AU2015204404B1 - Creation of Surface-mounted Sills or Hobs on Cast-in-situ Concrete Building Slabs - Google Patents
Creation of Surface-mounted Sills or Hobs on Cast-in-situ Concrete Building Slabs Download PDFInfo
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- AU2015204404B1 AU2015204404B1 AU2015204404A AU2015204404A AU2015204404B1 AU 2015204404 B1 AU2015204404 B1 AU 2015204404B1 AU 2015204404 A AU2015204404 A AU 2015204404A AU 2015204404 A AU2015204404 A AU 2015204404A AU 2015204404 B1 AU2015204404 B1 AU 2015204404B1
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Abstract
Apparatus for the moulding of surface-mounted sills or hobs onto previously cast-in-situ concrete building slabs, said apparatus comprising two parallel, continuous side members, the upper and lower edges of each of which are turned inwardly through two 90* bends to create horizontally arranged upper first returns and lower first returns and vertically-arranged upper second returns and lower second returns, said side members being joined in a fixed spatial relationship by spacer elements welded to said upper and lower second returns to create a mould in the form of a long box more or less open at the top and bottom; said mould being secured to the upper surface of a previously cast-in-situ concrete building slab by a plurality of transversely-arranged clamping pieces in the form of flat strips of metal turned downwardly though 90* at each end to create legs of a length greater than the width of said side member lower second returns, the overall length of said clamping pieces being such that, when said clamping pieces are placed transversely within said mould, the outer end surfaces of said legs abut the inner surfaces of said side members, the lower edges of said legs abutting the upper surfaces of lower first returns; said clamping piece legs being urged against said lower first returns by a plurality of suitable masonry anchors, the lower parts of which are accommodated within suitable bores drilled into said concrete building slab, the upper threaded part of a wedging bolt of each said masonry anchor passing up through a complementary aperture in its complementary said clamping piece, nuts threaded onto said wedging bolt threaded upper parts being tightened against said clamping pieces, urging said mould side member lower first returns against the upper surface 5 of said concrete slab thereby securing said mould to said concrete slab.
Description
CREATION OF SURFACE-MOUNTED SILLS OR HOBS ON CAST-IN-SITIJ CONCRETE BUILDING SLABS
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 to cast-in-situ concrete building slabs. More particularly, it relates to moulds for the casting of such sills or hobs onto such cast-in-situ concrete building slabs.
Particularly in the construction of multi-storey, reinforced-concrete 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, fabricated or pre-cast curtain wall panels and the like, providing a watertight barrier beneath such building elements to prevent the ingress of rain water, snow melt 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 building slab. These commonly take the form of simple or complex metal sections or solid timber sections. In other applications, pre-fabricated sills or hobs of various materials are sealingly fixed to the surface of a concrete slab; concrete sills or hobs are poured on the surface of a previously-cast parent concrete building slab; or concrete sills or hobs are poured simultaneously with the pouring of a parent concrete building slab, said building elements then being fixed to and supported by any of the said forms of sill or hob.
Where concrete sills or hobs are poured simultaneously with a cast-in-situ parent concrete building slab, the mould is supported at an appropriate height above formwork upon a plurality of discrete chairs fixed to the formwork and which remain embedded in the slab, the mould and chairs being set in place concurrently with and as part of the process of installing steel reinforcing bar in the formwork with a concomitant time and cost saving. Typical of such methods are those taught by Pantano in Australian Patent Applications Nos. 2011274299 and 2014213545. In these methods, an elongated hollow mould is employed for the integral formation of a raised sill or hob on the surface of a cast-in-situ, parent concrete building slab, the mould comprising two generally parallel, continuous side members joined in a fixed spatial relationship by spacer elements which permit the entry of concrete from above to pass through the mould to formwork below upon which the concrete slab is to be formed, filling of the mould as part of the concrete pouring process creating a sill or hob contiguous or monolithic with the parent concrete slab beneath.
Many instances occur where it is not feasible to employ the method described in the preceding paragraph. An example is that occurring at the outer edge of a cast-in-situ concrete slab of a building where it is necessary to install safety screens. Such screens are supported from short beams fixed to the upper surface of the slab along its edges and orientated normal to each edge. In circumstances such as this, concrete sills or hobs are poured onto the surface of a previously cast-in-situ concrete building slab using a long box mould, normally made from wood.
The mould is more or less open at the top and bottom, is fixed in appropriate positions to the concrete slab, reinforcement material is optionally positioned in the mould and the mould is then filled with concrete, which is allowed to cure. The mould is then stripped away, the sill or hob is waterproofed appropriately and, as required, said building elements are fixed to it. A commonly used form of permanent mould for the pouring of surface-mounted concrete sills or hobs on concrete building slabs comprises two elongated metal side members having upper and lower returns created on them by turning their upper and lower edges inwardly through 90°, narrow metal strips of suitable longitudinal spacing being spot-welded transversely between the two upper returns and between the two lower returns to lock the side members together in a fixed positional relationship. As the thickness of the sheet metal stock employed to create such moulds is normally approximately 0.5 mm, the mould has a low beam strength and, in long lengths, is torsionally very flexible. As the mould is normally manufactured and installed in long lengths, care therefore needs to be exercised in handling it. This mould is normally fixed to the surface of a previously cast-in-situ concrete building slab by passing hard nails through the lower transverse metal strips into the concrete slab using a nail gun, the positions of said upper transverse strips in relation to said lower transverse strips being longitudinally staggered to avoid obstructing access of the nail gun. As filling of the mould with concrete results in only a relatively narrow strip of concrete contacting the surface of the concrete building slab beneath, better attachment of the sill or hob to the slab is achieved by grouting the lower ends of short lengths of steel reinforcing bar into suitably spaced holes drilled into the slab, the reinforcing bar extending upwards into the interior of the mould and being embedded when the mould is filled with concrete. Apart from the difficulties of handling long lengths of this mould because of its fragility, in practice difficulty has been experienced in securely nailing it to concrete building slabs. Penetration of nails through said transverse metal strips causes a downwards peening of the surrounding metal that may prevent the mould from sitting closely against the surface of the concrete slab, nails are sometimes not properly set into the concrete due to the nature of the concrete or the striking of aggregate pieces, and pieces of concrete spalling away from the concrete slab have also preventing the mould from sitting closely against the surface of the concrete slab. Further, where lengths of steel reinforcing bar are grouted or bonded into the concrete slab, a high rate of failure of said grouting or bonding has occurred due to the difficulty of properly cleaning out bores drilled into the concrete slab before the process of grouting or bonding is performed. Failure of the nailed fixing and the grouting or bonding of the reinforcing bar have allowed localised movement of the sill or hob with a resultant tearing of the waterproofing membrane laid over it.
