US2939198A - Shuttering for concrete - Google Patents

Description

J1me 1960 c. E. NICHOLLS 2,939,198

SHUTTERING FOR CONCRETE Filed Sept. 3, 1957 7 Sheets-Sheet 1 June 7, 1960 c. E. NICHOLLS SHUTTEIRING FOR CONCRETE 7 Sheets-Sheet 2 Filed Sept. 3, 1957 June 7, 1960 c. E. NICHOLLS SHUTTERING FOR CONCRETE '7 Sheets-Sheet 3 Filed Sept. 3, 1957 June 7, 1960 c. E. NICHOLLS SHUTTERING FOR CONCRETE 7 Sheets-Sheet 4 Filed Sept. 3, 1957 III? June 7, 196 0 c. E. NICHOLLS SHUTTERING FOR CONCRETE 7 Sheets-Sheet 5 Filed Sept. 3, 1957 June 7, 1960 c. E. NICHOLLS 2,939,198

SHUTTERING FOR CONCRETE Filed Sept. 3, 1957 7 Sheets-Sheet 6 June 7, 19% c. E. NICHOLLS 2,939,198

SHUTTERING FOR CONCRETE Filed Sept. 3, 1957 7 Sheets-Sheet 7 SHUTTERHNG FOR CONCRETE Cecil Eric Nicholls, London, England, assignor to Blaw- Knox Limited, a British company, London, England Filed Sept. 3, 1957, Ser. No. 681,491

11 Claims. (Cl. 25-131) This invention relates to shuttering or forms for poured concrete which is to be employed in the construction of walls, circular tanks, silos, shafts, soflits and other structural works.

It is the chief object of the invention to provide an improved shuttering which is of moderate weight and enhanced strength while being relatively easy to erect and to dismantle either as individual pieces or in erected sections. it is a further object to provide shuttering wherein the time lag normally involved by reason of the necessity for cleaning and oiling after stripping may be eliminated. It is also an object to provide shuttering wherein the necessity for small loose parts is obviated so that a saving both in time and maintenance costs may be effected. Still another obejct is to provide shuttering able to be subjected to the action of either immersion or external type vibrators without the loosening of sections or loss of small loose parts.

According to one aspect of the invention the shuttering comprises a plurality of panels of constant height and thickness, adapted to be assembled in successive courses and in bonded relationship in such a manner as automatically to ensure an alignment thereof and a plurality of uprights or soldiers adapted to be disposed in spaced relation along the length of the shuttering to retain and support the panels with alternate courses, of which they are adapted to be interlocked. Preferably the uprights or soldiers each comprise a plurality of interlockable sections, each of which is equal in length to the vertical dimension of two panels. In addition, for incorporation in alternate courses, that is, those courses wherein the panels are not interlocked with the uprights or soldiers, there are provided a spacing or bonding element adapted to interlock the adjacent vertical edges of each two adjoining panels.

In accordance with a further aspect of the invention, there is provided for forming a shuttering, a fabricated or composite panel comprising two sheets of similar dimensions which are maintained in spaced parallel relationship by means of spacing strips or the like, the whole being welded or otherwise secured together to produce a rigid unitary structure. Preferably, the spacing strips or the like will comprise metal rollings or pressings of channelled or substantially U-shaped cross-section, all or certain of such strips being positioned in relation to the sheets so that the assembled panel will incorporate tongued and grooved edges by which they may be assembled in interlocking relationship with each other and with supporting members or soldiers and/ or with spacing or binding elements.

In order that the invention may be clearly understood and readily carried into effect the same will be hereinafter fully described with reference to the accompanying drawings in which:

Fig. 1 is a perspective view of a portion of erected shuttering embodying the invention and illustrating the construction of the components and the manner of assembly;

nited States Patent ice Fig. 2 is an exploded perspective view illustrating the construction and manner of assembly of the uprights or soldiers employed in the assembly shown in Fig. l and also illustrating a portion of a panel adapted to be locked to the appropriate soldier;

Fig. 3 is a perspective view of a portion of a shuttering embodying the invention and incorporating an angled corner; -Fig. 4 is a perspective view illustrating a portion of single sided shuttering embodying the invention and which is also adapted for use as a cantiliver form;

Fig. 5 is an exploded perspective view illustrating a shuttering for use in the construction of a curved wall;

Fig. 6 is a perspective and exploded view illustrating theuse of shuttering in the forming tunnels;

Fig; 7 is a perspective view illustrating the method of interconnecting the ends of panels employed in the assembly shown in Fig. 6; and

Fig. 8 is a perspective view of a soffit panel suitable for supporting the underside of suspended floors, slabs, beams and the like during construction.

