AU2011250774A1 - Prefabricated formwork element - Google Patents

Abstract

C \NRPortbl\DCCKXM\3988305_ .DOC-14/11/2011 A prefabricated formwork element for a concrete ground slab, including a body section; 5 and one or more external reinforcing bars extending outwardly from a common side of the body section, wherein the one or more reinforcing bars are arranged to extend at least partially into the ground slab. 20a 20b L C=>(= z' w Figure 1 12 10 10 10 ............................................ ..... ............... ........ ... ........ ..... ................................... ............................................... .............................................. ................................................... ................................................... ................................................... ................................................... ............................I ...................... ................................................... ................................................... 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Description

P/00/OIl Regulation 3.2 AUSTRALIA Patents Act 1990 COMPLETE SPECIFICATION STANDARD PATENT (ORIGINAL) Name of Applicant: Mark Curmi, of 68 Westcott Parade, Rockbank, Victoria 3335, Australia Actual Inventor: Mark Curmi Address for Service: DAVIES COLLISON CAVE, Patent & Trademark Attorneys, of I Nicholson Street, Melbourne, 3000, Victoria, Australia Ph: 03 9254 2777 Fax: 03 9254 2770 Attorney Code: DM Invention Title: "Prefabricated formwork element" The following statement is a full description of this invention, including the best method of performing it known to us: C:\NRPorbl\DCC\RJCU988268 LDOC - 14/11/l I C \NRPonbl\DCC\KXM\3988305 1.DOC-14/ll/2011 PREFABRICATED FORMWORK ELEMENT Technical Field of the Invention 5 The present invention relates to a prefabricated formwork element for a concrete ground slab and method of manufacturing the same. Background of the Invention 10 Concrete ground slabs for driveways, for example, are built on site in the desired location for the slab. The construction method broadly involves the steps of: a. levelling the ground over which the slab will be positioned; 15 b. constructing formwork; c. pouring concrete into the formwork; d. curing the concrete; and e. removing the formwork. 20 The formwork is a temporary mould into which concrete, or similar materials, is poured. The formwork is typically built on site out of timber and plywood, for example. If the slab is to be reinforced, then reinforcing bars, also referred to as "rebars", are positioned within the formwork before the concrete is poured in. Plastic tipped metal, or plastic, bar chairs are used to hold the rebars away from the bottom and sides of the formwork, so that when 25 the concrete sets it completely envelops the reinforcement. For a ground slab, the formwork may consist only of sidewalls pushed into the ground. The process of constructing the formwork for a ground slab may be time consuming and labour intensive. Further, the formwork is constructed in-situ and is subject to the 30 elements whilst it is being erected. This may delay the time in which it takes to construct the formwork. Moreover, inclement conditions may have an adverse effect on the timber C NRPortbl\DCCKXMX98805_L DOC-14/1112011 -2 and/or plywood which may warp and change the shape and/or quality of the resultant ground slab. Finally, it is a typically labour intensive and time consuming task to remove the formwork once the slab has cured. 5 Further issues arise where the area to be concreted is to include drains and other pipes that extend at least partially through the slab. Typically, the pipes are installed in the desired locations before the slab is poured. However, difficulties can arise because the slab must be delicately poured around the pipe outlets to avoid damaging the same. It may be difficult and time consuming to pour concrete around pipe outlets. This is particularly the 10 case where it is desirable to achieve an aesthetically pleasing finish around an outlet. It is generally desirable to overcome or ameliorate one or more of the above mentioned difficulties, or at least provide a useful alternative. 15 Summary of the Invention In accordance with one aspect of the invention, there is provided a prefabricated formwork element for a concrete ground slab, including: (a) a concrete body section; and 20 (b) one or more external reinforcing bars extending outwardly from a common side of the body section, wherein the one or more reinforcing bars are arranged to extend at least partially into the ground slab. 25 In accordance with another aspect of the invention, there is provided a method of manufacturing the above-described formwork element, including the steps of: (a) constructing a frame defining sides of the formwork element on a flat surface; (b) arranging bar chairs on the surface inside the frame; (c) arranging the internal reinforcing bars inside the frame, the internal reinforcing 30 elements being separated from the surface by the bar chairs; (d) arranging the one or more external reinforcing bars to extend outwardly from a C:\NRPorbO\DCC\KXM\39883O5_ I DOC- 14/11/2011 -3 common side of the body section; and (e) pouring concrete into the frame. Preferably, the step of arranging the external reinforcing bars includes the step of coupling 5 the external reinforcing bars to the internal reinforcing bars. In accordance with another aspect of the invention, there is provided formwork for a concrete ground slab, including a plurality of the above described formwork elements arranged in series so as to frame an area for a ground slab. 10 In accordance with another aspect of the invention, there is provided a ground slab framed by the above-described formwork. In accordance with another aspect of the invention, there is provided a prefabricated 15 concrete ground slab element, including: (a) a concrete body section; and (b) a plurality of external reinforcing bars extending outwardly from opposite sides of the body section, wherein the external reinforcing bars are arranged to extend at least partially into a ground 20 slab. In accordance with another aspect of the invention, there is provided a method of manufacturing the above-described ground slab element, including the steps of: (a) constructing a frame defining sides of the formwork element on a flat surface; 25 (b) arranging bar chairs on the surface inside the frame; (c) arranging the internal reinforcing bars inside the frame, the internal reinforcing elements being separated from the surface by the bar chairs; (d) arranging the one or more external reinforcing bars to extend outwardly from opposite sides of the body section; and 30 (e) pouring concrete into the frame.

