This invention relates generally to the provision, as part of the building construction process, of sills or hobs for the fixing of windows, curtain walls and the like or the provision of level changes in cast-in-situ concrete slabs. More particularly, it relates to moulds for the casting of such sills or hobs or the provision of level changes made integrally with cast in-situ concrete building slabs.
Particularly in the construction of multi-storey buildings, it is common to provide raised sills or hobs of some form to cast in-situ concrete slabs. Such sills or hobs act as supports for building elements such as window frames, curtain wall panels and the like, providing a watertight barrier beneath such building elements to prevent the ingress of rain water and condensation. Said building elements may incorporate lower frames or sills that bear directly upon and are sealed to a supporting surface such as a cast in-situ concrete slab. These commonly take the form of simple or complex metal sections or solid timber sections. In other applications, separate sills or hobs of similar form are sealing fixed to a said supporting surface and said building elements are fixed to and supported by said sills or hobs. In yet other applications, concrete sills or hobs are formed on said cast in-situ concrete slabs to support said window frames, curtain wall panels and the like. In these applications, long box moulds which are more or less open at the top and bottom are fixed to concrete slabs in appropriate positions, filled with concrete and the concrete allowed to cure. Said sills or hobs are then waterproofed appropriately and said building elements then fixed to them. The separate forming of said sills or hobs on cast in-situ concrete slabs is inefficient and time consuming, requiring the re-attendance of several building trades personnel to a building site to accurately measure up and fix said moulds in position and then to fill them with concrete. Additionally, irregularities in the trowelled surfaces of said cast in-situ concrete slabs may require the removal of concrete in order for said moulds to be set at the correct level. When it is considered that a multi-storey building may require several thousand lineal metres of such sills or hobs, the magnitude of the inefficiency and loss of time will be appreciated. Similarly, many situations exist in the construction industry in which steps or level changes are required in concrete slabs. Normally, these are provided by the construction of appropriate formwork. Not only is the construction of formwork a time-consuming process requiring the services of skilled personnel hut, after curing of a concrete slab, the formwork must be stripped out and discarded, thereby incurring further expenditure of labour and loss of value.
The object of the present invention is to provide a system that permits installation of sill or hob forming moulds or devices for the forming of level changes to be integrated into the process of fixing steel reinforcement preliminary to the pouring of concrete slabs, and with the process of filling said sill or hob moulds and the making of said level changes being integrated into the process of in-situ casting of concrete building slabs.
According to the present invention, sill or hob moulds in the form of long boxes more or less open at the top and bottom are installed during the process of installing reinforcing bar. Said moulds are supported from formwork upon a row of discrete chairs which permit the height of said moulds to be adjusted such that their lower edges are set at the intended surface level of the finally cast slab. Fabricated short mould sections are used to join straight runs of said moulds end to end and at directional changes through angles of 90°, 45° or angles of other magnitude. During casting of the parent concrete building slab, said moulds are simultaneously filled with concrete and trowelled off to a level surface. The concrete of the sill or hob so created is thus integral with that of said concrete building slab and is thus much less prone to water infiltration. Various methods are provided to positively prevent water infiltration. Said moulds are made in a variety of cross-sectional shapes and different methods are provided for attaching them to said chairs and adjusting their heights. Provision is made for said sill or hob moulds to be made regularly curved to different radii or in other irregular alignments. Similarly, level changes in cast in-situ concrete slabs are made by supporting upon a row of discrete chairs a length of suitable section, the upper part of a stepped concrete surface then being formed more or less level with the upper edge of the section and the lower part of the stepped concrete surface being formed more or less level with the lower edge of the section, the section serving a retaining function until said concrete has cured. Wherever possible, standard moulds for the making of said sills or hobs are employed as said section. In both cases, said sill or hob moulds and said section are left in place in said concrete slab.
The various aspects of the present invention will be more readily understood by reference to the following description of preferred embodiments given in relation to the accompanying drawings in which:
FIG. 1 is a transverse cross-sectional view of a sill or hob mould supported on a chair fixed to formwork, the mould filled with concrete and the concrete building slab cast beneath it;
FIG. 2 is a fragmentary transverse cross-sectional view of the upper part of one embodiment of said sill or hob mould;
FIG. 3 is a view from above of said sill or hob mould of FIG. 2;
FIG. 4 is a fragmentary view from above of one embodiment of the transverse bottom part of a chair of the present invention;
FIG. 5 is a fixing disk employed with chairs of the embodiment depicted in FIG. 4;
FIG. 6 is a view from above of a 90° corner join straight runs of said sill or hob mould;
FIG. 7 is a transverse cross-sectional view of another embodiment of said sill or hob mould depicting two embodiments of said chair;
FIG. 8 is a transverse cross-sectional view of an embodiment of said sill or hob mould intended to be extruded in continuous lengths from a suitable thermoplastic polymer or light metal alloy material;
FIG. 9 is a transverse cross-sectional view of an embodiment of said sill or hob mould made with an asymmetric shape;
FIG. 10
a is a fragmentary transverse cross-sectional view of means to join spacers to the side panels of said sill or hob moulds;
FIG. 10
b is a fragmentary transverse cross-sectional view of the joining means of FIG. 10a following their setting;
FIG. 11 is a fragmentary transverse cross-sectional view of means to join said sill or hob moulds to said chairs;
FIG. 12 is a fragmentary transverse cross-sectional view of means to join said sill or hob moulds to said chairs or to join spacers to the side panels of said sill or hob moulds;
FIG. 13
a is fragmentary transverse cross-sectional view of means to join spacers to the side panels of said sill or hob moulds;
FIG. 13
b is a fragmentary transverse cross-sectional view of the joining means of FIG. 13a following their setting;
FIG. 14 is a fragmentary transverse cross-sectional view of means to join said sill hob moulds to said chairs;
FIG. 15 is a fragmentary transverse cross-sectional view of alternative means to join said sill or hob moulds to said chairs;
FIG. 16 is a fragmentary view from above of one embodiment of spacers inserted between side panels of said sill or hob moulds;
FIG. 17 is a fragmentary view from above of another embodiment of spacers inserted between side panels of said sill or hob moulds;
FIG. 18 is a fragmentary transverse cross-sectional view of means to join spacers to side panels of said sill or hob moulds;
FIG. 19 is a side view in skeletal form of an embodiment of a chair to support said sill or hob moulds which permits precise height adjustment.