Referring to the drawings in detail, and more particularly to Figs. 1 and 2, it will be seen that the shuttering therein consists primarily of a plurality of rectangular panels 10 which may be produced in a range of standard sizes and are so constructed that they may be erected in courses similarly to brick-work. The panels 10, when erected, are adapted to be retained and aligned vertically by means of uprights or so called soldiers which are designated generally by the reference numerals 11 and arranged at predetermined distances apart. It may be mentioned here that panels of other shapes and sizes may be employed, for example, at the ends for flushing and for completing particular dimensions, but mainly panels from the selected range will be employed which will all be of the same width or height. Each panel 10 comprises a fabricated 'or composite structure consisting of two similarly dimensioned steel sheets 12 which are maintained in spaced parallel relation by means of spacer or bracing strips 13 interposed therebetween and welded or otherwise secured thereto. The spacing or bracing strips 13 interposed between the two plates 12 are preferably pressed or rolled from sheet metal to have channelled or substantially U-shaped cross-sections. The composite panel so formed is conveniently provided at three of its edgm, that is, at its two vertical edges and one horizontal edge, with outwardly projecting tongues or the like 14 which extend along the length of such edges. At its fourth edge, the'panel is formed with a longitudinally extending recess 15, the arrangement being such that, when two panels are appropriately arranged one on the other in edge to edge relationship, the tongue 14 at the horizontal edge of one panel engages in the recess 15 of the horizontal edge of the other panel. Conveniently, the tongues along the three edges of the panel are formed by channel defining strips similar to those constituting the spacer strips 13, such strips being so arranged with respect to the appropriate edge portions of the sheets 12 that, in each case, the base of the channel will project outwardly from the panel. However, in the case of the strips employed to form the tongues 14, it is necessary to form the same so that, when one panel is superimposed on the other in edge to edge relation, as described above, the tongue on one panel is of such width or thickness that it fits snugly into the channel constituting the recessed edge of the other panel. The edge recess 15 is readily defined by reversing a normal spacer strip 13 so that the mouth of the channel thereof faces outwardly, while the outer or free edges of the limbs of the U or channel are flush with the edges of the sheets 12.

As will be seen from Figs. 1 and 2, the uprights or soldiers 11 are also conveniently pressed or rolled from sheet metal and are of box-like or other suitable section so that they will be sufficiently rigid to retain the panels in position; Each soldier 11 is preferably of a height or length equivalent to thewidth'or height of two standard panels 10 and the arrangement issuch that succes sive soldiers can besuperimposed, one on the other in first course in position, and the soldiers being maintained end-to-end relationship,'thereby to provide a soldier or upright of any required length or'height in multiples equal to two panel widths or heights. Each of the joints between the successive soldiers is, in the embodiment illustrated, formed by a pair of plates 16 each carrying a plurality of tapered dowels 17 adapted to engage in apertures 18 formed in the abutting ends of two adjoining soldiers 11. As will be seen in Fig. 2, each soldier carries, at its upper end, a transverse bolt 19 which projects outwardlyfrom each sidethereof and is adapted to project through a slot 20 in each of the plates 16 when the latter are placed in position. The plates. 16 are held in place by nuts 21 threaded onto the respective end portions of the bolt 19. Center catches or any joint between successive soldiers as described above.

other suitable devices may be employed in place'of the Each soldier is provided, at one of its faces, with a stepped or protruding portion 22 equivalent in thickness to the thickness of one of the panels 10 and incorporating, at each of its lateral edges, outstanding flanges 23 each adapted to locate the tongue 14 on the vertical edge of a panel 10. The protruding portion 22 on the soldier is of a height or length equivalent only to the height or width of one panel. At its opposite or outer face, each soldier has a cleat rigidly attached thereto in the form of a shorttubular bar or rod 24 which extends transversely with respect to the longitudinal axis of such soldier, so that the rod 24 is horizontal when the soldier is vertical and provides an attachment for initial scafiold strutting or for the attachmentof working scaffolding, working platforms and the like.