C -\NRPonbl\DCC\KXM\3988305_ DOC-14/11/2011 -4 Preferably, the step of arranging the external reinforcing bars includes the step of coupling the external reinforcing bars to the internal reinforcing bars. In accordance with another aspect of the invention, there is provided a prefabricated 5 formwork element for a concrete ground slab, including: (a) a concrete body section; and (b) one or more external reinforcing bar connectors arranged on a common side of the body section, wherein the connectors are arranged so that external reinforcing bars, when coupled to the 10 connectors, extend at least partially into the ground slab. Preferably, the connectors include ferrule bars seated in the body section which open into said side of the body section for engagement with external reinforcing bars. 15 Preferably, the formwork element includes a ferrule connector bar coupled to, and extending through the body section between, the ferrule bars. In accordance with another aspect of the invention, there is provided a method of manufacturing the above-described formwork element, including the steps of: 20 (a) constructing a frame defining sides of the formwork element on a flat surface; (b) coupling nail plates for respective ones of the connectors to internal sides of the formwork; (c) coupling ferrule bars to respective ones of the nail plates; (d) coupling the ferrule connector bar to the ferrule bars; and 25 (e) pouring concrete into the frame. In accordance with another aspect of the invention, there is provided formwork for a concrete ground slab, including a plurality of the above-described formwork elements arranged in series so as to frame an area for a ground slab, the connectors being coupled to 30 respective external reinforcing bars.

C \NRPortb1\DCCKXM 981305_1 DOC 14/11/2011 -5 In accordance with another aspect of the invention, there is provided a ground slab framed by the above-described formwork. In accordance with another aspect of the invention, there is provided a method for 5 manufacturing a paver, including the steps of: (a) constructing a frame defining sides of the paver on a flat surface; (b) arranging bar chairs on the surface inside the frame; (c) arranging the internal reinforcing bars inside the frame, the internal reinforcing elements being separated from the surface by the bar chairs; and 10 (d) pouring concrete into the frame. In accordance with another aspect of the invention, there is provided a paver formed in accordance with the above described method. 15 In accordance with another aspect of the invention, there is provided a method for manufacturing a prefabricated drain, including the steps of: (a) constructing a frame defining sides of the drain on a flat surface; (b) arranging drain insert on the surface inside the frame; (c) arranging internal reinforcing bars inside the frame; and 20 (d) pouring concrete into the frame. In accordance with another aspect of the invention, there is provided a prefabricated drain formed in accordance with the above-described method. 25 Preferably, the drain is suitable for use in a concrete show base. In accordance with another aspect of the invention, there is provided a concrete shower base including the above described drain. 30 In accordance with another aspect of the invention, there is provided a prefabricated retaining wall element for a concrete retaining wall, including: C.NRPortbl\CCKXM\39883031. DOC-14/11/2011 -6 (a) a body section; and (b) one or more slots extending through the body section, each being shaped to receive an external reinforcing bars extending upwardly from a footing of a concrete slab. 5 Preferably, he retaining wall element includes internal reinforcing bars. In accordance with another aspect of the invention, there is provided a method of manufacturing the above described retaining wall element, including the steps of: 10 (a) constructing a frame defining sides of the formwork element on a flat surface; (b) arranging bar chairs on the surface inside the frame; (c) arranging the internal reinforcing bars inside the frame, the internal 15 reinforcing elements being separated from the surface by the bar chairs; (d) arranging one or more hollow conduits to extend through the body section; and (e) pouring concrete into the frame. 20 In accordance with another aspect of the invention, there is provided a retaining wall including a footing having one or more external bars extending upwardly therefrom and one or more of the above described retaining wall elements fitted over the one of more external bars of the footing so that slots of the retaining wall elements receive respective ones of the bars of the footing. 25 Brief Description of the Drawings Preferred embodiments of the present invention are hereafter described, by way of non limiting example only, with reference to the accompanying drawing in which: 30 Figure 1 is a front perspective view of a formwork element; C:NRPonb\DCC\KXM\3983O5_l. DOC-14/II/2011 -7 Figure 2 is a plan view of a ground slab framed by formwork including a series of the formwork elements shown in Figure 1; Figure 3 is a plan view of the formwork element shown in Figure 1 during a stage of manufacture; 5 Figure 4 is a plan view of the formwork element shown in Figure 1 during another stage of manufacture; Figure 5 is a plan view of the formwork element shown in Figure I during yet another stage of manufacture; Figure 6 is a plan view of the formwork element shown in Figure 1 during still another 10 stage of manufacture; Figure 7 is a plan view of the ground slab and formwork shown in Figure 2 during a stage of manufacture; Figure 8 is a side view of another formwork element; Figure 9 is a front perspective of the formwork element shown in Figure 8; 15 Figure 10 is a plan view of a ground slab framed by formwork including a series of the formwork elements shown in Figure 8; Figure I1 is a plan view of the ground slab and formwork shown in Figure 10 during a stage of manufacture; Figure 12 is a plan view of the formwork element shown in Figure 8 during a stage of 20 manufacture; Figure 13 is a plan view of the formwork element shown in Figure 8 during another stage of manufacture; Figure 14 is a side view of a nail plate; Figure 15 is a plan view of the formwork element shown in Figure 8 during yet another 25 stage of manufacture; Figure 16 is a side view of a ferrule bar; Figure 17 is an end view of the ferrule bar shown in Figure 16; Figure 18 is a plan view of the formwork element shown in Figure 8 during still another stage of manufacture; 30 Figure 19 is a plan view of the formwork element shown in Figure 8 during again another stage of manufacture; C.\NRPobl\COKXOOV988305_I DOC-14/1 I/2 1 -8 Figure 20 is a plan view of the formwork element shown in Figure 8 during further again another stage of manufacture; Figure 21 is a plan view of a paver; Figure 22 is a plan view of the paver shown in Figure 21 during a stage of manufacture; 5 Figure 23 is a plan view of the paver shown in Figure 21 during another stage of manufacture; Figure 24 is a plan view of the paver shown in Figure 21 during yet another stage of manufacture; Figure 25 is a plan view of the paver shown in Figure 21 during still another stage of 10 manufacture; Figure 26 is a plan view of the paver shown in Figure 21 during again another stage of manufacture; Figure 27 is a plan view of the paver shown in Figure 21 during further again another stage of manufacture; 15 Figure 28 is a plan view of the paver shown in Figure 21 during still again another stage of manufacture; Figure 29 is a plan view of a prefabricated drain; Figure 30 is a plan view of the drain shown in Figure 29 during a stage of manufacture; Figure 31 is a plan view of the drain shown in Figure 29 during another stage of 20 manufacture; Figure 32 is a plan view of the drain shown in Figure 29 during yet another stage of manufacture; Figure 33 is a plan view of the drain shown in Figure 29 during still another stage of manufacture; 25 Figure 34 is a plan view of a formwork element; Figure 35 is a plan view of the formwork element shown in Figure 34 during a stage of manufacture; Figure 36 is a plan view of the formwork element shown in Figure 34 during another stage of manufacture; 30 Figure 37 is a plan view of the formwork element shown in Figure 34 during again another stage of manufacture; C 988 105_1.DOC- 14/11/2011 -9 Figure 38 is a plan view of the formwork element shown in Figure 34 during further again another stage of manufacture; Figure 39 is a plan view of a light unit of the formwork element shown in Figure 34; Figure 40 is a cross-section view of the light unit shown in Figure 39; 5 Figure 41 is a perspective view of a retaining wall element; and Figure 42 is a plan view of the retaining wall element shown in Figure 42 during a stage of manufacture. Detailed Description of Preferred Embodiments of the Invention 10 EMBODIMENT #1 The prefabricated formwork element 10 shown in Figure 1 is used to create formwork 12 for the concrete ground slab 14 shown in Figure 2. As shown in Figure 1, the formwork 15 element 10 includes a concrete body section 16; and two external reinforcing bars 18 extending outwardly from a common side 20 of the body section 16. However, the formwork element 10 could alternatively include one or more external reinforcing bars 18 extending outwardly from the common side 20 of the body section 16. The reinforcing bars 18 are arranged to extend at least partially into the ground slab 14. 20 As particularly shown in Figures 3 to 6, the formwork element 10 is manufactured by performing the step of: (a) constructing a frame 22 defining four sides 22a, 22b, 22c, 22d of the body section 25 16 of the formwork element 10 on a flat surface 24; (b) arranging bar chairs 26 on the flat surface 24 inside the frame 22; (c) arranging the internal reinforcing bars 28 inside the frame 22, the internal reinforcing bars 28 being separated from the flat surface 24 by the bar chairs 26; (d) arranging the two external reinforcing bars 18 to extend outwardly from the 30 common side 20 of the body section 16; and (e) pouring concrete 30 into the frame 22 so that the frame 22 is completely filled.