The primary objects of the present invention are to provide a mould for the making of surface-mounted sills or hobs which is strong and rigid enough to be handled in long lengths, which may be readily and securely fixed to cast-in-situ concrete building slabs, which incorporates provisions to permit the ready adjustment of alignment, and which employs anchorages of which may be positioned anywhere along the length of a mould. A secondary object of the present invention is to provide a mould which may be adapted, in specific applications, to employment without filling with concrete, in which embodiment it may be employed as a duct to accommodate cabling and the like.
According to the present invention, moulds for the creation of surface-mounted sills or hobs are fixed to the surface of a cast-in-situ concrete building slab following its curing. Said moulds take the form of long boxes more or less open at the top and bottom, comprising two parallel, continuous side members joined in a fixed spatial relationship by spacer elements welded to them, the moulds permitting concrete to enter from above to pass through to the concrete slab below. The upper and lower edges of each of the two said side members are turned inwardly through two 90° bends to create horizontally-arranged upper and lower first returns and vertically-arranged upper and lower second returns. The gauge of metal employed in making the side members is sufficient to provide adequate beam strength and torsional stiffness. Beam strength of the mould is augmented by the presence of said upper first and second returns which act to prevent crippling failure in compression, said upper and lower second returns being stabilised by said spacer elements welded to them. Said spacer elements most commonly take the form of narrow sections, transversely cut from a length of metal tubing of square or rectangular cross-sectional shape. Where necessary, narrow sections transversely cut from two lengths of metal tubing of different square or rectangular cross-sectional shapes are employed, welded, as required, to each other and to said upper and lower second returns of said side members. Said moulds are seemed to the upper surface of a cured, cast-in-place concrete building slab by a plurality of clamping pieces. Typically, the clamping pieces take the form of fransversely-arranged strips of metal of suitable width turned downwardly though 90° at each end to create legs of a length greater than the width of said lower second returns of said side members, the overall length of each said clamping piece being such that, when said clamping pieces are placed transversely within said mould, the outer end surfaces of said legs abut the inner surfaces of said side members, the lower edges of said legs abutting the upper surfaces of said lower first returns. Said clamping pieces are made from metal of a gauge sufficient to provide the required strength and are optionally ribbed or otherwise shaped to provide additional strength, being secured in place urging said lower first returns of said mould side members against the upper surface of a concrete building slab by suitable masonry anchors. The lower parts of said masonry anchors are accommodated within suitable bores drilled into the concrete building slab, providing a reliable means of anchoring. The upper threaded part of the wedging bolt of each said masonry anchor passes up through an aperture in its complementary clamping piece, a nut threaded and tightened onto said threaded part urging said clamping piece legs against said lower first returns of said mould side members, thereby urging said lower first returns against the upper surface of a concrete building slab. Said mould is then filled with concrete, the surface of which is trowelled off to provide a straight and level upper surface of said sill or hob. Following curing of the concrete filling, said sill or hob is suitably waterproofed. Apertures in said clamping pieces are preferably made over-sized or slotted to permit adjustment of the transverse alignment of said mould. Longitudinal positioning of the mould may be adjusted before said clamping pieces are tightened into place. Suitable joining means are provided to join straight runs of said mould end to end, at T-junctions and at directional changes through angles of 90°, 45° or angles of other magnitude. Said joining means are adaptable to closing of the end of a run of said mould. Provision is made to employ said mould unfilled with concrete to perform the function of sill or hob and a cable duct.
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:
Figure 1 is a transverse cross-sectional view of a hob mould prior art example;
Figure 2 is a transverse cross-sectional view of a hob mould of the present invention;
Figure 3 is a fragmentary transverse cross-sectional view of the upper edge of an alternative embodiment of a side member of the mould of the present invention;
Figure 4 is a view from above of a first embodiment of the clamping pieces;
Figure 5 is a is a view from above of a second embodiment of the clamping pieces;
Figure 6 is a view from above of a length of the mould of the present invention;
Figure 7 is a transverse cross-sectional view of an alternative embodiment of the mould of the present invention;
Figure 8 is a cross-sectional view through a transverse centre-line of a joining piece employed to join sections of the mould of the present invention end-to-end;
Figure 9 is a longitudinal cross-sectional view (with respect to the longitudinal axis of the mould) of the joining piece of Figure 8;
Figure 10 is a view from above of a joining piece employed to join sections of the mould of the present invention at right-angles;
Figure 11 is a face view of an alternative embodiment of spacer element of the present invention;
Figure 12 is a view from above of the spacer element of Figure 11;
Figure 13 is a view from above of a clamping piece ribbed for greater strength;
Figure 14 is a side view of the clamping piece of Figure 13;
Figure 15 is a schematic side view of a first alternative embodiment of the clamping piece of the present invention;
Figure 16 is a schematic side view of a second alternative embodiment of the clamping piece of the present invention;
Figure 17 is a schematic side view of a third alternative embodiment of the clamping piece of the present invention;
Figure 18 is a transverse cross-sectional view of a fourth alternative embodiment of the clamping piece of the present invention.
No significance should be deduced from the fact that the various figures are drawn to differing scales.