In additionto the panels 10 and the soldiers 11, the shuttering includes spacer or bonding elements 25 (Fig. 1) which each have a length or height equivalent to the height or width of one panel and a width equivalent to that of a soldier. The spacer or'bonding elements 25, which are also preferably fabricated from welded or otherwise secured together sheet metal parts, are each so constructed that two opposed longitudinal edges will berecessed; as indicated at 2 6', and adapted to receive the tongues 14 on the shorter or-vertical edges of two vertically, a second course of panels 10 is applied, the panels of such second course being longitudinally ofiset with respect to those of the first course, thereby to give a bonded effect such as is produced in brick-work. As indicated above, the tongues 14 on the upper edges of the panels of the bottom course will engage in the recesses 15 in. the lower edges of the panels of the second course so that the courses will be aligned and positively located with respect to each other. By virtue of the bonded formation, that is, thestaggering of the panels in the successive courses,v either each panel or only certain panels of the second course, depending upon the spacing between the soldiers, will pass across or in front of a soldier 11 and the outer face of such panel will, in fact, abut the face of the soldier. Since the stepped or projecting portion 22 of each soldier has a height which is equal only to the height or width of one panel, that is, the panel of the first course, the inner face of the panel of the second course passing across a soldier above the portion 22 will belallowed to lie in the same vertical plane as the panel of the first course.

It will be noted that each soldier is provided, at its lower end, with a small inverted channel portion adapted to accommodate the tongue 14 on the upper edge of the panel of the second course. In order that the bonding of the second course shall be consistent with 'that of the first course, it is necessary to introduce one of the spacing or bonding elements 25 between adjacent panels of the second course, such elements being, as indicated above, equal-in width to the'soldiers 11 which are eifectively interposed between adjacent panels adjacent panels 10. Further, one end of'each spacer or bonding element 25 is also recessed, as indicated at 27, while the other end is provided with a tongue 28 having dimensions corresponding to those of the tongues 14 on the panels 10. If desired, each spacer or bonding element may also be provided, at one or both sides, with a peg or pin 29 adapted on assembly to engage in an aperture (not shown) on the edge of a panel 10, thereby to positively locate the spacer element in relation to such panel.

To erect a simple section of the shuttering a selected number of soldiers 11 each comprising one or more sec tions are taken and, as illustrated in Fig. 1, a panel 10 is placed in position between each successive pair of such soldiers, thereby to form a first course. The

tongues 14 on the vertical edges of each panel lll'bear against the outstanding flanges 23 on the stepped or projecting portions 22 of the soldiers and the panel and soldiers are latched together by the engagement of a projection 30 on each flange 23 with an appropriately shaped aperture in the abutting inner side wall of the respective tongue 14 which is in abutment'with said flange. To complete the latching operation a sliding cam latch 31, which is located in alignedapertures 3.2 in the soldier and includes tongue portions 33, is moved into its operative position to cause the tongue portions 33 to engage in apertures 34 in-the outer side .walls of most course, of panels.

10 of the first course. The spacing or bonding elements 25 which serve eifectively to secure together the adjacent edges of adjoining panels 10 in the second course are also, by virtueof therecessed lower ends thereof, interlocked with the panels 10 of the first course. As indicated above, the spacer or bondingelements 25 may also be effectively located withrespect to the adjacent panels by virtue of the engagement of the pins or pegs 29' associated therewith in appropriate apertures in the edges of "the adjacent panelsltl. With two courses in position, a third course may then be added, with the panels of such third course being arranged in the same sections forming the soldiers 11 are each equivalent in height tov two ,courses of panels and, therefore, before addingthe' thirdcourse, it will be necessary, if it has notalready'been done, to extend the soldiers by adding one or more additional sections thereto. Upon completion of "the third course, a further course, similar in arrangement to ,the second course and incorporating spacer or bonding elements 25, may then be added and so on.