C:WRPorth\DC\KXM39 305_1DOC-14/11/201 -10 The internal reinforcing bars 28 are preferably welded together to form a common mesh. Alternatively, the internal reinforcing bars 28 are tied together to form a common mesh. The internal reinforcing bars 28 are preferably F62 or F42 steel reinforcing bars. 5 As particularly shown in Figure 5, the external reinforcing bars 18 are seated in slots 32a, 32b of the frame 22 and extend at least partially into the body section 16. The external reinforcing bars 18 are preferably coupled to the internal reinforcing bars 28. The external reinforcing bars 18 are preferably Y12 or Y16 reinforcing bars. 10 The external reinforcing bars 18 of the formwork element 10 are arranged to engage reinforcing bars 34 of the ground slab 14 in the manner shown in Figure 7. In the embodiment shown in Figures 1 to 7, the formwork element 10 is generally 15 rectangular in shape and has the following dimensions: a. L = 600 mm; b. W = 400 mm; and c. D = 100 mm. 20 The formwork element 10 alternatively includes any suitable combination of length "L", width "W", and depth "D". Further, although the body section 16 has been above described as being rectangular, the body section 16 is alternatively any shape suitable for being part of the formwork 12. For example, the body section 16 may be "L" shaped. 25 The concrete 30 is, for example, sand, cement and 7ml crush rock. An upper side 36 of the body section 16 of the formwork element preferably includes decorative patterns, colours, textures, etc. 30 The formwork 12, comprising a plurality of formwork elements 10, provides a border for C:\NRPortbl\DCC(KXM\39883(51. DOC- 14/1112011 -11 the ground slab 14 once the slab 14 has cured. The formwork elements 10 are prefabricated off site so that the formwork 12 can be quickly constructed on site. EMBODIMENT #2 5 The ground slab element 50 shown in Figures 2 and 7 is constructed in an analogous manner to that of the formwork element 10. To this end, the ground slab element 50 includes all of the features of the formwork element 10 with the exception that the external reinforcing bars 18 of the ground slab element 50 extend through the body section 16 so as 10 to extend outwardly from opposite sides 20a, 20b of the body section 16. Like parts are referenced with like reference numerals. The external reinforcing bars 18 of the ground slab element 50 are arranged to engage the ground slab 14 in the manner shown in Figure 7. 15 The upper side 36 of the ground slab element 50 includes decorative features and, as such, the slab element is used a decorative feature for a ground slab 14 for a driveway, for example. Alternatively, the upper side 36 of the body section 16 of the slab element 50 include indicia representing a traffic sign. In this example, the slab element 50 is inset into a road. 20 EMBODIMENT #3 The prefabricated formwork element 100 shown in Figures 8 and 9 is used to construct formwork 102 for the ground slab 104 shown in Figure 10. The formwork element 100 25 includes a concrete body section 106; and four external reinforcing bar connectors 108 arranged on opposite sides 11 Oa, 11 Ob of the body section 106. The connectors 108 are arranged so that external reinforcing bars 112, when coupled to the connectors 108, extend at least partially into the ground slab 104 for coupling to the reinforcing bars 114 seated in the formwork 102 in the manner shown in Figure 11. The formwork element 100 could 30 alternatively include any number of connectors on any side of the body section 106.

