专利汇可以提供Moulding accessory and method of using same专利检索,专利查询,专利分析的服务。并且A moulding accessory to form a void around a recessed lifting loop in a moulded concrete product such as a concrete cladding panel. The moulding accessory is formed from a body which is sized and shaped to fit with said lifting loop. The body is hollow, but sufficiently strong to form the void when concrete is poured. The body permits access to the lifting loop without needing to remove the body from the void. A method of forming a concrete product is also disclosed.,下面是Moulding accessory and method of using same专利的具体信息内容。
I claim:
This invention relates generally to the field of moulded concrete products and in particular to a moulding accessory of the type that is used to form a void in a moulded concrete product.
Modern building construction techniques focus on quick and efficient building designs which use low cost readily available materials. A particular type of building design which is popular for commercial and industrial buildings consists of an internal steel framework on which cladding is mounted to form the building enclosure. Although various types of cladding can be used, one preferred type of cladding is concrete panel cladding. These concrete panels can be moulded or pre-cast in advance, and then erected onto the metal frame at the building site. Alternatively, these concrete panels may be cast on the site and once sufficiently cured, erected in place on the building frame.
Such concrete panels come in a variety of sizes with many different types of exterior finishes. To produce such panels requires an appropriately sized and shaped mould in order to produce the desired size and shape of panel. The panels may be pre-tensioned, post-tensioned or otherwise reinforced with reinforcing steel. The panels are placed side by side and one on top of another in order to form an external skin on the building. They may be placed on bracket mounts and are bolted or otherwise attached to the metal framework.
The panels are typically made in advance and stored until needed. This means that the panels must be manoeuvrable. However, it is more efficient to have several large panels rather than many small ones. Therefore, the panels tend to be large and can weigh thousands of pounds. Typically, lifting loops are provided on the panels to permit the panels to be lifted by lifting equipment and positioned in place. However, since the panels must sit side by side and one on top of another, such lifting loops are typically recessed and formed within a void space in the edges of the panel, to permit the panels to be butted up close one to another. In order to fit a lifting hook into the lifting loop the void is necessary around the recessed lifting loop. Recessed lifting loops may be provided on the top, bottom sides or ends of the panel. Typically, at least two recessed lifting loops are provided on a side, and a single recessed lifting loop is provided along a top edge. This permits the panel to be lifted by a series of lifting hooks which hold the panel in a stable manner to permit it to be easily positioned by the lifting equipment, such as a crane, onto a vehicle carrier and then eventually in place on the exterior of a building.
In the past, shaped Styrofoam® has been used during the moulding step to form a void around the recessed lifting loops. The Styrofoam® however, while providing an adequate sized and shaped void space, is messy, expensive and awkward to use.
Typically what is required is to obtain large sheets of Styrofoam® from a Styrofoam® supplier which are then individually cut into the necessary void shape. Cutting Styrofoam® sheets takes time, and typically creates highly statically charged particles which tend to stick to all surfaces. As a result, Styrofoam® particles can become stuck to surfaces of the concrete where they can create blemishes if not removed prior to the concrete setting.
A further problem of the Styrofoam® inserts is that they are difficult and awkward to remove from the cured concrete product. Essentially, the Styrofoam® needs to be chipped out of the void by hand, which creates additional electro static debris and is messy, time consuming and expensive. Further, the concrete is rough and workers can scrape their hands as they pick the Styrofoam® out of the finished product in order to create the intended void. Even once removed, the broken bits of Styrofoam® need to be swept up and disposed of, which is both time consuming and expensive.
What is needed is a more efficient way to form voids around recessed lifting hooks that are formed in moulded concrete products, such as cladding panels. In circumstances where the lifting hook is not recessed, no void is required. However, as with concrete panels which are intended to abut and be placed closely adjacent to one another, the lifting loops must be recessed so that the lifting loops do not interfere with abutting placement of adjacent panels. In this case, a void needs to be formed around the recessed lifting loop sufficient to permit a lifting hook to be placed under the lifting loop to permit lifting equipment to lift the moulded concrete product.
What is desired is a moulding accessory to form the void around the recessed lifting loop which is inexpensive and easy to use. What is further desired is for the moulding accessory to be sized and shaped to fit around the lifting loop before the concrete is completely poured. The body of the accessory needs to be sufficiently strong to resist the pressures of the concrete as the concrete is poured around the moulding accessory. Further, the moulding accessory should be usable without creating a lot of unnecessary and hard to deal with dust or garbage. Ideally the moulding accessory will not create any waste whatsoever. Lastly, the moulding accessory should be quick to implement to avoid the labour expense and risk of injury associated with picking apart the Styrofoam® material used to form voids of the prior art.
Therefore, according to one aspect of the present invention there is provided a moulding accessory for forming a void around a recessed lifting loop in a moulded concrete product, the moulding accessory comprising:
a body sized and shaped to fit with said lifting loop, said body being sufficiently rigid to form said void as said concrete is poured;
wherein said body permits a lifting means to access said recessed lifting loop without needing to remove said body from said void.