In those cases where two sets of shuttering are erected in spaced relation to define a space therebetween into which concrete may be poured, for example, as illustrated in Fig. 1, spacer ties 36 may be inserted through the soldiers 11 and, where required, through apertures 48f in thespacer or bonding elements 25. With .the shuttering erected. to an appropriate height, concrete may be'poured up to the top of the forms and allowed to set. If the height of the structure, is to be increased, following setting of 'the concrete, the bottom panels lilmay beremoved and .replaced on top of the upper- On replacing the panels, the latter are preferably reversed so that thezclean face, that is, the outerface, when in. the first course, will be then directed inwardly, while the previous inner face will be exposed'to allow for cleaning and oiling. Subsequently, the panels 10' of'the second course and. th

spacer or bonding elements 25 are removed, together with the lowermost sections of the soldiers after removal of the spacer ties 36. The removed soldier sections are positioned on the topmost soldier sections and the panels of the second course, having been reversed, are replaced together wtih the spacing or bonding elements 25 to form a new top course. Upon completion of this further or top course, the spacer ties 36 may be again inserted so that the extended shuttering is ready for further pouring of concrete, during which time cleaning and oiling of the previously fouled faces of the panels may proceed. This sequence of operations may, within reason, be carried on indefinitely and can be programmed so that the alternate pouring of concrete and replacement of the panels continues without interruption.

In addition to the components above described, the shuttering embodying the invention is provided with internal or external corner pieces 37 and 38, respectively, of box-like or other suitable section to be interlocked, or otherwise connected, to the rectangular panels 10 so that, on assembly, an appropriately angled corner may be produced, as indicated in Fig. 3. Each corner piece is preferably of a height or length equivalent to the width or height of two standard panels 10, and the arrangement is such that successive corner pieces may be superimposed one on the other in end-to-end relationship, thereby to provide a corner piece or upright of any required length or height. The connection of the corner pieces 37 and 38 to the standard panels 10 may, for example, readily be effected by means of the Anti-Luce tailboard fitting described in British Patent No. 680,850.

In addition to the range of standard panels above referred to, it may be feasible to provide similarly constructed panels of differing dimensions. However, in those cases where odd sized panels are required, the production of which in steel would be uneconomical, it may be preferable to make such panels of wrought timber, laminated board or the like as indicated at 39 (Fig. 3) and to provide appropriately grooved metal edging pieces or inserts 40 which will allow such odd sized panels to be interlocked with the standard panels 10 or with the corner pieces or soldiers. Moreover, while reference has specifically been made above to the welding of the panels, the parts of the latter may be secured together in any desired manner, for example, by rivetting or even by adhesives.

In the case of a single sided erection, as illustrated in Fig. 4, that is, where only one set of shuttering is employed, the soldiers 11 may be retained in the required position during the initial or set-up stage by means of struts attached to the cleats or transverse bars 24. $1ch struts may conveniently be formed by tubular scafiolding members attached to the cleats by standard coupling or connector devices employed in the erection of tubular scaffolding. In the case of shuttering set up in a single sided manner, extra strength is obtained by afifixing standard scafiold tubing 41 to the cleats 24 of the soldiers by means of standard fittings 42 normally employed with tubular scaffolding, as shown in Fig. 4. Retention of the successive course of panels to the concrete for subsequent re-erection of the lowermost course on the top course is effected, in this case, by means of loop ties instead of the spacer ties 36 which are employed in the assembly shown in Fig. 1.

The shuttering embodying the invention is also adapted for use in cantilever forms for the type of concrete pouring employed during the construction of dams, hydroelectric works, foundations and other projects using mass concrete in depth. In such cases, an additional interlocking foot section 43 (Fig. 4) is provided for the lowermost section of each soldier 11, and, to facilitate the stripping and replacing of shuttering on sloping surfaces, such as, downstream faces of dams, such foot sections may be fitted with aligning devices and/or trailing;

- i) v Wheels or the like (not shown) to prevent damage to green concrete. As indicated above, in order to strengthen the soldiers for extra depth of concrete to be poured,

standard scaffold tubing 41 may be aifixed to the soldier sections by means of standard fittings 42 normally employed with tubular scaffolding, and such bracing tubing is also similarly attached to the foot sections 43.