C:\NRPonblDCC\KXM\39M8305_1 DOC-14/i 112011 - 12 As shown in Figures 12 to 20, the formwork element 100 is manufactured by performing the steps of: (a) constructing a frame 116 defining four sides I1 6a, I1 6b, 116c, 11 6d of the body section 106 of the formwork element 100 on a flat surface 118; 5 (b) arranging bar chairs 120 on the flat surface 118 inside the frame 116; (c) arranging the internal reinforcing bars 122 inside the frame 116, the internal reinforcing bars 122 being separated from the flat surface 118 by the bar chairs 120; (d) coupling to pairs of spaced apart nail plates 124, of the type shown in Figure 14, to 10 opposed internal sides I 16a, 1 16b of the frame 116; (e) coupling ferrule bars 126 to respective ones of the nail plates 124; (f) coupling ferrule connector bars 128a, 128b to respective pairs of ferrule bars 124; (g) pouring concrete 130 into the frame 116 (h) removing the frame 116 once the concrete 130 has set; and 15 (i) removing the nail plates 124. The ferrule bars 126 of the connectors 108 open into respective sides IOa, 1 lOb the body section 106 for engagement with respective external reinforcing bars 112. The ferrule bars include helical threads 132 for coupling to and securing therein respective ones of the 20 external reinforcing bars 112. The diameter of each of the helical threads DT is selected to be suitable for engagement with a Y12 or a Y16 external reinforcing bar 112, for example. The external reinforcing bars 112 can thereby be connected to the body section 106 to suit the needs of the formwork 102 being constructed. 25 The ferrule connector bars 128a, 128b extend through apertures 134 in respective pairs of ferrule bars 126. The diameter Ds of each aperture 134 is suitable to receive the ferrule connector bars 128a, 128b which are preferably Y 12 or Y16 reinforcing bars. The internal reinforcing bars 122 are preferably welded together to form a mesh. 30 Alternatively, the internal reinforcing bars 122 are tied together to form a mesh. The internal reinforcing bars 122 are preferably F62 or F42 steel reinforcing bars.

C :NRPorbI\DC('KXMW98830_ .DOC-14/11/2011 -13 The reusable plastic nailing plate 124 is simply nailed to the frame 116, and the ferrule bar 126 screws on to the thread 136. After removing the frame 116, the plastic nailing plates 124 are unscrewed from the ferrule bars 124 to leave a 10mm deep recess. Popular sizes 5 are also available with built-in antennae for easy location of plates after casting. Where coil threaded ferrule bars 126 are used at bracing locations, a special nailing plate 124 is available. In the embodiment shown in Figures 8 to 20, the formwork element 100 is generally 10 rectangular in shape and has the following dimensions: a. L = 600 mm; b. W = 600 mm; and c. D = 100 mm. 15 The formwork element 100 alternatively includes any suitable combination of length "L", width "W", and depth "D". Further, although the body section 106 has been above described as being rectangular, the body section 106 is alternatively any shape suitable for being part of the formwork 102. For example, the body section 106 may be "L" shaped. 20 The concrete 130 is, for example, sand, cement and 7ml crush rock. An upper side 138 of the body section 106 of the formwork element preferably includes decorative patterns, colours, textures, etc. 25 The formwork 102, comprising a plurality of formwork elements 100, provides a border for the ground slab 104 once the slab 104 has cured. The formwork elements 100 are prefabricated off site so that the formwork 102 can be quickly constructed on site. 30 In an alternative embodiment, the connectors 108 are hollow tubes (not shown) that are arranged in the body section 106 of the formwork element 100 before the concrete 312 is C\NRPonbhtDC0KXM\3988105_I DOC-14111/2011 - 14 poured. The tubes 318 are preferably of a diameter suitable to receive external reinforcing members such as Y12 or Y16 bars 112. When the formwork element 100 is completed, the external reinforcing bars 112 can be coupled to tubes with a fastener such as an epoxy resin. The external reinforcing bars 112 can be used to couple the formwork element 100 5 to reinforcing members 114 of the ground slab 104. EMBODIMENT #4 The formwork element 100 can be used as a prefabricated concrete ground slab element 10 150 by connecting external reinforcing bars 108 to extend outwardly from opposite sides 11 Oa, 11 Ob of the body section 106 in the manner shown in Figure 11. In doing so, the external reinforcing bars 108 are arranged to extend at least partially into the ground slab 14. 15 The ground slab element 150 shown in Figures 10 and 11 is constructed in an analogous manner to that of the formwork element 100. To this end, the ground slab element 150 includes all of the features of the formwork element 100 with the exception that all four external reinforcing bars 108 are connected to the connectors 108 of the body section 106. Like parts are referenced with like reference numerals. The external reinforcing bars 108 20 of the ground slab element 150 are arranged to engage the ground slab 104 in the manner shown in Figure 0117. The upper side 138 of the ground slab element 150 includes decorative features and, as such, the slab element 150 is used a decorative feature for a ground slab 104 for a 25 driveway, for example. Alternatively, the upper side 138 of the body section 106 of the slab element 150 includes indicia representing a traffic sign. In this example, the slab element 150 is inset into a road. EMBODIMENT #5 30 The paver 200 shown in Figure 21 is used as a decorative brick, tile, stone, or block. The C\NRPonb\DCC XM\3988305_I DOC-14/l1/2011 - 15 paver 200 is preferably installed over a compacted stone sub-base (not shown) and a levelling bed of sand (not shown). The paver 200 is designed for boarder for driveways, shopping centre or any other concrete work that will be laid around them. 5 As particularly shown in Figures 22 to 28, the paver 200 is constructed by performing the steps of: (a) drawing an outline 202 of the paver 200 on a base plate 204; (b) coupling convex moulds 206 to base plate 204 within the permitter of the outline 202; 10 (c) constructing a frame 208 including four sides 208a, 208b, 208c, 208d which define the shape of paver 200; (d) arranging bar chairs 210 on the flat surface 204 inside the frame 208; (e) arranging internal reinforcing bars 212 inside the frame 208, the internal reinforcing bars 212 being separated from the flat surface 204 by the bar chairs 15 210; (f) pouring concrete 214 into the frame 208; (g) removing the frame 208 once the concrete 214 has set; and (h) removing the moulds once the paver has been removed from the frame. 20 The method further includes the step of marking an outer peripheral surface 216 of the paver 200 with decorative indicia. In the example shown in Figure 21, a stencil 218 is applied to the outer surface 216 of the paver 200. A pigment 220 is then applied over the stencil 218. When the pigment 220 has set, the stencil 218 is removed leaving the image of three bricks 200a, 200b, 200c shown in Figure 28. Once completed, the paver 200 is 25 removed from the frame 208 and finished off with a clear sealer. In doing do, the process of laying pavers 200 can be sped up. That is, one paver 200 needs to be laid for every three normal pavers. The internal reinforcing bars 212 are preferably welded together to form a mesh. 30 Alternatively, the internal reinforcing bars 212 are tied together to form a mesh. The internal reinforcing bars 212 are preferably F62 or F42 steel reinforcing bars.