FIG. 20 is a fragmentary, transverse cross-sectional view of clamping means to attach a chair to reinforcing bar;
FIG. 21 is a transverse cross-sectional view of an alternative embodiment of chair comprising threaded rods supported from a base plate;
FIG. 22 is a fragmentary, transverse cross-sectional view of an alternative embodiment of clamping means to attach a chair to reinforcing bar;
FIG. 23 is a fragmentary, transverse cross-sectional view of alternative means of attaching a threaded rod of a chair to its supporting base plate;
FIG. 24 is a view from above of an embodiment of the plate of a rod and plate-type chair;
FIG. 25 is a fragmentary transverse cross-sectional view of adjustable means to fix said sill or hob mould to the rods of a rod and plate-type chair;
FIG. 26 is a view from above of an alternative embodiment of rod and plate-type chair;
FIG. 27 is a fragmentary, transverse cross-sectional view of an alternative embodiment of clamping means to attach a chair to reinforcing bar;
FIG. 28 is a fragmentary, transverse cross-sectional view of means allowing lateral positional adjustment in fixing said sill or hob mould to a chair;
FIGS. 29
a, 29b, 29c and 29d are transverse cross-sectional views of alternative forms of chair;
FIG. 30 is a transverse cross-sectional view of a chair incorporating the section of FIG. 29d to support a sill or hob mould at an of adjustable height;
FIG. 31 is a face view of a bifurcated attachment tab arrangement;
FIG. 32 is a face view of the reverse side of a base plate or sill or hob mould at the point of attachment of a chair incorporating the section of FIG. 29d;
FIG. 33 is a partial longitudinal cross-sectional view of a stepped concrete slab made in accordance with a first embodiment of the present invention;
FIG. 34 is another partial longitudinal cross-sectional view of a stepped concrete slab made in accordance with a second embodiment of the present invention.
The various figures are drawn to different scales and no inference should be drawn from this.
With reference to FIGS. 1, 2 and 3, sill or hob mould 1 is supported upon chair 2 which is, in turn, fixed to formwork 3. Said sill or hob mould comprises side panels 4 joined in spatial relationship at their upper edges by a plurality of spacer clips 5. Said side panels are joined in fixed spatial relationship at their lower edges by spacer piece 6 being tack-welded to upstanding flanges 7 formed on lower transverse flanges 8. Conveniently, said spacer piece takes the form of a short section cut from a continuous length of rectangular tube section. With additional reference to FIGS. 2 and 3, the upper edges of said side panels are turned through 90° to create upper transverse flanges 9 which are engaged by tabs 10 of said spacer clips to retain said clips in position. Said upper edges of said side panels are maintained in spatial relationship by their abutment with the inner surfaces of downturned edge flanges 11 of said spacer clips and the said engagement of said upper transverse flanges by tabs 10. Upstanding flanges 7 formed on lower transverse flanges 8 and upper transverse flanges 9 act to stiffen, respectively, the lower and upper edges of said sill or hob mould side panels.
Chair 2 is fixed to formwork 3 by nails 12 or other suitable fastenings being driven through suitable apertures in transverse bottom part 13 of said chair. Chair side panels 14 pass upwardly with a lateral separation such as to provide sliding contact of their inner surfaces with the outer surfaces of said sill or hob mould side panels. Transverse bridge 15 fixed to said chair side panels with suitable fastenings 16 supports said sill or hob mould at the desired height above said formwork. Said side panels of said sill or hob mould are secured to said chair side panels by suitable fastenings passing through both. Said sill or hob mould, said chair and the area above said formwork to the desired level are then filled with concrete 18, thereby embedding said chair, and slab surface 19 and the upper surface of the concrete filling of said sill or hob mould are trowelled off to create the desired surface finishes. The fixing of bridge 15 and said sill or hob mould to said chair and the fixing of said chair to said formwork is normally carried out by the appropriate trades during the fixing of reinforcement bar, plates or mesh within said formwork. The height of said bridge is normally set to position the lower edge of said sill or hob mould at the surface of said concrete slab when poured. In alternative embodiments (not shown), the lower edge of said sill or hob mould is set above or below said slab surface when poured. In the preferred embodiment, where a large number of said chairs are required to have said bridges and said sill or hob moulds fixed to them, suitable jigs are provided to position said components appropriately, one to another, and to install said fastenings. Said fastenings optionally take the form of pop rivets, conventional screws or bolts screwed into tapped holes, conventional self-tapping screws, self-piercing and self-drilling/self-tapping screws, self-piercing rivets, hot-melt adhesives, quick-setting two-part adhesives, spot welding or any other suitable fixing means. When the concrete of said slab has cured, said formwork is stripped away and fastenings 12 are hammered flat or preferably cut off or ground away with an angle grinder or the like. In an alternative embodiment (not shown), sill or hob mould side panels 4 are attached to the outer edges of lower transverse flanges 8 by simple hinges, the arrangement permitting said sill or hob moulds to be opened out and shipped flat. When required for use, said side panels are pivoted upwardly through approximately 90° and a plurality of spacer clips 5 is slidingly engaged with upper transverse flanges 9 of said side panels, thereby retaining said sill or hob moulds in a fixed rectangular form.