As referred to previously, the simplest method of providing sills or hobs to previously cast-in-situ concrete building slabs is through the use of long box moulds, normally constructed from wood by tradesman carpenters or formworkers. In the construction of large, multi-storey buildings, in which many hundreds of lineal metres of such sills or hobs may be required, the use of wooden moulds is inefficient in terms of time and labour useage. With reference to Figure 1, in order to provide such sills or hobs more efficiently, a form of simple permanent mould has been devised. Said permanent mould comprises two elongated metal side members 1 having upper and lower returns 2, 3 created on them by turning their upper and lower edges inwardly through 90°, narrow metal strips 4, 5 of suitable longitudinal spacing being spot-welded transversely between the two upper returns and between the two lower returns to lock the side members together in a fixed positional relationship. As the thickness of the sheet metal stock employed to create such moulds is normally 0.5 mm, the mould has a low beam strength and, in long lengths, is torsionally very flexible. As the mould is normally manufactured and installed in long lengths, care must therefore be exercised in handling it. This mould is normally fixed to the surface of a previously cast-in-situ concrete building slab 6 by passing hard nails (concealed by steel reinforcing bar 7) through the lower, transversely-arranged metal strips 5 into concrete building slab 6 using a nail gun, the positions of said upper, transversely-arranged metal strips in relation to said lower transversely-arranged strips being longitudinally staggered to avoid obstructing access of the nail gun. As filling of the mould with concrete results in only a relatively narrow strip of concrete contacting the surface of said concrete building slab beneath, better attachment of said sill or hob to said concrete slab is achieved by grouting or bonding the lower ends of short lengths of steel reinforcing bar 7 into suitably spaced bores 8 drilled into said concrete slab, said reinforcing bar extending upwards into the interior of said mould and being embedded when said mould is filled with concrete. Apart from the difficulties of handling long lengths of said mould because of its fragility, in practice difficulty has been experienced in securely nailing it to concrete building slabs. Penetration of said hard nails through said transversely-arranged metal strips causes a downwards peening of the surrounding metal that may prevent said mould from sitting closely against the surface of said concrete slab, said nails are sometimes not properly set into said concrete slab due to the nature of the concrete or the striking of aggregate pieces, and pieces of concrete spalling away from said concrete slab have also preventing said mould from sitting closely against the surface of said concrete slab. Further, should said mould not be correctly positioned during said nailing process, no adjustment of position can be made. Experience has shown that, where said lengths of steel reinforcing bar are grouted or bonded into said bores in said concrete slab, a high rate of failure of said grouting or bonding has occurred due to the difficulty of properly cleaning out said bores before said process of grouting or bonding is performed. Most seriously, failure of said nailed fixing and said grouting or bonding of said reinforcing bar into said concrete slab have allowed localised movement of a said sill or hob with a resultant tearing and loss of integrity of the waterproofing membrane laid over it.
With reference to Figures 2 and 10, in order to overcome the shortcomings of the mould described in relation to Figure 1, the present invention provides a more robust permanent mould which may be positionally adjusted during fixing and which utilises a stronger and more secure method of fixing to a cast-in-situ concrete building slab. Said mould takes the form of long boxes more or less open at the top and bottom, comprising two parallel, continuous side members 9 joined in a fixed spatial relationship by spacer elements 14 welded to them, the mould permitting concrete to enter from above and pass through to said concrete slab 6 below. The upper and lower edges of each of said side members are each turned inwardly through two 90° bends to create horizontally-arranged upper first returns 10 and lower first returns 11 and vertically-arranged upper second returns 12 and lower second returns 13. The thickness of the sheet metal employed in making said side members is selected according to the dimension of said mould to provide a mould of adequate beam strength and torsional stiffness and, in the preferred embodiment, falls in the range 0.5 millimetres to 5.0 millimetres. Beam strength of said mould is augmented by the use of wider said side member upper first and second returns, said wider returns acting to prevent crippling failure in compression, said upper and lower second returns being stabilised against forced displacement by the welding to them of said spacer elements. With additional reference to Figure 3, in an alternative embodiment, in order to further increase the beam strength of said mould, said mould side member second return is made wider and its free, lower edge is turned through 180° to form third return 28. In a further alternative embodiment (not shown), in order to further increase the beam strength of said mould, longitudinal ribbing is optionally provided in side members 9. Said ribbing optionally takes the form of a single, shallow, V-shaped (inwards) depression extending over between 50% and 80% of the width of said side members or multiple, narrow, V-shaped or U-shaped (inwards) depressions having a width in the range 10% to 25% of the width of said side members and a depth in the range 20% to 100% of the width of said depressions. In a further alternative embodiment (not shown), said mould side member second return is made wider and its free, lower edge is turned through 90° to form a third return, the free edge of said third return just touching the inner surface of said side member and, optionally, tack-welded to it at regular intervals falling in the range 20 millimetres to 300 millimetres. Also in the preferred embodiment, said upper and lower first returns are made with a width falling in the range 0.15 to 0.4 of the overall transverse width of said mould. Also in the preferred embodiment, said upper and lower second returns are made with a width falling in the range 0.125 to 0.25 of the overall height of said mould. Spacer elements 14 most commonly take the form of narrow sections, transversely cut from a length of metal tubing of square or rectangular cross-sectional shape. Also in the preferred embodiment, the width of said spacer elements (measured parallel to the longitudinal axis of said mould) falls in the range 2.5 to 20 millimetres and the thickness of said spacer elements falls in the range of 1.0 to 5.0 multiples of the thickness of said side members. Also in the preferred embodiment, said spacer elements are tack-welded to said upper and lower second returns within the interior of said mould such that no welding appears above said upper first returns or below said lower first returns. Also in the preferred embodiment, the longitudinal spacing of said spacer elements (centreline to centre-line, with reference to the longitudinal axis of said mould) falls in the range of 1.0 to 5.0 multiples of the overall width of said mould. With additional reference to Figures 11 and 12, in an alternative embodiment, said spacer elements take the form of vertically-arranged, flat pieces of sheet metal 25 of suitable width and height, the side edges 26 of which are turned through 90° and welded to said mould side member upper and lower second returns, suitable apertures 27 being optionally provided in said spacer elements to facilitate their embedding. In an alternative embodiment (not shown), in order to improve the crush strength of said mould, vertically-arranged ribbing is optionally provided in side members 9. In a further alternative embodiment (not shown), a clamping piece 15 is made in combination with a spacer element of any suitable form. In this embodiment, said combination clamping piece and spacer element is preferably made in a single piece by laser cutting from sheet metal stock, followed by stamping or pressing.