The shuttering embodying the invention is also adaptable for use in the construction of curved walls on vertical structures, but in such cases the vertical soldiers 11 are omitted. In this case, however, as illustrated in Fig. 5, the panels 10 are turned on end, that is the length of each panel will extend vertically. In addition to the panels the spacing or bonding elements 25 are also employed, such elements being disposed at the upper and lower ends of each panel. The bonding elements 25 at the upper ends of the panels 10 will provide means, whereby a second course of panels may be located on the first course if such second course is necessary. In order to produce a chordal effect, the panels may be hingedly interconnected, such hinge connections being conveniently associated with the spacing or bonding elements 25. For example, a fitting or bracket may be provided which is indicated generally at 44 and which com- :prises a plurality of hingedly interconnected sections having depending tongues or projections adapted to engage in the recesses 26 present in the then upper edges of the spacing or bonding elements 25. The fitting 44 incorporates locking means indicated generally at 45 to ensure that the panels may be disposed and retained in the required angular relationship with respect to each other. In such cases, retention of the panels to the con- 'crete to permit subsequent climbing, that is, re-erection of the lowermost course of panels as the uppermost course of panels, will be effected by means of loop ties associated with all or only some of the panels.

The shuttering embodying the invention may also be adapted for the forming of curved tunnel linings and the like, as illustrated in Fig. 6. In such cases, the shuttering panels 10 with the spacing or bonding elements 25 interposed therebetween in each course, but Without soldiers 11, are afiixed to specially constructed ribs 46. The panels 10 are fixed to the ribs by means of button headed bolts 47 or some other device applied through the hole 48 in a spacer or bonding element 25. As indicated above the hole 48 in each of the elements 25 may be used, when the shuttering is erected in spaced relation to define a space into which concrete may be poured, as indicated in Fig. l, to allow for the insertion of the spacer ties 36. The free ends of the panels 10 forming the ends of the unit may be securely fixed one to the other along the periphery of the tunnel or the like by end plates located in a groove or recess in the vertical edges of the appropriate panel. The panels will, in this case, be constructed generally in the manner hereinbefore described, but with only one vertical edge of each panel having a tongue, and the other vertical edge having a groove or recess. As shown inFig, 7, two units of forms may be joined together in end-toend relationship by means of plates 49 similar in construction to the end plates mentioned above, but constructed in such a manner that they may be securely fixed on to the other by means of Anti-Luce tailboard fittings indicated at 50 and disclosed in detail in the specification of British Patent No. 680,850, or some :such device. The shuttering arrangement described above will in effect follow the profile of the curved tunnel or the like in chords equal to the height or width of the panels 19.

In addition to the previously described shuttering components it is also proposed to provide sofiit panels,] as shown in Fig. 8, which are of similar but' lighter construction than the panels 10 and are intended for supporting the underside of suspended concrete floors, slabs and the like during construction. For such work a pluor substantiallyU-shaped cross-section, and certain of such strips are so positioned in relation to the edges of the sheets 51 that the assembled panel will have grooved or recessed edges adapted to .receive small timber sections or springdeviceslsuch as are indicated at 53, or other means which will serve to effect interlocking of adjacent panels. The spring devices 53 also form a convenient means of keying the forms together to enable removal of the forms as a complete sheet.

The shuttering above described has the advantage that while it is relatively light it possesses great strength. Furthermore, by reason of the fact that the panels and bonding elements arereversible, one exposed face thereof can be cleaned and oiled so as to be ready-for subsequent use while the panel or element is intact in use, and thus, since both faces of the panels'are used alternatively, the shuttering will have a longer useful life. The design also ensures ease of erection and dismantling and, moreover, since there are no small; loose parts, such as keys or the like, there will be a saving in maintenance costs and increased convenience in use.

I claim: 7 v 7' e l. A shuttering assembly for forming concrete comprising a plurality of rectangular panels arranged in successive courses and having substantially equal thickness and vertical and horizontal edges, said panels having means along their opposed horizontal edges which are interengageable along the divisions between said successive courses to ensure alignment of the latter, a plurality of uprights spaced apart in; the direction along said courses and having. projecting portions interposed between the vertical edges of adjacent panels of alternate courses while the panels of the other courses extend across said uprights between said projecting portions of the latter, and spacing elements interposed between the vertical edges of the panels in said other courses, each of said spacing elements having the same thickness and vertical dimension as said panels and a horizontal dimension equal to that of said projecting portions so that the panels of said other courses are "uniformly staggered with respect to the panels of said alternate courses.