With reference to FIGS. 4 and 5, a said chair in fixed into place on said formwork by the sprigs 22 of a fixing plate 21 being driven through suitable apertures 20 provided in transverse bottom part 13 of said chair. Said fixing plate is die-punched from a suitable metal sheet material and radially arranged projections 22 are turned through 90° to create attachment sprigs. The use of said fixing plate facilitates the accurate fixed location of said chair, said fixing plate being installed by a single blow from a suitable punch with a round, flared head, a suitable aperture being provided in bridge 15 (as depicted in FIG. 1) to provide access for said punch. In alternative embodiments (not shown), said chairs are fixed to said formwork using any suitable nails, screws or adhesives.
With reference to FIG. 6, two runs 23, 24 of said sill or hob mould are joined by joining member 25. Said joining member is fabricated from suitable sheet material, having the same width and depth as said sill or hob mould. In the preferred embodiment, said sill or hob mould side panels are provided at their upper and lower edges with transverse flanges (typically depicted as 9 and 8 in FIG. 7). Also in the preferred embodiment, the inner edges of said transverse flanges are turned through a further 90° to form inwardly directed flanges parallel to said side panels (depicted as 7 in FIG. 1). The ends of transverse spacers 26 are turned through 90° and spot welded to said upstanding flanges and maintain said side panels in fixed spatial relationship. Oblique strap 29 is spot welded to upper and lower transverse flanges 8 to strengthen the corner of said joining member. Transverse straps 27 are spot welded to said upper and lower transverse flanges to maintain a precise geometry of said sill or hob mould at the joining point, said sill or hob mould runs abutting said joining member at points 28. Doublings (not shown) are fixed to the inner surfaces of said joining member and extend outwardly to enter and abut the inner surfaces of the ends of said sill or hob mould side panels with a suitable degree of overlap. The fixing of said doublings to said side panels of said sill or hob moulds using suitable fastenings is the method of joining said sill or hob mould runs to said joining member. Said joining member is supported from said formwork by a chair having a square or equi-armed, L-shaped base, one corner or the apex 30 of which, respectively, is exposed. In the preferred embodiment, said corner or apex is fixed to said formwork (depicted as 3 in FIG. 1) using a fixing plate (depicted as 21 in FIG. 5). In alternative embodiments, any conventional fixing means are employed. Upwardly extending chair side panels 14 are fixed to or formed on the edges of said chair in appropriate positions such that their internal surfaces make sliding contact with the external surfaces of said sill or hob mould side panels. Bridges (depicted as 15 in FIG. 1) are fixed to said chair side panels to support said joining member at an appropriate height above said formwork. Said chair side panels are fixed to said sill or hob mould side panels in the manner described in relation to FIG. 1. Said joining members are optionally fabricated in different forms to join lengths of said sill or hob mould at a range of angles. Said joining members and said sill or hob mould are optionally made from a variety of materials, including light metal alloys, steel alloys and engineering polymers, where necessary, appropriately treated against corrosion.
With reference to FIG. 7, in an alternative embodiment, said sill or hob mould is made with symmetrical side panels, the upper and lower edges of which are turned through 90° to create upper and lower transverse flanges 8, 9. The ends of transverse spacers 32, 33 are turned through 90° and spot welded to said side panels. In an alternative embodiment (not shown), said spacers are made in continuous, zig-zag-type form with small flats parallel to said sill or hob mould side panels provided between each angled part, said flats being spot welded to said side panels. Said embodiment is suited for continuous production in which said side panels are formed up from continuous lengths of flat, rolled metal strip and straightened, said side panels are brought together with said continuous, zig-zag-type spacers between them and said spacers are spot welded to said side panels. Depending upon the dimensions of said sill or hob mould, the vertical width of said transverse spacers and said zig-zag-type spacers falls in the range 10 millimetres to substantially the same height as said sill or hob mould. In an alternative embodiment (not shown), said sill or hob mould is formed up from continuous lengths of rolled metal strip in a generally U-shaped form and panels of suitable size are punched or otherwise cut out from the lower transverse panel to create voids separated by narrow transverse strips. In this embodiment, for stiffening purposes, the upper edges of said side panels of said sill or hob mould are at least turned through 90° to form transverse flanges (depicted as 9 in FIG. 2). In the preferred embodiment, robotic spot welding means are employed to fix said spacers to said sill or hob mould side panels. Said chair is made with two overlapping or telescopic side panels 14, 34, the abutting surfaces of which are in sliding contact. Said side panels are made with coincident slotting and a bolt 35 passes through said slotting such that, when nut 37 is tightened onto the threaded end of said bolt, said side panels are captured between the ends of crush tube 36, the head of said bolt and said nut. The upper ends of chair side panels 34 are turned through 90° to create transverse fixing flanges 31. Said sill or hob mould is fixed to said chair by suitable fastenings 39 passing through lower transverse flanges 8 and transverse fixing flanges 31. The height of said sill or hob mould above formwork 3 is set by loosening nut 37, slidingly adjusting the height of said chair and re-tightening said nut. In an alternative embodiment (not shown), separate guide slots are provided in one pair of said chair side panels (14, 14 or 34, 34) which are engaged by suitable guide buttons provided on the other pair of said chair side panels, said embodiment acting to maintain said side panels in alignment during their said sliding adjustment. In another alternative embodiment (not shown), only one pair (14, 14 or 34, 34) of said chair side panels is slotted and said bolt is retained