Said mould is secured to the upper surface of a cured, cast-in-situ concrete building slab 6 by a plurality of transversely-arranged clamping pieces 15. In the preferred embodiment, said clamping pieces take the form of strips of metal of suitable width and thickness turned downwardly though 90° at each end to create legs 16 of a length greater than the width of side member lower second returns 13, the overall length of said clamping pieces being such that, when said clamping pieces are placed transversely within said mould, the outer end surfaces of said legs abut the inner surfaces of said side members, the lower edges of said legs abutting the upper surfaces of lower first returns 11. Said clamping pieces are made of a width and from sheet metal of a gauge sufficient to provide the required beam strength, in the preferred embodiment, having a thickness falling in the range of 0.5 to 5.0 multiples of the thickness of said side members. Also in the preferred embodiment, the width of said clamping pieces falls in the range of a multiple of 0.2 to 1.0 of the overall width of said mould. In alternative embodiments (not shown), said clamping pieces are made from any suitable material, including metal alloys and polymers, and formed by stamping, forging, die-casting, injection-moulding or the like and may be ribbed or otherwise shaped to provide additional beam strength. With additional reference to Figures 13 and 14, in an alternative embodiment, said clamping pieces are provided with strengthening ribbing 17 extending more or less from end to end. Said ribbing optionally takes the form of a single rib, as depicted in Figures 13 and 14, or two or more, more or less parallel, ribs extending substantially throughout the length of said clamping pieces. Said clamping pieces are secured in place urging said mould side member lower first returns against the upper surface of a cast-in-situ concrete building slab 6 by suitable masonry anchors 18 which provide a reliable means of anchoring. The lower parts of said masonry anchors are accommodated within suitable bores 19 drilled into said concrete building slab. The threaded upper part 20 of the wedging bolt 22 of each said masonry anchor passes up through a complementary aperture in its said complementary clamping piece, nuts 21 threaded and tightened onto said threaded upper parts urging said legs of said clamping pieces against mould side member lower first returns 11 and, by urging said lower first returns against the upper surface of concrete building slab 6, secures said mould to said concrete slab. Said mould is then filled with concrete, the surface of which is trowelled off to provide a straight and level upper surface of said sill or hob. Following curing of said concrete filling, said sill or hob is externally waterproofed by means of a membrane or the like.
In an alternative embodiment, said concrete filling of said mould has a waterproofing compound mixed with it. With additional reference to Figures 4 and 5, in the preferred embodiment, said complementary apertures in said clamping pieces are preferably made over-sized (as depicted in Figure 5) or slotted (as depicted in Figure 4) to permit adjustment of the transverse alignment of said mould during its fixing to said cast-in-situ concrete building slab. Obviously, longitudinal positioning of said mould may be adjusted before said nuts of said clamping piece masonry anchors are tightened to secure said mould in place on said concrete building slab.
With reference to Figure 7, in an alternative embodiment in which the cross-sectional shape of said mould is not symmetrical in cross-sectional shape, said spacer elements are specially fabricated, for example, by bending up lengths of narrow metal strip or rod, or by welding together narrow sections transversely cut from two or more lengths of metal tubing of different square or rectangular cross-sectional shapes, said fabricated spacer elements then being welded to upper and lower returns of conventionally or irregularly shaped said side members. In this embodiment, used to create a rebated sill or hob on a cast-in-situ concrete building slab, upper spacer elements 29 and lower spacer elements 30 are welded together and upper second return 12 of conventionally-shaped side member 9 is welded to said upper spacer elements. Similarly, vertically-arranged return 31 of irregularly-shaped side member 32 is welded to said upper spacer elements. Lower second return 13 of said conventionally-shaped side member is welded to said lower spacer elements and horizontally-arranged returns 33, 34 of said irregularly-shaped side member are welded to said lower spacer elements. Said mould is secured to a cast-in-situ concrete building slab by means of a plurality of centrally-located masonry anchors (axis of masonry anchors depicted in broken line as 36) the lower parts of which are accommodated within bores drilled into said concrete slab, nuts being threaded and tightened onto threaded upper parts of wedging bolts of said masonry anchors against clamping pieces (positions depicted in broken line as 35), urging said legs of said clamping pieces against said mould side member lower first returns and, by urging said lower first returns against the upper surface of concrete building slab 6, secures said mould to said concrete slab. Said mould is then filled with concrete to create said sill or hob. In this embodiment, suitable apertures are provided in the upper part of said irregularly-shaped side member to permit access for a tool to tighten said masonry anchor nuts. In an alternative embodiment, not shown, the axis of said masonry anchors is displaced to be located in the zone between returns 12 and 31. Where it is necessary for said clamping pieces to be made long, they are suitably strengthened by any combination of thickening, ribbing or arching.
With additional reference to Figures 8 and 9, joining means are provided to join straight lengths of said mould end-to-end. In this embodiment, the simple clamping piece 15 described in relation to Figure 2, having legs 16 formed at each end, is adapted by having up to double the normal width and an upstanding stabilisation panel 37 provided along each side. Provided in the upper parts of said panels are two suitably-located slots 38. To join the ends of two lengths of said mould, they are brought into abutment at said joining means, with said clamping piece legs simultaneously bearing against both abutting end parts of said mould side member lower first returns and with said mould side member upper second returns of both said lengths engaging said slots. Threading and tightening of said nut onto said threaded upper part of said wedging bolt of said masonry anchor (not shown), the lower part of which is accommodated in a bore drilled into said cast-in-situ concrete building slab beneath, urges said clamping piece and its said legs against said mould side member lower first returns of both said lengths and, thereby, urges said mould into contact with said concrete slab. Engagement of said mould side member upper second returns of both said lengths with said slots positionally stabilises said mould side members, preventing their flexural displacement. In this embodiment, said clamping piece is made sufficiently wide to properly engage the ends of said mould side member lower first returns of both said lengths. In the preferred embodiment, suitable apertures (not shown) are provided in said stabilisation panels to permit a free distribution of the subsequent concrete filling of said mould.