C:NRPotbl\DCC\KXM\398305_ 1DOC-14/11/2011 - 16 The base plate 204 is preferably MDF board which creates a nice flat base and once the concrete is dry, the paver 200 removes easy. 5 The moulds 206 create a small lip in the bottom of the paver 200 so when it is laid is connects nice and neat to the flat area and lock and bond in with the mortar. The concrete 214 is, for example, sand, cement and 7ml crush rock. 10 The above described techniques for manufacturing the paver 200 can be applied to any shape of paver 200, including curved concrete pavers (not shown). The pavers 200 are preferably 40 mm thick concrete and the internal reinforcing bars are F52. The width and length of the paver 200 depends on the stencil or pattern used. 15 EMBODIMENT #6 The prefabricated drain 300 shown in Figure 29 is used as a prefabricated formwork element for a ground slab, for example. In use, the drain 300 is arranged in position within 20 the formwork and the concrete is poured around it to complete the ground slab. The drain 300 can preferably used to terminate any conduit that is arranged to extend through a concrete slab. For example, the drain 300 can be installed in a driveway that includes a drainage system. Alternatively, the drain 300 can be used to terminate an outlet conduit in an exposed aggregate shower base. 25 As particularly shown in Figures 30 to 33, the drain 300 is constructed by performing the steps of: (a) drawing an outline 302 of the drain 300 on a base plate 304; (b) constructing a frame 306 including a central aperture member 308 which define the 30 shape of drain 300; (c) arranging internal reinforcing bars 310 inside the frame 306, the internal CkNRPonb1\DCC\KXM\3981 05_l .DOC-14/11/2011 - 17 reinforcing bars 310 being separated from the flat surface 304 by the bar chairs not shown; (d) pouring concrete 312 into the frame 306; and (e) removing the frame 306 once the concrete 312 has set. 5 The method further includes the step of marking an outer peripheral surface 314 of the drain 300 with decorative indicia. In the example shown in Figure 29, a pigment 316 is then applied over surface 314. When the pigment 316 has set, the drain 300 is removed from the frame 306 and finished off with a clear sealer. 10 The reinforcing bars 310 are preferably F52 and the concrete 312 is preferably about 60 mm thick. As particularly shown in Figure 32, the drain preferably includes hollow tubes 318 that are 15 arranged in the frame 306 before the concrete 312 is poured. The tubes extend radially away from the central aperture 308 and open on an outer peripheral side of the drain 300. The tubes 318 are preferably of a diameter suitable to receive external reinforcing members such as Y12 or Y16 bars (not shown). When the drain 300 is completed, the external reinforcing bars can be coupled to tubes 318 with a fastener such as an epoxy 20 resin. The external reinforcing bars can be used to coupled the drain to reinforcing members of the ground slab. In an alternative embodiment, the drain 300 has a square shape, or another shape desired. 25 In a further embodiment, the drain 300 includes external reinforcing bars (not shown) which are arranged in accordance with the above described construction techniques for the formwork element 10, 100 and the paver 200. EMBODIMENT #7 30 The prefabricated formwork element 400 shown in Figure 34 is used to create formwork C /NRPorbfCCkX.W9UI/2_ I DOC-IJ4l 1/201I - 18 for a concrete ground slab (not shown) in an analogous manner to formwork element 10, in the manner shown in Figures 35 and 36. All of the above described features and construction techniques for formwork elements 10 are equally applicable to the formwork element 400. 5 For example, in the embodiment shown in Figures 35 and 36, the formwork element 400 includes a concrete body section 416; and two external reinforcing bars 418 extending outwardly from a common side 420 of the body section 416. However, the formwork element 400 could alternatively include one or more external reinforcing bars 418 10 extending outwardly from the common side 420 of the body section 416. The reinforcing bars 418 are arranged to extend at least partially into a ground slab (not shown). As particularly shown in Figures 35 and 36, the formwork element 400 is manufactured by performing the step of: 15 (a) constructing a frame 422 defining four sides 422a, 422b, 422c, 422d of the body section 416 of the formwork element 400 on a flat surface 424; (b) arranging bar chairs 426 on the flat surface 424 inside the frame 422; (c) arranging the internal reinforcing bars 428 inside the frame 422, the internal 20 reinforcing bars 428 being separated from the flat surface 424 by the bar chairs 426; (d) arranging the two external reinforcing bars 418 to extend outwardly from the common side 420 of the body section 416; and (e) pouring concrete 430 into the frame 422 so that the frame 422 is completely filled. 25 The internal reinforcing bars 428 are preferably welded together to form a common mesh. Alternatively, the internal reinforcing bars 428 are tied together to form a common mesh. The internal reinforcing bars 428 are preferably F62 or F42 steel reinforcing bars. 30 As particularly shown in Figure 35, the external reinforcing bars 18 are seated in slots 432a, 432b of the frame 422 and extend at least partially into the body section 416. The C:\NRPonb\DCC\KXM\3 O8305_ .DOC-141112011 - 19 external reinforcing bars 418 are preferably coupled to the internal reinforcing bars 428. The external reinforcing bars 418 are preferably Y12 or Y16 reinforcing bars. The external reinforcing bars 418 of the formwork element 400 are arranged to engage 5 reinforcing bars of a ground slab (not shown). In the embodiment shown in Figures 34 to 36, the formwork element 400 is generally rectangular in shape and has the following dimensions: 10 a. L = 600 mm; b. W = 400 mm; and c. D = 100 mm. The formwork element 4000 alternatively includes any suitable combination of length "L", 15 width "W", and depth "D". Further, although the body section 416 has been above described as being rectangular, the body section 416 is alternatively any shape suitable for being part of the formwork. For example, the body section 416 may be "L" shaped. The concrete 430 is, for example, sand, cement and 7ml crush rock. 20 An upper side 436 of the body section 416 of the formwork element preferably includes decorative patterns, colours, textures, etc. The formwork element 400 can preferably be used in formwork 12 shown in Figure 2 to 25 provide a border for the ground slab 14 once the slab 14 has cured. The formwork elements 400 are prefabricated off site so that the formwork 12 can be quickly constructed on site. The formwork element 400 includes a light unit 440 seated therein. As particularly shown 30 in Figures 37 and 38, the light unit 440 includes a hollow receptacle 442 that is open at one end 444 and a screen 446 that is shaped to close over the open end of the receptacle. The C:NRPonbI\DCC\KXM\3988305_I DOC-14/1 1/2011 - 20 screen 446 is coupled to the open end of the receptacle 442 by fasteners 448. The fasteners 448 are preferably screws. Alternatively, the fasteners are any other suitable means for coupling the two parts 442, 446 together, including an adhesive. 5 The light unit 440 also includes seated therein a light source 450. In the embodiment shown, the light source is a light bulb. Alternatively, the light source 450 could be any other suitable light emitting device. The light source 450 is electrically coupled to an electric power cable 452 which extends through the concrete body section 416 of the formwork element 400 for electric connection to an adjacent formwork element 400 or to a 10 power source. The screen is preferably at least partially transparent so that light emitted by the light source can shine through it. 15 The light unit also includes a bracket 454 which supports the receptacle over a lower surface on which the formwork element 400 is constructed. The bracket preferably raises the screen 100 mm off the surface so as to be planar with an upper side of the formwork element 400. 20 In an alternative embodiment the external reinforcing bars 418 extend through the body section 416 so as to extend outwardly from opposite sides 420a, 420b of the body section 16. EMBODIMENT #8 25 The prefabricated formwork element 400 shown in Figure 34 is also used to create formwork for a concrete ground slab (not shown) in an analogous manner to formwork element 100, in the manner shown in Figures 39 and 40. All of the above described features and construction techniques for formwork elements 100 are equally applicable to 30 the formwork element 400. Like parts have been numbered with like reference numerals.