in suitable apertures in said other pair of side panels. Chair side panels 14 are fixed to formwork 3 by suitable fastenings (typical positions indicated in broken line as 38) driven through suitable apertures in transverse bottom part 13. In an alternative embodiment, a transverse partition (position depicted in broken line as 40) is provided joining the upper ends of chair side panels 34 and a transverse partition (position indicated in broken line as 41) is provided joining the lower ends of chair side panels 14. Height adjustment screws (positions indicated in broken line as 42) pass between said partitions, in the preferred embodiment, said screws being of the inter-screw type in which a male screw of conventional form with an extended threaded part engages a female (tubular) screw with an extended threaded part. Shortening of said screws (by deepening the engagement of the male screw with the female) acts to increase the height of said sill or hob mould above said formwork. In an alternative embodiment, said screws are long screws of conventional form and their heads are rotationally captured at one said partition, the other ends of said screws engaging nuts fixed to the other said partition. Rotation of said screws in the appropriate sense increases or decreases the height of said sill or hob mould above said formwork. The height of said sill or hob mould is normally set to position its lower edge at the finished surface of said slab when poured. In alternative embodiments (not shown), the lower edge of said sill or hob mould is set above or below said slab surface when poured. With additional reference to FIG. 28, in an alternative embodiment, chair 2 is made with a transverse top part 95 joining the upper edges of side panels 14 and said chair is fixed to formwork 3 by fastenings passing through suitable tabs or flanges 93 formed on the lower edges of said side panels. Said transverse top part is made with transversely arranged slots (not shown) which permit the lateral position of sill or hob mould 1 to be adjusted before said sill or hob mould is fixed to said chair with suitable fastenings (typical positions indicated as 94). In the preferred embodiment, said fastenings take the form of bolts passing through any of a plurality of suitable apertures (not shown) in narrow, transversely arranged strips 96 joining the lower edges of said sill or hob mould side panels, through said slots and screwably tightened into nuts (not shown) positioned beneath said chair transverse top part.
With reference to FIG. 8, said sill or hob mould is extruded in a continuous length from a thermoplastic polymer material or light metal alloy material. Said extruded section comprises two side panels 43 connected at the lower end by a transverse web which is punched or otherwise cut out to create voids 46 separated by narrow transverse strips. Longitudinal rails 44, 45 are provided along the upper and lower inner, edges of said side panels and channels 47, 48 are provided in said rails. Said channels are made with an approximately circular cross-sectional shape to which access is gained via slots. Said slots are orientated, respectively in relation to channels 47, 48, upwardly and downwardly. Said slots taper inwardly to a width being approximately 10% to 20% smaller than the diameter of said channels and, as such, form constricted entries to said channels. Said chair side panels (not shown) are made with their upper edges substantially cylindrical in form and with a diameter able to be neatly accommodated within channels 48. Said sill or hob mould is fixed to said chair by said chair side panel upper edges being forced through said slots to frictionally engage channels 48. Closure 49 is made with shallow longitudinal rails 50 along each edge, the free edges of said rails being made in substantially cylindrical form with a diameter able to be neatly accommodated within channels 47. Said closure is fixed to said sill or hob mould by said rail edges being forced through said slots to frictionally engage channels 47. In an alternative embodiment (not shown), suitable apertures are punched or otherwise cut out from said closure to create voids separated by narrow transverse strips. In another alternative embodiment (not shown), said sill or hob mould is extruded in a single section, with side panels 43 connected at their upper and lower ends by transverse webs which are both punched or otherwise cut out to create voids separated by narrow transverse strips. In another alternative embodiment (not shown) said chair side panels are made from metal sheet and their upper edges are made into a substantially cylindrical form by rolling or by fixing a wire along said edges, the diameter of said rolling or said wire being such as to be neatly accommodated within channels 48.
With reference to FIG. 9, said sill or hob mould is made in asymmetric cross-sectional form, with a first flat face 52 and a second face 53 shaped to suit a particular application. In the embodiment shown, said second face is made concave with said mould increasing in width downwardly to suit the mounting of a hospital wall in which vinyl floor tiles are curved to pass from the floor surface to the wall surface. The arrangement is intended to improved hygiene by eliminating the difficult-to-clean zone normally existing at the junction of a wall with a floor surface. The upper edges of said side panels are turned through 90° to create upper transverse flanges 54 and transverse or zig-zag-type spacers 57 of the type described in relation to FIG. 7 are spot welded to said side panels. Longitudinally arranged angles 55, 56 are spot welded to the lower inner edges of said side panels and transverse or zig-zag-type spacers 58 of the type described in relation to FIG. 7 are spot welded to said angles. Curved side panel 53 is extended vertically downwards to create apron 59 such that, when said sill or hob mould is embedded in the surface of a concrete building slab (typical surface level of said slab indicated as 19), said apron forms a positive moisture barrier.
With reference to FIG. 10a, the lower edge of said sill or hob mould side panel 4 is turned through 90° to create lower transverse flange 8. Tab 61 is spot welded at its lower end to said side panel. Flat 60 of a zig-zag-type spacer 33 of the type described in relation to FIG. 7 abuts said side panel. With additional reference to FIG. 10b, said tab has been bent downwardly and against said flat, thereby fixing said spacer to said side panel.