With additional reference to Figure 10, joining means are provided to join lengths of said mould at an angle of 90°. In this embodiment, the ends of said mould are mitred and are joined in abutment by a combination clamping piece 39 of truncated, equi-armed L-shape and of suitable thickness having a plurality of suitably-positioned, downwardly-projecting legs (depicted in broken line as 40) along each edge. The dimensions of said combination clamping piece is such that, when said clamping piece is positioned to cover the end zones of said mould lengths brought into mitred abutment (line of abutment depicted in broken line as 53), the outer end surfaces of said legs abut the inner surfaces of said mould side members, the lower edges of said legs abutting the upper surfaces of said mould side member lower first returns (view of said lower first returns obscured by upper first returns 10). Suitably-positioned, upstanding stabilisation pieces 41 and 44 are fixed to the upper surface of said combination clamping piece by the fixing into place of tabs 42, 45, respectively, at their lower ends by tackwelding, spot-welding or other fixing method. Said stabilisation pieces are provided in their upper parts with suitably-located slots which are aligned with and accommodate said mould side member upper second returns (indicated in broken line as 48) when said mould ends are brought into mitred abutment. The threaded upper part of the wedging bolt of a masonry anchor (not shown) passes up through centrally-located aperture 20 in said combination clamping piece, the lower part of said masonry anchor being accommodated in a bore drilled into said cast- in-situ concrete building slab beneath. Tightening of a nut on said upper threaded part of said wedging bolt of said masonry anchor, urges said clamping piece legs against said mould side member lower first returns and, thereby, urges said mould into contact with said concrete slab. Engagement of said mould side member upper second returns with said stabilisation piece slots positionally stabilises said mould side members, preventing their flexural displacement. In this embodiment, said legs of said combination clamping piece may take the form of discrete legs (as depicted in the figure) to engage said mould side member lower first returns, or may take the form of a single, elongated leg extending throughout the zone indicated by bracket 47. In the preferred embodiment, suitable apertures (not shown) are provided in said combination clamping piece to permit the concrete filling of said mould to contact said cast-in-situ concrete building slab beneath, thereby exerting stabilising and attachment effects. Those skilled in the art will readily understand how the joining method employing said combination clamping piece may be readily adapted to joining the ends of lengths of said mould at T-junctions and at angles less than 90°. In an alternative embodiment (not shown), upstanding stabilisation pieces 41 and 44 are deleted.
With reference again to Figure 8, the joining means depicted are adapted to fixing the end of a run of said mould to said concrete building slab and to closing its open end. In this embodiment, said clamping piece is turned downwardly at 90° at each end to create legs to abut the upper surfaces of said mould side member lower first returns and with a single, upwardly extending, first panel part 37 the upper edge of which is coincident with the upper surface of said mould and which is made with a width such that its side edges just contact the inner surfaces of said side members and a downwardly-extending second panel (not shown). Said second panel is made with the same width as that of said first panel and is shaped and dimensioned to just contact the inner surfaces of said side members and the upper surfaces of said side member lower first returns and, between them, the upper surface of said concrete building slab. Said first panel is provided in its upper part with suitably-located slots which accommodate said mould side member upper second returns, and said second panel is provided in its lower part with similar suitably-located slots which accommodate said mould side member lower second returns. Said clamping piece is employed to fix the end of said mould to said concrete building slab in the manner described with said first and second panels acting to close the open end of said mould. In the preferred embodiment, the edges of said first and second panels are sealed to adjacent mould and concrete surfaces by means of a suitable mastic or sealant to minimise leakage of concrete during filling of said mould. In an alternative embodiment (not shown), an extruded sealing section made from a suitable elastomeric polymer is provided along the appropriate edges of said first and second panels to seal said edges to the adjacent mould and concrete surfaces to minimise leakage of concrete during filling of said mould.
In an alternative embodiment (not shown), said mould is made from metal sheet material of a suitable gauge to provide the crush strength required and is used unfilled with concrete as a combination sill or hob and a cable duct. In another alternative embodiment, said mould accommodates a conduit for cabling, with the remainder of its interior space filled with concrete to perform the function of sill or hob.
With additional reference to Figures 15, 16, 17 and 18, a said clamping piece takes the form of a beam part 15 which is optionally a flat strip of metal with an inherent beam strength determined by its width and thickness; a strip of metal 15 ribbed to provide greater beam strength; a cast, pressed or forged strip of metal 15 having greater beam strength; an arched strip of metal 15 having greater beam strength; or a strip of metal 15 with side flanges 52 having greater beam strength; said legs taking the form of straight, downwardly projecting legs as described in relation to Figure 2, or short lengths of round tubing 49 welded to the ends of said beam part; or short lengths of square or rectangular tubing (not shown) welded to the ends of said beam part; or a square or rectangular part 50 formed at each end of said beam part; or a part-circular section 51 formed at each end of said beam part. Where a more or less closed section is formed at the end of beam part 15, the end of the formed section is optionally left free and in contact with the underside of said beam part or is welded to the underside of said beam part.
Where necessary, said masonry anchor is optionally wholly accommodated within said bore drilled into said cast-in-situ concrete building slab and said wedging bolt is extended up though said clamping piece, a crush tube being placed between the underside of said clamping piece and the upper surface of said concrete slab or the upper end of said masonry anchor.
In an alternative embodiment (not shown), a gasket is provide fixed to the under surface of lower first returns 11, said gasket acting to prevent leakage of concrete during filling of said mould, particularly when said mould is bridging a depression in a previously-poured concrete slab. In the preferred embodiment, said gasket is made from a soft, polymer foam material with a width in the range 50% to 80% of the width of said lower first returns and projects from said lower first return surface by a distance of up to double the width of said lower first return. Also in the preferred embodiment, said gasket is fixed to the under surface of said lower first in a shallow channel, said channel being of sufficient depth to accommodate said gasket when it is fully compressed.
Claims (36)
1. Apparatus for the moulding of surface-mounted sills or hobs onto previously cast-in-situ concrete building slabs, said apparatus comprising two parallel, continuous side members, the upper and lower edges of each of which are turned inwardly through two 90° bends to create horizontally-arranged upper first returns and lower first returns and vertically-arranged upper second returns and lower second returns, said side members being joined in a fixed spatial relationship by spacer elements welded to said upper and lower second returns to create a mould in the form of a long box more or less open at the top and bottom; said mould being secured to the upper surface of a previously cast-in-situ concrete building slab by a plurality of transversely-arranged clamping pieces in the form of flat strips of metal turned downwardly through 90° at each end to create legs of a length greater than the width of said side member lower second returns, the overall length of said clamping pieces being such that, when said clamping pieces are placed transversely within said mould, the outer end surfaces of said legs abut the inner surfaces of said side members, the lower edges of said legs abutting the upper surfaces of said lower first returns; said clamping piece legs being urged against said lower first returns by a plurality of suitable masonry anchors, the lower parts of which are accommodated within suitable bores drilled into said concrete building slab, threaded upper parts of a wedging bolt of each said masonry anchor passing through a complementary aperture in its complementary said clamping piece, nuts threaded onto said wedging bolt threaded upper parts being tightened against said clamping pieces, urging said mould side member lower first returns against the upper surface of said concrete slab thereby securing said mould to said concrete slab.