C \NRPob\CC\X 39885 DOC.14/11 2011 -21 Embodiment #9 The prefabricated retaining wall element 500 shown in Figure 41 and 42 is used to create a retaining wall on a concrete footing (not shown). As shown in Figure 41, the retaining 5 wall element 500 includes a concrete body section 516; and three slots 518a, 518b, 518c that extend through the body section 516. The slots 518a, 518b, 518c are each shaped to receive reinforcing bars (not shown) extending upwardly out of a footing. Alternatively, the retaining wall element 500 includes any suitable combination of slots 518 to match the configuration of bars extending from the footing. 10 As particularly shown in Figure 42, the retaining wall element 500 is manufactured by performing the step of: (a) constructing a frame 522 defining four sides 522a, 522b, 522c, 522d of the body 15 section 516 of the retaining wall element 500 on a flat surface 524; (b) arranging bar chairs 526 on the flat surface 524 inside the frame 522; (c) arranging the internal reinforcing bars 528 inside the frame 522, the internal reinforcing bars 528 being separated from the flat surface 524 by the bar chairs 526; 20 (d) arranging the conduits 518a, 518b, 518c to extend through the body section 516 of the retaining wall element 500; and (e) pouring concrete 530 into the frame 522 so that the frame 522 is completely filled. The internal reinforcing bars 528 are preferably welded together to form a common mesh. 25 Alternatively, the internal reinforcing bars 528 are tied together to form a common mesh. The internal reinforcing bars 528 are preferably F62 or F42 steel reinforcing bars. In the embodiment shown in Figures 41 and 42, the retaining wall element 500 is generally rectangular in shape and has the following dimensions: 30 a. L = 4000 mm; C:\NRPotbI\DCC\KXW398305_LDOC.-14/l/2011 - 22 b. W = 1500 mm; and c. H = 500 mm. The retaining wall element 500 alternatively includes any suitable combination of length 5 "L", width "W", and height "H". Further, although the body section 516 has been above described as being rectangular, the body section 516 is alternatively any shape suitable for being part of a retaining wall. For example, the body section 516 may be "L" shaped. The concrete 530 is, for example, sand, cement and 7ml crush rock. 10 Many modifications will be apparent to those skilled in the art without departing from the scope of the present invention Throughout this specification, unless the context requires otherwise, the word "comprise", 15 and variations such as "comprises" and "comprising", will be understood to imply the inclusion of a stated integer or step or group of integers or steps but not the exclusion of any other integer or step or group of integers or steps. The reference to any prior art in this specification is not, and should not be taken as, an 20 acknowledgment or any form of suggestion that the prior art forms part of the common general knowledge in Australia.