With reference to FIG. 11, the lower edges of said sill or hob mould side panel side panel 4 of have been turned through approximately 180° to create channels 62 with lipped, constricting edges 63. The upper edges of chair side panels 64 are made with substantially cylindrical edges 66 which are turned through approximately 180° at bends 65. In the preferred embodiment, said chair side panels are made from metal sheet and their upper edges are made into substantially cylindrical form by rolling or by fixing of a wire along said edges, the diameter of said rolling or said wire being such as to be neatly accommodated within channels 62. Said sill or hob mould is fixed to said chair side panel edges by edges 66 being forced past constricting edges 63 to be frictionally captured within channels 62. The turned ends 60 of transverse spacer 33 (or flats of zig-zag-type spacers of the type described in relation to FIG. 7) are spot welded to said sill or hob mould side panels. In an alternative embodiment (not shown), part of said lower edges of said sill or hob mould side panels of suitable width are turned upwardly and tightly through 180° and approximately half of the upturned part is then turned downwardly through 180° to create downwardly orientated channels with constricting edges of the type depicted in FIG. 11. The upper edges of said chair side panels are made rolled or wired as described in relation to FIG. 11, said edges being of a diameter as may be neatly accommodated within said channels. Said sill or hob mould is fixed to said chair by said rolled or wired edges being forced past said constricting edges to be frictionally captured within said channels.
With reference to FIG. 12, short, downwardly projecting parts of the lower edges of said sill or hob mould side panels 4 are double folded to create a plurality of more or less triangular sections 68. Short upwardly projecting parts of the upper edges of said chair side panels are double folded to create a plurality of more or less triangular sections 69 able to be neatly accommodated within sections 68. Said sill or hob mould is fixed to said chair side panels by sections 69 being interdigitated between sections 68, the former then being displaced laterally to enter and be frictionally captured within the latter. In an alternative embodiment (not shown), the turned ends 70 of transverse spacer 33 (or flats of zig-zag-type spacers of the type described in relation to FIG. 7) are made with downwardly extending parts which are double folded into more or less triangular sections able to be frictionally captured within sections 68 in the manner described.
With reference to FIG. 13a, the lower edges of said sill or hob mould side panels 4 are double folded to form lower transverse flanges 72 with short lengths of upstanding flange 73 formed on them. The turned ends 70 of transverse spacers 33 (or flats of zig-zag-type spacers of the type described in relation to FIG. 7) are made with short lateral extensions 71 formed on their lower edges. With additional reference to FIG. 13b, lengths of upstanding flange 73 have been folded down to capture short lateral extensions 71, thereby fixing said transverse spacers to said side panels.
With reference to FIG. 14, the lower edges of sill or hob mould side panels 4 are turned inwardly through 90° and approximately half of said turned part turned outwardly through 180° to create outwardly orientated attachment channel 74. The upper edges of said chair side panels are treated in a reciprocal way to create inwardly orientated attachment channel 76. Said sill or hob mould is fixed to said chair by the free end 77 of said chair side panel upper edge being accommodated within attachment channel 74 and the free end of sill or hob mould side panel lower edge 78 being accommodated within attachment channel 76. The turned ends 70 of transverse spacers 33 (or flats of zig-zag-type spacers of the type described in relation to FIG. 7) are spot welded to said sill or hob mould side panel.
With reference to FIG. 15, The lower edges of said sill or hob mould side panels are turned through 90° to create lower transverse flange 79. The upper edges of said chair side panels are turned through 90° to create attachment flanges 80. Said sill or hob mould is fixed to said chair by the abutting said lower transverse flange and attachment flange being clamped together by screw means 82 of a plurality of suitably spaced clamps 81. The turned ends 70 of transverse spacers 33 (or flats of zig-zag-type spacers of the type described in relation to FIG. 7) are spot welded to said sill or hob mould side panel.
With reference to FIG. 16, the side panels 4 of said sill or hob mould are joined at their upper and lower edges by a continuous length of zig-zag-type spacers of the type described in relation to FIG. 7, said spacers being attached to said side panels as described in relation to FIGS. 13a and 13b. In this embodiment, flats of said spacers are provided with short lateral extensions 71 formed on their lower edges, short upstanding flanges 73 formed on the inner edges of lower transverse flanges 72 being folded down to capture said short lateral extensions. Said embodiment is suited for continuous production in which said side panels are formed from rolled metal strip and straightened, said side panels are brought together with said continuous, zig-zag spacers between them and said spacers are fixed in the manner described to said side panels. In an alternative embodiment (not shown), said spacers are made in the form of a continuous sinusoidal curve and are clipped into place in the manner described in relation to this Figure or are spot welded into place at the points of contact with said side panels.
With reference to FIG. 17, side panels 4 of said sill or hob mould are joined by a plurality of transverse spacers 26, the turned ends 70 of which are spot welded to the upper and lower edges of said side panels. Said embodiment is suited for continuous production in which said side panels are formed up from flat, rolled metal strip and straightened, said side panels are brought together with said transverse spacers between them and said spacers are spot welded to said side panels.
With reference to FIG. 18, the lower and upper edges of sill or hob mould side panels 4 are turned through two 90° folds to form lower and upper transverse flanges 77, each having short upstanding or downwardly directed (as appropriate) flanges 76 formed on them. Clips 74 are folded over the turned ends 70 of transverse spacers 33 (or flats of zig-zag-type spacers of the type described in relation to FIG. 7) and lateral extensions 75 of said clips are positioned to abut said lower or upper (as appropriate) transverse flanges. Upstanding or downwardly directed (as appropriate) flanges 76 are then folded inwardly to capture said turned ends of transverse spacers 33 (or flats of zig-zag-type spacers of the type described in relation to FIG. 7), thereby joining said sill or hob mould side panels one to another.
