WO1992000433A2

WO1992000433A2 - Dismountable shuttering system and method of building a walled structure

Info

Publication number: WO1992000433A2
Application number: PCT/GB1991/000978
Authority: WO
Inventors: Patrick Moreland; Jöger Ebenhaezer GROENEWALD
Original assignee: Patrick Moreland; Groenewald Joeger Ebenhaezer
Priority date: 1990-06-19
Filing date: 1991-06-18
Publication date: 1992-01-09
Also published as: AU8096691A; IL98555A0; WO1992000433A3

Abstract

A dismountable shuttering system comprises shutter panels (12) which are arranged adjacent one another and on opposite sides of a cavity (72), upright panel supports (14, 52, 60, 66) each arranged between an adjacent pair of the panels, transverse panel supports (16) arranged transversely of the upright panel supports on the outside of the panels, and ties (18) which extend across the cavity and disengageably engage at opposite ends thereof with the transverse panel supports. The panels have rebates (34) in their vertical edges into which free edge portions (22, 22.1, 22.2, 22.3) of the upright panel supports are accommodated. The upright panel supports have hook-like elements (24, 56, 64, 70) which engage with the transverse panel supports through gaps between adjacent panels. A mortar mix including an air entraining agent is introduced into the cavity and allowed to set, whereafter the shuttering system is stripped.

Description

DISMOUNTABLE SHUTTERING SYSTEM AND METHOD OF BUILDING A WALLED STRUCTURE

THIS INVENTION relates to a dismountable shuttering system and to a method of building a walled structure.

According to the invention there is provided a dismountable shuttering system which, when erected, comprises: shutter panels having an inside and an outside, and being arranged adjacent one another and on opposite sides of a cavity to be filled with a cementitious material to form a walled structure; upright panel supports each arranged between an adjacent pair of the panels, each upright panel support having retaining formations which seat on the inside of the panels, on either side of the upright panel support, thereby retaining the panels against displacement inwardly of the cavity; transverse panel supports arranged transversely of the upright panel supports, on the outside of the panels, the upright panel supports and/or the transverse panel supports having engagement formations whereby the transverse panel supports disengagably engage with the upright panel supports through gaps between the adjacent panels; and ties which extend across the cavity, and disengageably engage at opposite ends thereof with the transverse panel supports on opposite sides of the cavity.

Each shutter panel, on the inside thereof, may have a rebate along each vertical edge thereof, said retaining formations being in the form of free vertical edge portions of the respective upright panel supports, which free edge portions are accommodated in the rebates of the adjacent panels, and each upright panel support having an inside surface which is flush with the inside surfaces of the adjacent panels.

Each upright panel support may comprise a plurality of vertically spaced, upwardly open, hook¬ like elements which protrude outwardly beyond the adjacent panels, and in each of which hook-like element a respective transverse panel support is receivable, each hook-like element having a horizontally extending portion supporting the transverse panel support from below, and an upwardly extending portion keeping the transverse panel support in position against the outside of the panels.

The upright panel supports and the transverse panel supports may have complementary interlock formations which inter-engage to locate the transverse panel supports against displacement with respect to the upright panel supports in a direction longitudinally of the transverse panel supports.

The interlock formations may comprise a series of transverse slots in the transverse panel supports, into which slots complementary parts of the upright panel supports enter.

The ties may pass through holes in the panels.

At least some of the upright panel supports may comprise an angle section member, the panels adjacent these upright panel supports extending at a corresponding angle to one another.

The dismountable shuttering system may further include first inserts located between a door or window frame in the cavity and the facing panels on opposite sides of the cavity, to close gaps between the door or window frame and the respective panels.

The dismountable shuttering system may still further include a second insert extending between said panels on opposite s^'ides of the cavity, to form the upper surface of a gable or parapet wall.

The dismountable shuttering system may still further include a third insert extending between said panels on opposite sides of the cavity, to form the undersurface of an archway.

The invention extends to a method of building a walled structure, which comprises erecting shuttering in situ to define a cavity corresponding to the shape of the walled structure, introducing a mortar mix which includes an air entraining agent into the cavity, allowing the mortar mix to set, and thereafter stripping the shuttering.

The invention will now be described in more detail, by way of example, with reference to the^' accompanying drawings.