2. The apparatus of Claim 1 in which said upper and lower first returns are made with a width falling in the range 0.15 to 0.4 of the overall transverse width of said mould and said upper and lower second returns are made with a width falling in the range 0.125 to 0.25 of the overall height of said mould.
3. The apparatus of Claim 1 in which said complementary apertures in said clamping pieces are made over-sized or slotted to permit adjustment of the transverse alignment of said mould during its fixing to said concrete slab, the longitudinal positioning of said mould being adjusted before said nuts of said masonry anchors are tightened to lock said mould into place on said concrete slab.
4. The apparatus of Claim 1 in which sheet metal employed in making said side members is selected to provide a mould of adequate beam strength and torsional stiffness and, depending upon the dimensions of said mould, has a thickness falling in the range 0.5 millimetres to 5.0 millimetres.
5. The apparatus of Claim 1 in which the longitudinal spacing of said spacer elements (centre-line to centre-line, measured parallel to the longitudinal axis of said mould) falls in the range 1.0 to 5.0 multiples of the overall width of said mould.
6. The apparatus of Claim 1 in which said spacer elements take the form of narrow sections, transversely cut from a length of metal tubing of square or rectangular cross-sectional shape and have a width (measured parallel to the longitudinal axis of said mould) falling in the range 2.5 to 20 millimetres and a thickness falling in the range 1.0 to 5.0 multiples of the thickness of the material of said side members.
7. The apparatus of Claim 1 in which said spacer elements optionally take the form of vertically-arranged, flat pieces of sheet metal of suitable width and height, the side edges of which are turned through 90° and welded to said mould side member upper and lower second returns, suitable apertures being optionally provided in said spacer elements to facilitate their embedding.
8. The apparatus of Claim 1 in which said clamping pieces are made from sheet metal having a thickness falling in the range 0.5 to 5.0 multiples of the thickness of the material of said side members and a width falling in the range of a multiple of 0.2 to 1.0 of the overall width of said mould.
9. The apparatus of Claim 1 in which said clamping pieces are made from any suitable material, including metal alloy and polymer materials, are formed by stamping, forging, die-casting, injection-moulding or the like, and are optionally thickened, ribbed, arched, edge-flanged or otherwise shaped to provide additional beam strength.
10. The apparatus of Claim 1 in which the beam strength of said mould is augmented by the use of wider side member upper first and second returns, said wider returns acting to prevent crippling failure in compression, said upper and lower second returns being stabilised against forced displacement by the welding to them of said spacer elements.
11. The apparatus of Claim 1 in which the beam strength of said mould is further augmented by making said mould side member second return wider and with its free, lower edge turned through 180° to form a third return.
12. The apparatus of Claim 1 in which the beam strength of said mould is further augmented by making said mould side member second return wider and its free, lower edge turned through 90° to form a third return, the free edge of said third return just touching the inner surface of said side member and, optionally, tack-welded to the inner surface of said side member at regular intervals falling in the range 20 millimetres to 300 millimetres.
13. The apparatus of Claim 1 in which, where said mould has an asymmetrical cross-sectional shape, said spacer elements are specially fabricated by bending up lengths of narrow metal strip or rod, or by welding together two or more narrow sections transversely cut from lengths of metal tubing of different square or rectangular cross-sectional shapes, said fabricated spacer elements then being welded to upper and lower returns of conventionally or irregularly shaped said side members; said mould being secured to a cast-in-situ concrete building slab by means of a plurality of more or less centrally-located masonry anchors, the lower parts of which are accommodated within bores drilled into said concrete slab, nuts threaded and tightened onto said threaded upper parts of said wedging bolts of said masonry anchors urging said legs of said clamping pieces of suitable length against said mould side member lower first returns and, by urging said lower first returns against the upper surface of said concrete slab, secures said mould to said concrete slab.
14. The apparatus of Claims 1 and 13 in which, after said mould is secured to said concrete slab, it is filled with concrete, the upper surface of which is trowelled off to provide a straight and level upper surface of said sill or hob.
15. The apparatus of Claim 14 in which concrete filling of said mould has a waterproofing compound mixed with it or, following curing of said concrete filling, said sill or bob is externally waterproofed by means of a membrane or the like.
16. The apparatus of Claim 1 in which joining means to join two straight lengths of said mould end-to-end comprise a clamping piece up to double the normal width, having legs formed at each end and an upstanding stabilisation panel along each side, said stabilisation panels being provided in their upper parts with two suitably-located slots; the ends of said lengths of said mould to be joined being brought into abutment at said joining means such that said clamping piece legs simultaneously bear against both abutting end parts of said mould side member lower first returns and with the ends of said mould side member upper second returns of both said lengths engaging said slots; threading and tightening of a nut onto said threaded upper part of said wedging bolt of said masonry anchor, the lower part of which is accommodated in a bore drilled into said cast-in-situ concrete building slab, urges said legs of said clamping piece against said mould side member lower first returns of both said lengths and, thereby, urges said ends into contact with said concrete slab, securing them in abutment; engagement of said mould side member upper second returns of both said lengths with said slots positionally stabilising said mould side members, preventing their flexural displacement.
17. The apparatus of Claim 16 in which suitable apertures are provided in said stabilisation panels to permit a freer distribution of the concrete with which said mould is subsequently filled.