2. A shuttering assembly as in claim 1; wherein each 'of said panels has tongues along both of the vertical edges thereof and said means along their opposed horizontal edges are a tongue and groove, respectively, each of said spacing elements having grooves along both vertical edges thereof receiving said tongues along the vertical edges of adjoining panels in said other courses, while the opposedhorizontal edges of said spacing element have a tongue and groove, respectively, extending therealong and receiving the groove and tongue of panels vertical dimension equal to the thickness and 'vertical' dimension, respectively, of said panels and defines an operative surface flush with operative surfaces of said panels in all of said courses, each of said projecting portions further having laterally directed flanges along the opposite vertical edges thereof engaging said tongues along the adjoining vertical edges of said panels in said alternate courses for locating and supporting the latter.

4. A shuttering assembly as in claim 3; further compri ing loc ngme n c ied by ac of's up i h and movable into locking engagement with said adjoining vertical edges of the panels located against said laterally directed flanges;- V v I 5. A shuttering assembly asin claim' 3; wherein said panels and said spacingelernents have'smooth forming faces at the opposite sides thereof so-that said panels and spacing elements are reversible to permit the cleaning of one forming face while the other forming face is used to form concrete, I

6. A shuttering assembly as in claim 3; wherein said tongues along the vertical edges of the panels have apertures in the opposite sides thereof and said flanges of the projecting portions of said uprights include projections entering into said apertures at the confronting sides of said tongues along the vertical edges of the panels in said alternate courses; and further comprising locking elements carried by each of said uprights and movable to operative positions in which saidlocking elements enter the apertures at the sides of said tongues remote from said flanges andpositively lock said panels of the alternate courses with respect to said uprights.

7. A shuttering assembly asin claim 3; wherein each of saiduprights includes a plurality of elongated sections each having a length equal to the vertical dimension of two adjacent courses of said panels, and with a single projecting portion extending along the" lower half of said length, and separable means securing together said sections in end abutting relation. 7 i

8. A shuttering assembly as in claim '7'; wherein each of said sections has opposed sides with lateral openings therein and said separable means securing together said sections includes plates disposed against said opposed sides of the sections at the adjacent ends of the latter and including tapered dowels entering said lateral openings, anda bolt passing laterally through said section and said plates to hold the latter against saidr s ectionsp 9. A shuttering assembly as in claim7; further comprising a cleat on each of said sections adaptedfor connection to tubular scaffolding for bracing the shuttering assembly. 7

10 A shuttering assembly as in claim 7; wherein each of said panels includes a pair of parallel, spaced apart sheets having the same dimensions, and U-shaped, channel-defining members extending between said sheets and secured to the latter to form a rigid; unitary structure therewith, certain of said channel defining members extending along said horizontal andvertical edges of each panel, with the members extending along both vertical edges and one horizontal edge having their channel opening inwardly to define said tongues and with the member extending along the other horizontal edge having its channel opening outwardly to define said groove.

11. A shuttering assembly as in claim 7; wherein each of saidrspacing elements includes a pair of parallelspaced apart sheets having the same dimensions, and U-shaped, channel defining members extending between said sheets and secured to the latter at least alongthe vertical and horizontal edges of said sheets to form a unitary, rigid structure therewith, the shannel defining members along both vertical edges and one horizontal edge of each spacing element having their channels opening outwardly to define. said grooves, while the channel defining member along the other horizontal edge of said spacingelement has its channel opening inwardly to define saidtongue.

' References Cited in the file of this patent UNITED STATES PATENTS (Other references on followiug page) V 9 UNITED STATES PATENTS Anderson Aug. 21, 1934 Slayter et a1 Dec. 20, 1938 Summers Mar. 2, 1943 Rumble July 8, 1952 5 Jelks Feb. 3, 1953 10 Faye Nov. 3, 1953 Rumble Sept. 25, 1956 FOREIGN PATENTS Italy Feb. 22, 1943 Belgium Apr. 30, 1951

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