In the drawings: Figure 1 is a broken horizontal section through part of an erected shuttering system in accordance with the invention;

Figure 2 is a vertical section on line II-II in Figure 1 ;

Figure 3 is a pictorial view of part of a first type of upright panel support forming part of the shuttering system, for use along a straight section of wall being constructed;

Figure 4 is a plan view of part of a transverse panel support forming part of the shuttering system; Figure 5 is a pictorial view of part of a second type of upright panel support forming part of the shuttering system, for use at an outside corner of a wall being constructed;

Figure 6 is a pictorial view of part of a third type of upright component for use at an inside corner of a wall being constructed;

Figure 7 is a pictorial view of part of a fourth type of upright panel support forming part of the shuttering system, for use at the end of a wall being constructed; Figure 8 is a plan view of a tie forming part of the shuttering system, for tying together transverse panel supports on opposite sides of a wall being constructed;

Figure 9 is a vertical section of the tie, on line IX-IX in Figure 8:

Figure 10 is a horizontal section showing the use of a first type of insert to incorporate a door frame in a wall being constructed;

Figure 11 is a vertical section showing the use of a second type of insert to form the top of, for example, a gable wall;

Figure 12 is a vertical section showing the use of a third type of insert to form an archway in a wall; and Figure 13 is a pictorial view of a completed wall structure built with the shuttering system of Figures 1 to 12.

Referring first to Figures 1 to 4, reference numeral 10 generally indicates a dismountable shuttering system which comprises plywood shutter panels 12, first upright panel supports 14, transverse panel supports 16, and ties 18.

The upright panel supports 14 are T-shaped in cross section, having a leg 20 and flanges forming free edge portions 22 which extend on either side of the leg. To the leg 20 there are secured a number of upwardly open hook-like elements 24 each having a horizontally extending portion 26 and an upwardly extending portion 28. The hook-like elements 24 are spaced at intervals along the length of the upright panel support 14. Although only two of the hook-like elements 24 are shown in Figure 3, it is to be understood that each of the upright panel supports 14 will have several of the elements 24.

The shutter panels 12 have an inside 30 and an outside 32. On the inside, along each vertical edge thereof, the shutter panel has a rebate 34, whose dimensions are such that, when the shuttering system is in the assembled condition as illustrated in Figure 1 , the free edge portions 22 are accommodated in the rebates of the adjacent panels, and the inside surface 36 of the portions 22 is flush with the inside surface 30 of the panels 12. The portions 22 serve to retain the panels 12 against displacement inwardly of the cavity between opposite panels.

The transverse panel supports 16 are in the form of lengths of square section tubing which, on one side thereof and at regularly spaced intervals, have slots 38 cut therein. The slots 38 are slightly wider than the thickness of the legs 20, so that the legs can enter into the slots. The width of the square section tubing is slightly greater than the width of the gap between the leg 20 and the upwardly extending portion 28 of the hook-like elements 24, so that the only way in which the transverse panel supports 16 can fit into the gap is for the legs 20 to enter into the slots 38.

Referring more particularly to Figures 8 and 9, the tie 18 comprises a pair of L-shaped brackets 40.1 and 40.2, and a tie rod 42 which is welded at one end thereof to the vertical limb of the bracket 40.1. The other end of the tie rod 42 is screw threaded, as shown at 44. The screw threaded end 44 is able to pass through an opening 46 in the vertical limb of the bracket 40.2 and can receive a nut 48. The distance between the horizontal limb of the bracket 40.1 and the tie rod 42 is such that a transverse panel support 16 can fit snugly in the gap between them, as shown in Figure 9. The bracket 40.2 has a part 50 welded to the vertical limb thereof, the spacing between the part 50 and the horizontal limb of the bracket being such that a transverse panel support 16 can fit snugly between them.

Referring more particularly to Figure 5, reference numeral 52 indicates a second type of upright panel support, for use at an outside corner of a wall to be constructed. The upright panel support 52 comprises an angle section member 54 which has a series of vertically spaced hook-like elements 56 secured thereto as illustrated. The elements 56 are essentially the same as the elements 24, except that, they have parts that form locating lugs 58 adjacent the angle section member 54. The elements 56 are set back from the vertical edges of the member 54, leaving free edge portions 22.1 which have the same size and perform the same function as the portions 22.

Referring more particularly to Figure 6, reference numeral 60 indicates a third type of upright

SUBSTITUTE SHEET panel support, for use at an inside corner of a wall to be constructed. The upright panel support 60 comprises an angle section member 62 which has a series of vertically spaced brackets 64 secured thereto as illustrated, each of the brackets having a pair of rectangular notches therein. Each of the brackets 64 is equivalent to a pair of the elements 56 illustrated in Figure 5, with their ends being joined to one another. The brackets 64 are set back from the vertical edges of the member 62, leaving free edge portions 22.2 which have the same size and perform the same function as the portions 22.

Referring more particularly to Figure 7, reference numeral 66 indicates a fourth type of upright panel support, for use at the end of a wall to be constructed. The upright panel support 66 comprises a shallow channel section member 68 which has a series of vertically spaced hook-like elements 70 secured thereto as illustrated. The elements 70 are similar to the elements 56 illustrated in Figure 5. The elements 70 are set back from the vertical edge of the member 68, leaving free edge portions 22.3 which have the same size and perform the same function as the portions 22.