With reference to FIG. 19, sill or hob mould 1 is supported at either side upon parallelogram mechanisms formed from upper straps 84, 85, 86 the upper ends of which are pivotally joined to the lower edges of said sill or hob mould at pivots 78 positioned on each side of said sill or hob mould and pivotally joined to lower straps 87, 88, 89 at the ends of transverse nut bar 82, at laterally located pivots 92 and at transverse bearing bar 83. Said lower straps are pivotally joined to formwork 81 at pivots 79. Links 91 on either side maintain said nut bar and pivots 92 in fixed spatial relationship. Threaded rod 90 is rotationally captured in a medially positioned bearing (not shown) in said bearing bar and knob 80 is provided to turn it. Said threaded rod passes between laterally located pivots 92 and its distal end is screwably engaged with a medially positioned nut (not shown) in said transverse nut bar, rotation of said threaded rod in the appropriate direction acting to draw said bearing bar and said nut bar closer together or to increase their separation, thereby increasing the height of said sill or hob mould above said formwork of reducing said height. In the preferred embodiment, said straps are made from a stiff metal section and said pivots are made tight with no free play, thereby minimising any tendency for said sill or hob mould to sway or otherwise deviate from its desired position. The advantage of the said embodiment is its ability to provide precise height adjustment of said sill or hob mould. In the preferred embodiment, pivots 79 are fixed in common to a plate which is, in turn, fixed to said formwork.
With reference to FIG. 24, in an alternative embodiment, a chair to support said sill or hob mould comprises base plate 97 to which are fixed two, parallel, threaded supporting rods 98 of suitable length orientated normal to said base plate. Parallel slots 99 are provided in said base plate.
With additional reference to FIG. 20, in an alternative embodiment, base plate 97 is made with one or more slots 99. Clamp 107 comprises flat base part 100 on one end of which is formed supporting piece 101. Fixing screw 103 passes through a said slot and through medially positioned aperture 102 in said flat base part and its threaded part is screwably engaged with the complementary thread of a suitable aperture (not shown) provided in jaw 104. One end of said jaw is formed into tongue 105 which passes through a suitable aperture positioned towards the free end of said supporting piece. With said fixing screw loosened, said clamp may be slideably positioned along slot 99 of plate 97 and a reinforcing bar 106 may be positioned between adjacent faces of said flat base part and said jaw. Tightening of said fixing screw simultaneously locks said clamp to said plate and seizes said reinforcing bar between said flat base part and said jaw.
With reference to FIG. 21, in an alternative embodiment, a chair to support said sill or hob mould comprises base plate 97 to which are fixed two, parallel, threaded supporting rods 98 of suitable length orientated normal to said base plate. One or more slotted apertures 108 are provided in said base plate and suitable fastenings passing through said apertures are employed to fix said base plate to supporting bars (not shown) which are, in turn, fixed to reinforcing bars (not shown) by a variety of fixing means (not shown). Said slotted apertures permit positional adjustments of said base plate to be made before said base plate if fixed to said supporting bars. In other alternative embodiments (not shown), said chairs comprising base plate and parallel, threaded supporting rods are fixed to said formwork by means of suitable fastenings passing through slotted openings in said baseplate. In these embodiments, said slotted openings permit positional adjustment of said chair prior to tightening of said fastenings.
With reference to FIG. 22, in an alternative embodiment, the base plate 97 of a said chair is provided with one or more slots 99 from which clips 109 are supported by the screwable engagement of the threads of their fixing screws 110 with complementary threads of a bore 112 provided in attachment boss 111. Said fixing screws pass through said slots and, with said fixing screws loosened, said clips may be positioned to permit them to engage and be frictionally attached to reinforcing bars (not shown). Tightening of said fixing screws acts to fix said clips to said base plate and, thereby, to fix said base plate to said reinforcing bar.
With reference to FIG. 23, in an alternative embodiment, base plate 97 of a said chair is made with one or more slots 113. Threaded rods 114 of said chair are fixed to said base plate by upper nuts 117 being screwably displaced on the threading of said rods against lower nuts 115. Suitable shoulders 116 of said lower nuts engage said slots, thereby preventing said lower nuts from turning during tightening of said upper nuts. Obviously, the height of a said threaded rod on said base plate may be adjusted by screwably displacing said upper and lower nuts on said threaded rods.
With reference to FIG. 26, in an alternative embodiment, a chair to support said sill or hob mould comprises base plate 97 to which are fixed two, parallel, threaded supporting rods 98 of suitable length orientated normal to said base plate. Suitable apertures 118 are provided in said base plate to facilitate a flow of concrete through said base plate. Suitable fixing apertures 119 are provided around the periphery of said base plate and said base plate is secured to reinforcing bar (not shown) by wire ties passed through said fixing apertures, around said reinforcing bar and the ends twisted together and tightened.
With reference to FIG. 27, in an alternative embodiment, the base plate 97 of a said chair is provided with upstanding edge flanges 120 provided with longitudinally orientated slots 127. Clips 128 are supported from said edge flanges by their fixing screws 121 passing through said slots, through spacer tubes 122 and through attachment webs 123 of said clips such that their threaded parts screwably engage and are tightened into complementary threads in nuts 124. In the preferred embodiment, said clips are of the larger alligator type. With said fixing screws loosened, said clips may be positioned on said edge flanges to permit them to engage and be attached to reinforcing bars (not shown). Tightening of said fixing screws acts to fix said clips to said base plate edge flanges and, thereby, to fix said base plate to said reinforcing bar. Where the height of said base plate is required to be adjusted in relation of said reinforcing bar, said fixing screws are loosened, said clips are partially released from said reinforcing bar and said clips are rotated on said fixing screw as required to perform said height adjustment. Said clips are then permitted to engage said reinforcing bar and said fixing screws are re-tightened.