Claims (62)

1. A prefabricated formwork element for a concrete ground slab, including: (a) a body section; and 5 (b) one or more external reinforcing bars extending outwardly from a common side of the body section, wherein the one or more reinforcing bars are arranged to extend at least partially into the ground slab. 10

2. The formwork element claimed in claim 1, including internal reinforcing bars.

3. The formwork element claimed in claim 2, wherein the internal reinforcing bars are welded together. 15

4. The formwork element claimed in claim 2, wherein the internal reinforcing bars are tied together.

5. The formwork element claimed in any one of claims 2 to 4, wherein the internal reinforcing bars F62 or F42 steel reinforcing bars. 20

6. The formwork element claimed in any one of claims 1 to 5, wherein the external reinforcing bars extend at least partially into the body section.

7. The formwork element claimed claim 6, wherein the external reinforcing bars are 25 coupled to the internal reinforcing bars.

8. The formwork element claimed in any one of claims I to 7, wherein the external reinforcing bars are Y12 or Y16 reinforcing bars. 30

9. The formwork element claimed in any one of claims I to 8, including a light unit seated therein for generating light when coupled to a power source. C.\RPortblDCCKXM\3988305-1 DOC.14/1l/2011 - 24

10. The formwork element claimed in claim 9, wherein the light unit includes a hollow receptacle seated in an upper side of the body section, a light source seated in the receptacle and a screen closing the receptacle. 5

11. The formwork element claimed in claim 9, including an electric power cable for electrically coupling the light unit to a power source.

12. A method of manufacturing the formwork element claimed in any one of claims 2 to 11, including the steps of: 10 (a) constructing a frame defining sides of the formwork element on a flat surface; (b) arranging bar chairs on the surface inside the frame; (c) arranging the internal reinforcing bars inside the frame, the internal reinforcing elements being separated from the surface by the bar chairs; 15 (d) arranging the one or more external reinforcing bars to extend outwardly from a common side of the body section; and (e) pouring concrete into the frame.

13. The method claimed in claim 12, wherein the concrete couples the internal 20 reinforcing bars together.

14. The method claimed in claim 12, wherein the step of arranging the external reinforcing bars includes the step of coupling the external reinforcing bars to the internal reinforcing bars. 25

15. Formwork for a concrete ground slab, including a plurality of the formwork elements claimed in claims I to 11 arranged in series so as to frame an area for a ground slab. 30

16. A ground slab framed by the formwork claimed in claim 11. C:\NRPonbI\DCOKXYM\39R8)5_I DOC-14/11/2011 - 25

17. A prefabricated ground slab element, including: (a) a body section; and (b) a plurality of external reinforcing bars extending outwardly from opposite sides of the body section, 5 wherein the external reinforcing bars are arranged to extend at least partially into a ground slab.

18. The ground slab element claimed in claim 17, including internal reinforcing bars. 10

19. The ground slab element claimed in claim 18, wherein the internal reinforcing bars are welded together.

20. The ground slab element claimed in claim 18, wherein the internal reinforcing bars are tied together. 15

21. The ground slab element claimed in any one of claims 18 to 20, wherein the internal reinforcing bars F62 or F42 steel reinforcing bars.

22. The ground slab element claimed in any one of claims 18 to 21, wherein the 20 external reinforcing bars are coupled to the internal reinforcing bars.

23. The ground slab element claimed in any one of claims 17 to 22, wherein the external reinforcing bars extend through the body section so as to extend outwardly from opposite sides of the body section. 25

24. The ground slab element claimed in any one of claims 17 to 23, wherein the external reinforcing bars are Y12 or Y16 reinforcing bars.

25. A method of manufacturing the ground slab element claimed in any one of claims 30 13 to 20, including the steps of: (a) constructing a frame defining sides of the formwork element on a flat C:\NRPorth\DCC\KXWM\98 5_.DOC-14/1l/2011 - 26 surface; (b) arranging bar chairs on the surface inside the frame; (c) arranging the internal reinforcing bars inside the frame, the internal reinforcing elements being separated from the surface by the bar chairs; 5 (d) arranging the one or more external reinforcing bars to extend outwardly from opposite sides of the body section; and (e) pouring concrete into the frame.

26. The method claimed in claim 25, wherein the step of arranging the external 10 reinforcing bars includes the step of coupling the external reinforcing bars to the internal reinforcing bars.

27. A prefabricated formwork element for a concrete ground slab, including: (a) a body section; and 15 (b) one or more external reinforcing bar connectors arranged on a common side of the body section, wherein the connectors are arranged so that external reinforcing bars, when coupled to the connectors, extend at least partially into the ground slab. 20

28. The formwork element claimed in claim 27, wherein the connectors include ferrule bars seated in the body section which open into said side of the body section for engagement with external reinforcing bars.