18. The apparatus of Claim 1 in which means are provided to join the mitred ends of two lengths of said mould at an angle of 90° , said means comprising a clamping piece of truncated, equi-armed L-shape and of suitable thickness having a plurality of suitably-positioned, downwardly-projecting legs positioned along its inner and outer edges, the dimensions of said clamping piece being such that, when said clamping piece is positioned to cover the internal end zones of said mould lengths in mitred abutment, the outer end surfaces of said legs abut the inner surfaces of said mould side members and the lower edges of said legs abut the upper surfaces of said mould side member lower first returns to either side of said mitred zone; upstanding stabilisation pieces being fixed in appropriate positions to the upper surface of said clamping piece, said stabilisation pieces being provided in their upper parts with suitably-located slots which are aligned with and accommodate said mould side member upper second returns when said mould ends are brought into mitred abutment; the threaded upper part of said wedging bolt of a said masonry anchor passing up through a centrally-located aperture in said combination clamping piece, the lower part of said masonry anchor being accommodated in a bore drilled into said cast-in-situ concrete building slab, threading and tightening of a nut onto said threaded upper part of said wedging bolt of said masonry anchor urging said clamping piece legs against said mould side member lower first returns and, thereby, urges said mould into contact with said concrete slab, securing them in abutment; engagement of said mould side member upper second returns with said stabilisation piece slots positionally stabilising said mould side members, preventing their flexural displacement.
19. The apparatus of Claim 18 in which said legs of said combination clamping piece optionally take the form of discrete legs to engage said mould side member lower first returns or, where appropriate, a single, elongated leg.
20. The apparatus of Claim 18 in which suitable apertures are provided in said combination clamping piece to permit the concrete filling of said mould to contact said concrete building slab beneath, thereby exerting stabilising and attachment effects.
21. The apparatus of Claim 18 in which said combination clamping piece is adapted to join the ends of two or three lengths of said mould at a T-junction or at angles less than 90°.
22. The apparatus of Claim 1 in which the end of a run of said mould is fixed to said concrete building slab and its open end is closed using a clamping piece turned downwardly at each end to create legs the lower edges of which abut the upper surfaces of said mould side member first returns; said clamping piece being made with a single, upwardly-extending first panel the upper edge of which is coincident with the upper surface of said mould and having a width such that its side edges just contact the inner surfaces of said side members, and with a single, downwardly-extending second panel of the same width as said first panel, said second panel being shaped and dimensioned to just contact the inner surfaces of said side members and the upper surfaces of said side member lower first returns and, between them, the upper surface of said concrete building slab; said first panel being provided in its upper part with suitably-located slots which accommodate said mould side member upper second returns, and said second panel being provided in its lower part with similar suitably-located slots which accommodate said mould side member lower second returns; said clamping piece being employed to fix the end of said mould to said concrete building slab and said first and second panels acting to close the open end of said mould.
23. The apparatus of Claim 22 in which the edges of said first and second panels are sealed to adjacent mould and concrete surfaces by means of a suitable mastic or sealant to minimise leakage of concrete during filling of said mould.
24. The apparatus of Claim 22 in which an extruded sealing section made from a suitable elastomeric polymer is provided along the appropriate edges of said first and second panels to seal said edges to the adjacent mould and concrete surfaces to minimise leakage of concrete during filling of said mould.
25. The apparatus of Claim 1 in which said mould is made from metal sheet material of a suitable gauge to provide the crush strength required and is used unfilled with concrete as a combination sill or hob and a cable duct.
26. The apparatus of Claim 25 in which said mould accommodates a conduit for cabling, with the remainder of its interior space filled with concrete to perform the function of sill or hob.
27. The apparatus of Claim 1 in which said clamping piece comprises a beam part having legs at each end, said legs taking the form of simple, straight, downwardly-projecting legs; or short lengths of round tubing welded to the ends of said beam part; or short lengths of square or rectangular tubing welded to the ends of said beam part; or square or rectangular parts formed at each end of said beam part; or part-circular sections formed at each end of said beam part; the end of a formed section being optionally left free and in contact with the underside of said beam part or being welded to the underside of said beam part.
28. The apparatus of Claim 1 in which said spacer elements are welded to said mould side member upper and lower second returns within the interior of said mould such that no welding appears above said upper first returns or below said lower first returns.
29. The apparatus of Claim 1 in which, where necessary, said masonry anchor is optionally wholly accommodated within said bore drilled into said concrete building slab and said wedging bolt is extended up through said clamping piece, a crush tube being placed between the underside of said clamping piece and the upper surface of said concrete slab or the upper end of said masonry anchor.
30. The apparatus of Claim 1 in which said clamping piece is combined with any form of said spacer element, the combination preferably being made in a single piece by laser cutting from sheet metal stock, followed by stamping or pressing.
31. The apparatus of Claim 1 in which, to further increase the beam strength of said mould, longitudinal ribbing is optionally provided in said side members, said ribbing optionally taking the form of a single, shallow, V-shaped (inwards) depression extending over between 50% and 80% of the width of said side members, or multiple, narrow, V-shaped or U-shaped (inwards) depressions having a width in the range 10% to 25% of the width of said side members and a depth in the range 20% to 100% of the width of said depressions.
32. The apparatus of Claim 1 in which, in order to improve the crush strength of said mould, vertically arranged ribbing is optionally provided in said side members.
33. The apparatus of Claim 18 in which said upstanding stabilisation pieces are deleted.
34. The apparatus of Claim 1 in which a gasket is provided fixed to the under surface of said lower first returns, said gasket acting to prevent leakage of concrete during filling of said mould, particularly when said mould is bridging a depression in a previously-poured concrete slab; said gasket being made from a soft, polymer foam material with a width in the range 50% to 80% of the width of said lower first returns and projecting from said lower first return surface by a distance of up to double the width of said lower first return.
35. The apparatus of Claim 34 in which said gasket is fixed to the under surface of said lower first returns in a shallow channel, said channel being of sufficient depth to accommodate said gasket when it is frilly compressed.