With reference to FIG. 25, in an alternative embodiment, gill or hob mould 1 is supported on threaded supporting rods 98 fixed to a base plate (not shown). Threads of nuts 129 are screwably engaged with complementary threads of said supporting rods and tubular projections 130 formed on the upper ends of said nuts pass upwardly through suitable apertures 132 provided in narrow, transversely arranged strips 96 joining the lower edges of said sill or hob mould side panels 4. Dished, metal spring washers 131 are pressed over said tubular projections with small sprigs (not shown) formed around their central apertures engaging the external surfaces of said tubular projections, thereby retaining said spring washers in place and which, by urging said transversely arranged strips against shoulders 133 of said nuts, act to retain said sill or hob moulds in the correct vertical attitude on said supporting rods. In the preferred embodiment, said threading of said supporting rods is made coarse and said nuts are formed from a suitable thermoplastic polymer material providing a firm frictional engagement with said threading. Also in the preferred embodiment, the upper ends of said tubular projections are made hexagonal or other shape intended for engagement by a suitable tool employed to turn said nuts on said supporting rods. Also in the preferred embodiment, said tool is a tube spanner.
In alternative embodiments (not shown), the rods of said base plate and rod-type chair are made plain and unthreaded and said sill or hob mould is secured in place on said rods by suitable clips frictionally attached to said rods above and below the appropriate surfaces of said sill or hob mould.
With reference to FIGS. 29a, 29b, 29c and 29d, said sill or hob mould is supported upon a chair formed from a suitable length of folded metal section 134. The cross-sectional shape of said folded metal section is selected to provide torsional, transverse and longitudinal stiffness. In the preferred embodiment, said folded metal section is cut to length by shearing between two dies shaped to match its said cross-sectional shape. According to the attachment requirements of said folded metal section, it is optionally cut straight across or, where appropriate, said dies are shaped to provide a plurality of attachment tabs 135 formed on one or both ends. Said attachment tabs are employed, as appropriate, to fix the lower end of said chair to a base plate or its upper end to said sill or hob mould. In the preferred embodiment, suitably positioned slots are punched in said base plate or said sill or hob mould base using a portable hydraulically-operated punch. As depicted in FIGS. 30 to 32, said attachment tabs are passed up through said slots and are bent over flat to secure said folded metal section into place. In an alternative embodiment (not shown), said attachment tabs are twisted through approximately 90° to effect the attachment of said folded metal section. In another alternative embodiment (not shown), said attachment tabs are passed through suitable apertures and secured by welding. The embodiment of said folded metal section depicted at FIG. 29b is preferred as it provides the necessary positional stability with the use of only three said attachment tabs.
With reference to FIG. 30, a chair comprises folded metal section 134 and side panels 31. The lower end of said folded metal section is fixed to base plate 137 by a plurality of attachment tabs 135 passed through suitable slots and folded flat. Said base plate is suitably joggled to accommodate said attachment tabs and is fixed to formwork 3 by means of suitable fasteners (positions indicated as 136). The upper ends of said chair side panels are turned through 90° to create transverse fixing flanges 31. Sill or hob mould 4 is fixed to said chair by suitable fastenings (positions indicated as 39) passing through lower transverse flanges 8 of said sill or hob mould and transverse fixing flanges 31. Vertical slots (not shown) are provided alternatively in side panels 34 or the sides of said folded metal section with suitable apertures in the other. Suitable fastenings (positions indicated as 138) passing through said side panels and said sides of said folded metal sections permit sliding height adjustment of said sill or hob mould when loosened. Obviously, in an alternative embodiment (not shown), said folded metal section may be cut to the requisite length and its upper end fixed directly to said sill or hob mould. Where this embodiment is employed, transverse strips of material are provided across the lower surface of said sill or hob mould to permit said fixing of said folded metal section. In another alternative embodiment (not shown), a similar sectional shape moulded from a suitable polymer material replaces said folded metal section and its ends are fixed to said sill or hob mould or said base plate by its said attachment tabs being passed through suitable slots and fused with a suitable hot implement. Obviously, said folded metal section may take a large variety of other cross-sectional shapes.
With reference to FIG. 32, attachment tabs 135 on an end of folded metal section (position indicated in broken line as 134) are folded over flat to fix said folded metal section to sill or hob mould or baseplate 139.
With reference to FIG. 31, in an alternative embodiment, said attachment tabs are made in closely-spaced pairs 141, 142 and said folded metal section is fixed to sill or hob mould or baseplate 139 by passing said attachment tabs through a common slot 140 and then bending them flat in opposed senses.
With reference to FIG. 33, in a first embodiment in which a step or break in level of a poured concrete slab 147 is required, said step or level break is achieved by supporting upon a row of chairs 143 a length of suitable section 144, said chairs being fixed to formwork 145 by suitable fastenings (not shown) passing through suitable apertures provided in feet 146 of said chairs. Said stepped concrete slab is poured to the desired levels and the higher part 148 of the upper surface of said slab is then finished more or less flush with the upper edge of said section with the lower part 149 of the upper surface of said slab being formed more or less flush with the upper surface of the lower part 150 of said section. In this embodiment, said section optionally takes the form of any suitable of those disclosed herein and may be closed or, as depicted in the figure, open. Said chairs optionally take the form of any suitable of those disclosed herein. In an alternative embodiment, where said section is open as depicted in the figure, a return 151 is optionally provided at its upper edge to better reinforce said step or break in level. In this embodiment, the higher part 148 of the upper surface of said slab is finished more or less flush with the upper surface of said return.