29. The formwork element claimed in claim 28, including a ferrule connector bar 25 coupled to, and extending through the body section between, the ferrule bars.

30. The framework element claimed in claim 29, wherein the ferrule connector bar extends through apertures in the ferrule bars. 30

31. The formwork element claimed in any one of claims 27 to 30 wherein the connectors include helical threads for coupling to and securing therein respective C\NRPonbI\DCC\KXM398305_ DOC-14/ll/2111 - 27 ones of the external reinforcing bars.

32. The formwork element claimed in claim 27, wherein the connectors include hollow tubes shaped to receive and secure therein said external reinforcing bars. 5

33. The formwork element claimed in claim 27, wherein the external reinforcing members are secured to the connectors with a fastener.

34. The framework element claimed in any one of claims 27 to 33, including internal 10 reinforcing bars.

35. The formwork element claimed in claim 34, wherein the internal reinforcing bars are welded together. 15

36. The formwork element claimed in claim 34, wherein the internal reinforcing bars are tied together.

37. The formwork element claimed in any one of claims 34 to 36, wherein the internal reinforcing bars F62 or F42 steel reinforcing bars. 20

38. The formwork element claimed in any one of claims 17 to 37, wherein the external reinforcing bars are Y12 or Y16 reinforcing bars.

39. The formwork element claimed in any one of claims 17 to 38, one or more external 25 reinforcing bar connectors arranged on another common side of the body section, wherein the connectors are arranged so that external reinforcing bars, when coupled to the connectors, extend at least partially into the ground slab.

40. A method of manufacturing the formwork element claimed in any one of claims 31 30 to 39, including the steps of: (a) constructing a frame defining sides of the formwork element on a flat C:\NRPonbIl\DCC\KXM3988305_ .DOC-14/l/12011 -28 surface; (b) coupling nail plates for respective ones of the connectors to internal sides of the formwork; (c) coupling ferrule bars to respective ones of the nail plates; 5 (d) coupling the ferrule connector bar to the ferrule bars; and (e) pouring concrete into the frame.

41. The method claimed in claim 40, including the step of: (f) removing the frame once the concrete has set; and 10 (g) removing the nail plates.

42. The method claimed in claim 40 or claim 41, including, before step (e), the steps of arranging bar chairs on the surface inside the frame; and arranging the internal reinforcing bars inside the frame, the internal reinforcing elements being separated 15 from the surface by the bar chairs.

43. Formwork for a concrete ground slab, including a plurality of the formwork elements claimed in claims 27 to 39 arranged in series so as to frame an area for a ground slab, the connectors being coupled to respective external reinforcing bars. 20

44. A ground slab framed by the formwork claimed in claim 43.

45. A method for manufacturing a paver, including the steps of: (a) constructing a frame defining sides of the paver on a flat surface; 25 (b) arranging bar chairs on the surface inside the frame; (c) arranging the internal reinforcing bars inside the frame, the internal reinforcing elements being separated from the surface by the bar chairs; and (d) pouring concrete into the frame. 30

46. The method claimed in claim 38, including the step of marking an outer peripheral surface of the paver with indicia. C \NRPorbl\DCC\KXM\3988315_I DOC-14111/2011 - 29

47. The method claimed in claim 46, including the step of removing the frame once the concrete has set. 5

48. The method claimed in claim 47, including the step of arranging moulds on said flat surface within the frame; and removing the moulds once the paver has been removed from the frame.

49. A paver formed in accordance with the method claimed in any one of claims 45 to 10 48.

50. A method for manufacturing a prefabricated drain, including the steps of: (a) constructing a frame defining sides of the drain on a flat surface; (b) arranging a drain insert on the surface inside the frame; 15 (c) arranging internal reinforcing bars inside the frame; and (d) pouring concrete into the frame.

51. The method claimed in claim 50, including the step of marking an outer peripheral surface of the paver with indicia. 20

52. The method claimed in claim 50 or claim 51, including the step of removing the frame once the concrete has set.

53. A prefabricated drain formed in accordance with the method claimed in any one of 25 claims 50 to 52.

54. The drain claimed in claim 53, wherein the drain is suitable for use in a concrete show base. 30

55. A concrete shower base including the drain claimed in claim 53 or claim 54. C:NRPonbI\DCCWXM\3988305_I DOC.1/1/2011 - 30

56. A prefabricated retaining wall element for a concrete retaining wall, including: (a) a body section; and (b) one or more slots extending through the body section, each being shaped to receive an external reinforcing bars extending upwardly from a footing of a 5 concrete slab.

57. The retaining wall element claimed in claim 56, including internal reinforcing bars.

58. The retaining wall element claimed in claim 57, wherein the internal reinforcing 10 bars are welded together.

59. The formwork element claimed in claim 57, wherein the internal reinforcing bars are tied together. 15

60. The formwork element claimed in any one of claims 57 to 59, wherein the internal reinforcing bars F62 or F42 steel reinforcing bars.

61. A method of manufacturing the retaining wall element claimed in any one of claims 57 to 60, including the steps of: 20 (a) constructing a frame defining sides of the formwork element on a flat surface; (b) arranging bar chairs on the surface inside the frame; (c) arranging the internal reinforcing bars inside the frame, the internal reinforcing elements being separated from the surface by the bar chairs; 25 (d) arranging one or more hollow conduits to extend through the body section; and (e) pouring concrete into the frame.

62. A retaining wall including a footing having one or more external bars extending 30 upwardly therefrom and one or more of the retaining wall elements, as claimed in any one of claims 57 to 60, fitted over the one of more external bars of the footing C:\NRPonb\DCC\KXMYX83051.DOC-14/ i2ui i -31 so that slots of the retaining wall elements receive respective ones of the bars of the footing.