To erect the shuttering system 10, the panels 12 and the upright panel supports 14, 52, 60, and 66 are held upright in the required relative positions. A floor template may be used to assist in the positioning of the various upright panel supports. The transverse panel supports 16 are then placed in position by dropping them into the gaps of the hook-like elements 24, 56, 64, and 70. Entry of the legs 20 and lugs 58 into the slots 38 serve to locate the transverse panel supports 16 against displacement thereof relative to the upright panel supports 14, 52, 60, and 66 in a direction longitudinally of the transverse panel supports. The panels 12 now define between them a cavity 72.

By virtue of the fact that, through the upright panel supports 52 and -60, the shuttering system when assembled has parts extending at an angle to one another, the assembly will be fully self-supporting. No additional staying is required.

Provision for internal walls can also be made. In this event, where an internal wall is to join an external wall, two of the upright panel supports 60 are used on the inside, and another or fifth type of upright panel support (not illustrated) is used on the outside. The fifth type of upright panel support will be similar to the upright panel support 52, except that the member 54 will be flat instead of being of angle section. The fifth type of panel supports meed not necessarily always be used opposite the upright panel supports 60. They may also be used in other places, where long sections of straight wall are to be built, their use enabling shorter lengths of transverse panel supports 16 to be used. Use of the fifth type of panel supports gives added flexibility to the system, enabling walled structures of different designs to be built with the same shuttering components.

The various component parts of the shuttering system may be colour-coded and/or numbered to facilitate assembly.

The ties 18 are now placed in position. This is done by aligning the brackets 40.1 and 40.2 with pre-drilled holes in the panels 12, inserting the tie rod 42 through these openings and the opening 46 of the

BSTITUTE SHEET bracket 40.2, and tightening the nut 48 onto the screw threaded end 44. The ties 18 are provided to counteract pressure that will be exerted on the panels 12 when a fluid cementitious material is poured into the cavity 72. A number of the ties 18 are arranged at spaced intervals along the transverse panel supports 16.

Once the shuttering system 10 has been erected as described above, a cementitious mix is poured into the cavity 72. Applicant has found that a mortar mix which includes an air entraining agent is particularly suitable for this purpose. The following mix has been found to give good results (per cubic metre) :

River sand (grading MF 1 ,65 to MF 2,1 ) 1360 kg Portland cement 300 kg

Water 250 1

Air entraining agent (P707 Admix) 1850 ml -

After the mortar mix has set sufficiently for it to be self-supporting, the ties 18 are loosened and removed. The tie rods 42 should be withdrawn from the wall before the mortar mix has fully hardened. The. transverse panel supports 16 are now lifted out of the hook-like elements 24, 56, 64, and 70, whereupon the panels 12, and the upright panel supports 14, 52, 60, and 66 can readily be stripped from the wall.

Referring more particularly to Figure 10, reference numeral 74 indicates a door frame which is located between two opposite ^'shutter panels 12. Between each of the panels 12 and the door frame 74 there is a steel insert 76. The steel inserts 76 follow the outline of the door frame 74 and close the gaps between the door frame and the shutter panels 12. One of the steel inserts 76 has protruding locating pins 76.1 which can enter into holes drilled in the panels 12 so as to hold the insert in the correct position with respect to the panels. Both the inserts 76 have inwardly directed locating pins 78 whereby the door frame 74 is held in position with respect to the inserts. Reference"numeral 80 indicates mortar mix which has been poured into the cavity between the panels 12, adjacent the door frame 74. When the ties 18 have been tightened the panels 12 press tightly against the inserts 76 and the inserts in turn press tightly against the door frame 74. As a result there is a minimum of leakage of mortar mix. After the mortar mix has set, and the panels 12 stripped, the steel inserts 76 can be removed. The system as described with reference to Figure 10 can, with minor modification, also be used to incorporate a window frame in a wall.

Referring more particularly to Figure 11 , reference numeral 82 indicates a second type of insert which extends from one panel 12 to the other, for use in forming, for example, the^"top of a gable wall. The insert 82 has lips 82.1 which seat on the panel 12. Reference numeral 80 again indicates a mortar mix which has been poured into the cavity between the panels 12. When the ties 18 have been tightened, the panels 12 press tightly against the lips 82.1, thus minimising leakage of mortar mix. After the mortar mix has set and the panels 12 stripped, the insert 82 can be removed. The insert 82 may have any desired shape in side view, to form a gable wall with a corresponding shape. Where a gable wall is to be formed, the shuttering may be extended upwardly by using longer upright panel supports, and longer panels 12 or additional panels which form upward extensions of the panels 12. The extension may be rectangular, ie being as high at the ends of the gable wall as at the centre thereof, the shape of the gable wall being determined by the shape and/or position of the insert 82. Thus, by making use of different inserts 82, or a different arrangement of the inserts 82, different gable designs can be effected with the same shuttering components.

