprises a horizontal coupling 30 configured to allow formwork 1 to be coupled together in a horizontal alignment.
In the example shown, the second end 32 of each external lateral support 3b comprises a male or female fitting 33, 34.
The external lateral support 3b second end 32 of a formwork 1 may comprise alternating male and female fittings 33, 34 on each side of a formwork 1 configured to allow formwork 1 horizontal coupling 30 about the described horizontal plane.
In this example, a matrix 100 of the formwork 1 is described.
The formwork 1 forming the matrix 100 are aligned vertically. Each frame 2 of the formwork 1 alternates in orientation from a first matrix layer 110 of the formwork 1 in a frame 2 located below the plurality of legs 8 configuration, to a second matrix layer 120 of the formwork 1 in a frame 2 located above the plurality of legs 8 configuration. Vertical coupling of each formwork 1 couples the first matrix layer 110 of formwork 1 with the second matrix layer 120 of formwork 1 via the leg 8 second ends 12.
In this example, the use of a grill 70 or blank is described. Reference in the drawings and description below is made to a grill 70 comprising an outer frame 71 and internal webbing 72 with openings. The grill 70 may instead be a blank (not shown) in which case the internal webbing 72 of the grill 70 may be a plate or filled in structure that blocks entry to the leg 8 opening. Reference to grill 70 may be used interchangeably with a blank.
The formwork 1 leg 8 first end 10 is shaped to receive a grill 70 over the opening.
The leg 8 first end 10 comprises a recess and shoulder 22a adapted to nestingly receive a grill 70 or blank therein. The lateral supports 3 may also comprise a recess and shoulder 22b adapted to also nestingly receive part of a grill 70 or blank therein. The grills 70 comprise an outer frame 71 with a shaped internal shoulder 73, the shaped internal shoulder 73 of the grill 70 complementing the shape of the recess and shoulder 22a, 22b of the leg 8 first end 10 and lateral supports 3.
The grills 70 may connect to/interact with the legs 8 and lateral supports 3 to fix them in place relative to the formwork 1. Alternatively, the grills 70 may sit on the formwork 1 and not be directly connected to the formwork 1. The grills 70 may be seated on the formwork 1 via gravity and friction only.
This example describes a further embodiment of matrix 100 having side panels 80.
Side panels 80 may have an elongated rectangular shape with a length corresponding to the length of a matrix 100 side to be covered or a part thereof. The side panel 80 may have a length that covers at least two sets horizontally of formwork 1. The side panel 80 may have a height corresponding to the height of two formwork 1 stacked on top of each other in the alternating manner described earlier in this specification. The width of a side panel 80 may be smaller than the length or height or the side panel 80.
The side panel 80 may comprise opposing sides 81, 82 being an interior side 81 that faces the matrix 100 and, an exterior side 82 that faces away from the matrix 100. The interior side 81 may comprise fastening members (not shown) to fasten the side panel 80 to a formwork 1 or multiple formwork 1 of the matrix 100. The fastening members may snap fit to the formwork 1 although, other mechanisms of attaching the side panels 80 to the formwork 1 may also be used.
Side panels 80 on the matrix 100 may be useful to prevent ingress of backfill (not shown) into the matrix 100 once the matrix 100 is assembled and buried beneath a hardscape (not shown).
Aspects of the formwork, matrices, concrete matrices and methods of manufacture have been described by way of example only and it should be appreciated that modifications and additions may be made thereto without departing from the scope of the claims herein.