36. A method of moulding surface-mounted sills or hobs onto a previously cast-in-situ concrete building slab, said method consisting in the use of apparatus comprising a mould more or less open at the top and bottom, clamping pieces to apply a securing force to said mould and masonry anchors to urge said clamping pieces against said mould and, thereby, to secure said mould in place on the surface of said concrete slab; said mould comprising two parallel, continuous side members, the upper and lower edges of each of which are turned inwardly through two 90° bends to create horizontally-arranged upper first returns and lower first returns and vertically-arranged upper second returns and lower second returns, said side members being joined in a fixed spatial relationship by spacer elements welded to said upper and lower second returns, said returns being stabilised against forced displacement by the welding to them of said spacer elements; said mould being secured to the upper surface of a cured, cast-in-situ concrete building slab by a plurality of transversely-arranged clamping pieces in the form of flat strips of metal turned downwardly through 90° at each end to create legs of a length greater than the width of said side member lower second returns, the overall length of said clamping pieces being such that, when said clamping pieces are placed transversely within said mould, the outer end surfaces of said legs abut the inner surfaces of said side members, the lower edges of said legs abutting the upper surfaces of said lower first returns; said clamping piece legs being urged against said lower first returns by a plurality of suitable masonry anchors, the lower parts of which are accommodated within suitable bores drilled into said concrete building slab, the upper threaded part of a wedging bolt of each said masonry anchor passing through a complementary aperture in its complementary said clamping piece, nuts threaded onto said wedging bolt threaded upper parts and tightened against said clamping pieces, urging said legs of said clamping pieces against said mould side member lower first returns and, by urging said mould side member lower first returns against the upper surface of said concrete slab, thereby securing said mould to said concrete slab; said secured mould being filled with concrete, the surface of which is trowelled off to create a sill or hob having a straight and level upper surface.
Priority Applications (2)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| AU2015204404A AU2015204404B1 (en) | 2015-07-14 | 2015-07-14 | Creation of Surface-mounted Sills or Hobs on Cast-in-situ Concrete Building Slabs |
| AU2016256678A AU2016256678B2 (en) | 2015-07-14 | 2016-11-08 | Creation of Surface-Mounted Sills or Hobs on Cast-in-situ Concrete Building Slabs |
Applications Claiming Priority (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| AU2015204404A AU2015204404B1 (en) | 2015-07-14 | 2015-07-14 | Creation of Surface-mounted Sills or Hobs on Cast-in-situ Concrete Building Slabs |
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| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| AU2016256678A Division AU2016256678B2 (en) | 2015-07-14 | 2016-11-08 | Creation of Surface-Mounted Sills or Hobs on Cast-in-situ Concrete Building Slabs |
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| Publication Number | Publication Date |
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| AU2015204404B1 true AU2015204404B1 (en) | 2016-08-11 |
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| AU2015204404A Expired - Fee Related AU2015204404B1 (en) | 2015-07-14 | 2015-07-14 | Creation of Surface-mounted Sills or Hobs on Cast-in-situ Concrete Building Slabs |
| AU2016256678A Active AU2016256678B2 (en) | 2015-07-14 | 2016-11-08 | Creation of Surface-Mounted Sills or Hobs on Cast-in-situ Concrete Building Slabs |
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| Application Number | Title | Priority Date | Filing Date |
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| AU2016256678A Active AU2016256678B2 (en) | 2015-07-14 | 2016-11-08 | Creation of Surface-Mounted Sills or Hobs on Cast-in-situ Concrete Building Slabs |
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| Country | Link |
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| AU (2) | AU2015204404B1 (en) |
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| CN106013811A (en) * | 2016-05-13 | 2016-10-12 | 李藏柱 | Mounting method of prefabricated building |
| CN107165421A (en) * | 2017-06-12 | 2017-09-15 | 江苏建科建设监理有限公司 | A kind of construction method of concrete assembled building |
| CN107237438A (en) * | 2017-08-21 | 2017-10-10 | 江苏智信达建筑科技有限公司 | Self-positioning anti-floating Prefabricated composite case mould and its application method for large span hollow floor |
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| AU2004100510A4 (en) * | 2004-06-29 | 2004-07-22 | Stevens, Gordon Malcolm | Improvements in concrete construction |
| US20060043256A1 (en) * | 2004-08-30 | 2006-03-02 | Bogrett Blake B | Landscape edging form assembly and method |
| US7775499B2 (en) * | 2005-01-18 | 2010-08-17 | Metcalf Robert W | Foundation footing form and wall form support apparatus |
| EP2808451A1 (en) * | 2013-05-27 | 2014-12-03 | Marell Holding B.V. | Foundation |
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| US20090056258A1 (en) * | 2007-08-28 | 2009-03-05 | Currier Donald W | Forming Apparatus and System |
| US8424835B2 (en) * | 2008-04-03 | 2013-04-23 | Paladin Industrial, Llc | Method of supporting panel structures over concrete footings utilizing tie system for forming poured concrete walls |
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- 2015-07-14 AU AU2015204404A patent/AU2015204404B1/en not_active Expired - Fee Related
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- 2016-11-08 AU AU2016256678A patent/AU2016256678B2/en active Active
Patent Citations (4)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| AU2004100510A4 (en) * | 2004-06-29 | 2004-07-22 | Stevens, Gordon Malcolm | Improvements in concrete construction |
| US20060043256A1 (en) * | 2004-08-30 | 2006-03-02 | Bogrett Blake B | Landscape edging form assembly and method |
| US7775499B2 (en) * | 2005-01-18 | 2010-08-17 | Metcalf Robert W | Foundation footing form and wall form support apparatus |
| EP2808451A1 (en) * | 2013-05-27 | 2014-12-03 | Marell Holding B.V. | Foundation |
Cited By (4)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN106013811A (en) * | 2016-05-13 | 2016-10-12 | 李藏柱 | Mounting method of prefabricated building |
| CN106013811B (en) * | 2016-05-13 | 2018-08-10 | 李藏柱 | A kind of installation method of assembled architecture |
| CN107165421A (en) * | 2017-06-12 | 2017-09-15 | 江苏建科建设监理有限公司 | A kind of construction method of concrete assembled building |
| CN107237438A (en) * | 2017-08-21 | 2017-10-10 | 江苏智信达建筑科技有限公司 | Self-positioning anti-floating Prefabricated composite case mould and its application method for large span hollow floor |
Also Published As
| Publication number | Publication date |
|---|---|
| AU2016256678A2 (en) | 2017-02-02 |
| AU2016256678A1 (en) | 2016-11-24 |
| AU2016256678B2 (en) | 2019-02-14 |
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