Reference will now be made, by way of example only, to preferred embodiments of the invention with reference to the following figures.
A moulding accessory 10 according to the present invention is shown in an unfolded position in
The moulding accessory 10 is formed from a single sheet of material 12 which includes a number of elements. In
Turning to
As can be seen in
Also from
Turning to
Turning now to
As will be understood by those skilled in the art, the panel is typically formed in multiple step moulding process. In a first step, a portion of the panel is made, at which time the elements such as the lifting loop 68 may be set in place. The lifting loop 68 may be made from bent steel, but may be also any other type of fitting which permits a hook to be used to lift the completed concrete product once set. Thus, the term lifting loop as used herein means any kind of lifting hardware whether loop shaped or not. Then, the moulding accessory 10 of the present invention can be inserted in place, and the remainder of the panel moulded.
The moulding accessory 10 according to the present invention is shown in cross-sectional view in
In some cases there may be two recessed lifting loops formed along one edge of a panel. In such cases it is preferred to form the larger part of the void closer to the middle of the panel, for strength and other reasons. To keep the seamless edge of the present invention in the proper position in this case requires the use of two separate blanks, that are mirror images of one another. This requires two separate parts, a left-hand and a right-hand part to mould voids for two such lifting hooks, for example, along a side edge of a panel. Therefore the present invention further provides for markings on the blanks to assist in the folding of the blanks into the hollow void forming bodies. This marking may take the form of folding instructions, an indication of what is the inside or outside or merely marking the blanks as being left or right handed parts.
The next step of panel construction is to permit the second pour concrete to set and then once set, to raise or tilt the moulded concrete panel to an upright position after the form work is removed. At this time, according to the present invention the lifting loop is accessible to a lifting hook without requiring any further labourer steps. Although reference is made to the term lifting hook, this term comprehends any lifting means such as hooks, grapples, shackles or other lifting fittings or equipment. The benefits of the present invention can now be more fully appreciated. Rather than removing the void forming material as required in the prior art, according to the present invention, the moulding accessory 10 permits the lifting hook to be placed under the lifting loop without needing to remove the moulding accessory 10 from the moulded concrete product. Thus, the flexible cardboard is simply pushed, deformed or torn as the lifting hook is placed under the recessed lifting loop. The cardboard can remain inside of the recessed void in the lifting panel without needing to be removed. Even when the moulding accessory 10 is retained in the moulded concrete panel, access is available for the hook to engage the lifting loop.
It will now be appreciated that by forming the moulding accessory 10 as a hollow body, the body can, on the one hand hold up to the force of the poured concrete to reliably create a mould, while being collapsable by the force of the lifting hook on the other. The collapsing can be accomplished by the inherent flexibility of the sheet or cardboard material, by means of weakening perforations or by any other means that permits the void forming body to collapse out of the way. For example, for cardboard sheet material wetting can be used to reduce the strength of the material for easier hook penetration.
As can be seen from
Also shown in
Although it will be appreciated that sizes can vary, depending upon the specific moulding requirements, good results have been achieved with a moulding accessory 10 having a cross-sectional area of between 6 cm and 10 cm wide by 7 cm to 11 cm high. The length can also vary, but can be 20 cm to 25 cm, for the first embodiment and 40 cm to 60 cm for the second embodiment. The width of the notch will be sized to closely receive the lifting loop 68, but 2.5 cm gives adequate results.
The benefits of the present invention can now be more fully understood. Firstly, the blanks can be delivered and easily stored flat, since they are compact and lie flat. As compared to Styrofoam®, the cardboard which folds into a hollow body occupies much less space in its flat form. Thus, saves on both shipping and handling expenses. Additionally, the blanks can be easily folded into shape, with a minimum of effort or skill. The folding can even be done by unskilled labourers who are, due to injury and the like, restricted to light duty work. The folding of a blank into a hollow body is quick and easy compared to cutting out a Styrofoam® shape, and thus, is less expensive and less messy. By reason of the notch 50, the present invention is easily and securely positioned in place in the mould, and by being flush against one side of the mould readily resists displacement during the concrete pour. Presenting the seamless edge to the concrete helps keep the hollow interior free of concrete. Once the concrete has set or is sufficiently cured to permit the concrete product to be moved, the hollow body is flexible or breakable, to permit a lifting hook to be used under the recessed lifting loop, without even needing to remove the moulding accessory 10 from the panel void. This is quicker, less messy and much less expensive than having to chip out, clean up and dispose of bits of Styrofoam®.
It will be appreciated by those skilled in the art that while preferred embodiments of the invention have been described, many variations are possible without departing from the broad scope of the claims which follow. Some have been described above and others will be apparent to those skilled in the art. For example, while corrugated cardboard has been used and provides adequate results, various other materials can be used to form a hollow body which can be used to form a void in a moulded product.
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