Referring more particularly to Figure 12, reference numeral 84 indicates a third type of insert which can be inserted between opposite panels 12. The insert 84 has lips 84.1 which seat on the panels 12. In this configuration mortar mix 80 enters into the cavity between the panels 12 above the insert 84, the insert forming an archway in the wall that is being constructed. Here again, the insert 84 may have any desired shape in side view, so as to form an archway with a corresponding shape.

Referring finally to Figure 13, reference numeral 90 generally designates the walls of a single storey dwelling, comprising external walls 92 and internal walls 94, the end walls having gables 96. The entire structure illustrated in Figure 13 is produced by a single mortar pouring operation, the shuttering system described hereinbefore with reference to Figures 1 to 12 making this possible. It will be seen that the side walls have recesses 98 formed in their upper edges, these being shaped to accommodate the rafters (not shown) of a roof structure. The recesses 98 can be formed by removable metal inserts (not shown) placed between opposed panels 12. This makes subsequent beam filling between adjacent rafters unnecessary.

Claims

1. A dismountable shuttering system which, when erected, comprises: shutter panels having an inside and an outside, and being arranged adjacent one another and on opposite sides of a cavity to be filled with a cementitious material to form a walled structure; upright panel supports each arranged between an adjacent pair of the panels, each upright panel support having retaining formations which seat on the inside of the panels, on either side of the upright panel support, thereby retaining the panels against displacement inwardly of the cavity; transverse panel supports arranged transversely of the upright panel supports, on the outside of the panels, the upright panel supports and/or the transverse panel supports having engagement formations whereby the transverse panel supports disengagably engage with the upright panel supports through gaps between the adjacent panels; and ties which extend across the cavity, and disengageably engage at opposite ends thereof with the transverse panel supports on opposite sides of the cavity.

2. A dismountable shuttering system as claimed in claim 1 , wherein each shutter panel, on the inside thereof, has a rebate along each vertical edge thereof; wherein said retaining formations are in the form of free vertical edge portions of the respective upright panel supports, which free edge portions are accommodated in the rebates of the adjacent panels; and wherein each upright panel support has an inside surface which is flush with the inside surfaces of the adjacent panels.

3. A dismountable shuttering system as claimed in claim 2, wherein each upright panel support comprises a plurality of vertically spaced, upwardly open, hook-like elements which protrude outwardly beyond the adjacent panels, and in each of which hook¬ like element a respective transverse panel support is receivable, each hook-like element having a horizontally extending portion supporting the transverse panel support from below, and an upwardly extending portion keeping the transverse panel support in position against the outside of the panels.

4. A dismountable shuttering system as claimed in claim 3, wherein the upright panel supports and the transverse panel supports have complementary interlock formations which inter-engage to locate the transverse panel supports against displacement with respect to the upright panel supports in a direction longitudinally of the transverse panel supports.

5. A dismountable shuttering system as claimed in claim 4, wherein the interlock formations comprise a series of transverse slots in the transverse panel supports, into which slots complementary parts of the upright panel supports enter.

6. A dismountable shuttering system as claimed in any one of the preceding claims, wherein the ties pass through holes in the panels.

7. A dismountable shuttering system as claimed in any one of the preceding claims, wherein at least some of the upright panel supports comprise an angle section member, the panels adjacent these upright panel supports extending at a corresponding angle to one another.

8. A dismountable shuttering system as claimed in any one of the preceding claims, which includes first inserts located between a door or window frame in the cavity and the facing panels on opposite sides of the cavity, to close gaps between the door or window frame and the respective panels.

9. A dismountable shuttering system as claimed in any one of the preceding claims, which includes a second insert extending between said panels on opposite sides of the cavity, to form the upper surface of a gable or parapet wall.

10. A dismountable shuttering system as claimed in any one of the preceding claims, which includes a third insert extending between said panels on opposite sides of the cavity, to form the undersurface of an archwa .

11. A method of building a walled structure, which comprises erecting shuttering in situ to define a cavity corresponding to the shape of the walled structure, introducing a mortar mix which includes an air entraining agent into the cavity, allowing the mortar mix to set, and thereafter stripping the shuttering.

12. A method of building a walled structure, which comprises erecting a shuttering system as claimed in any of claims 1 to 10, to define a cavity corresponding to the shape of the walled structure, introducing a mortar mix which includes an air entraining agent into the cavity, allowing the mortar mix to set, and thereafter stripping the shuttering system.

13. A method as claimed in claim 11 or claim 12, wherein the mortar mix comprises the following components, in approximately the following quantities per cubic metre:

River sand (grading MF 1,65 to MF 2,1) 1360 kg

Portland cement 300 kg

Water 250 1

Air entraining agent 1850 ml

14. A shuttering system substantially as herein described and illustrated.

15. A method of building a walled structure, substantially as herein described and illustrated.