With reference to FIG. 34, in a second embodiment in which a step or break in level of a poured concrete slab 147 is required, said step or level break is achieved by supporting upon a row of chairs 143 a length of suitable section 152, said chairs being fixed to formwork 145 by suitable fastenings (not shown) passing through suitable apertures provided in feet 146 of said chairs. Said section is made more or less in the form of a square U-shape and supports within it a length of wood 153 or other suitable material of suitable width and cut to make a close fit within the interior of said section. In an alternative embodiment (not shown), said length of wood or other material is cut narrower than the interior width of said section and is secured in place against the higher slab side of said section by means of a plurality of suitable wedges. Said stepped concrete slab is poured to the desired levels and the higher part 148 of the upper surface of said slab is then finished more or less flush with the upper edge of said length of wood or other material or to a level marked upon its side. The lower part 149 of the upper surface of said slab is formed more or less flush with the upper surface of the lower part 154 of said section. In this embodiment, when said concrete has cured, said length of wood or other material is removed and the un-embedded side 155 of said section is cut away flush with said lower part of the upper surface of said slab using an angle grinder or similar implement. In an alternative embodiment (not shown), said section is made in the form of a simple L-shape and said length of wood or other material of suitable width is secured to it by suitable, horizontally arranged fastenings passing through it into the vertical part of said section.
In this embodiment (the creation of a step or break in level of a poured concrete building slab), said section optionally takes the form of any suitable of those disclosed herein and may be closed or open. Said chairs optionally take the form of any suitable of those disclosed herein. Chairs formed from a closed cross-sectional shape, for example, round, square, oval or triangular, all with plain, perforated or ribbed sides, are optionally employed where a void in a concrete slab may be tolerated.
In an alternative embodiment (not shown), a sealing compound is applied to the inner surfaces of said sill or hob mould, said sealing compound dispersing into the concrete with which said mould is filled. Said sealing compound preferably takes the form of one such as Xypex®, distributed by Xypex Australia, of 45 Union Road, North Albury, NSW 2641, Australia, in which reactive chemicals diffuse into concrete using water as a migrating medium and crystallise to form a non-soluble filling of pores and capillary tracts in the cured concrete. Said sealing compound is applied in dry form with a suitable binder to the inner surfaces of said sill or hob mould and is activated by the filling of said mould with concrete.
In another alternative embodiment (not shown), said sill or hob mould, immediately following pouring of a building concrete slab, is filled with concrete containing a waterproofing compound.
In another alternative embodiment (not shown), said sill or hob mould side panels are provided with vertical or horizontal fluting, ribbing or doubling or are otherwise treated to provide increased stiffness.
In another alternative embodiment (not shown), the upper and lower edges of said sill or hob mould side panels are rolled, ribbed or folded to provide increased stiffness.
In another alternative embodiment (not shown), channels or other sections are fixed to the upper and lower inner surfaces of said sill or hob mould side panels to provide increased stiffness.
In another alternative embodiment (not shown), transverse stiffeners of the type depicted as 27 in FIG. 6 are welded to the outer or inner surfaces of transverse upper and lower flanges (depicted as 8 and 9 in FIG. 7). Where said sill or hob mould is made from a light metal alloy material, said transverse stiffeners are optionally fixed by cold pressure welding. Where said sill or hob mould is made from a steel alloy material, said transverse stiffeners are fixed by spot welding.
In another alternative arrangement (not shown), the side panels of said chair are effectively made telescopic as depicted in FIG. 7 and the abutting surfaces of said side panels have formed on them complementary, ratchet-type projections which permit telescopic extension but prevent telescopic collapse. In use, said sill or hob mould is temporarily supported from said formwork at the correct height and said chair side panels are then telescopically extended and fixed to said mould to provide sustained support. Should there be a requirement to telescopically collapse said chair side panels, they are removed and physically separated for this purpose.
In another alternative embodiment (not shown), the height of said sill or hob mould on said chair is adjusted by positioning pairs of opposed wedges between them. Slots are provided through said wedges to accommodate a draw bolt which is employed to draw said wedges together or increase their spacing, as appropriate.
In another alternative embodiment (not shown), to minimise the possibility of conflict with reinforcing bar, plate or mesh installed in said formwork, the transverse bottom part of said chair (depicted as 13 in FIG. 1) is deleted and the lower edges of said chair side panels are provided with tabs, flanges of other means for attachment to said formwork.
In another alternative embodiment (not shown), a clearly visible gauge make is provided on the side panels of said chair or said sill or hob mould up to which concrete is filled in the pouring of a building concrete slab.
In another alternative embodiment (not shown), said sill or hob mould is made in a regularly curved planform to meet the needs of a particular architectural situation. In this embodiment, said sill or hob mould construction is of the type described in relation to FIG. 7, said side panels first being separately curved to the correct radius and then joined by transverse or zig-zag-type spacers which are preferably spot welded into place. Said chairs are positioned as required to support said curved mould. In another alternative embodiment (not shown), said sill or hob mould is made in an irregularly shaped planform to suit a particular architectural situation, the method of manufacturing said sill or hob mould being generally as described for that with a regularly curved planform.
In another alternative embodiment (not shown), a plurality of free standing said chairs are distributed over said formwork prior to pouring of a building concrete slab and are employed as level gauges during said pouring.
In another alternative embodiment (not shown), said chairs and said sill or hob moulds are made in ranges of heights and widths to suit a variety of architectural applications.
In the present invention, except where clearly impractical, any feature described in one embodiment should be taken as able to be used in combination with any feature of another embodiment.
Patent Application
20140035181
