The present invention relates to an adjustable concrete battery casting mould for use in the production of concrete construction elements. In particular, the present invention relates to an adjustable concrete battery casting mould for the production of concrete L-shaped structures of various thicknesses.

BACKGROUND OF THE INVENTION

Concrete is a very durable, low maintenance material with an inherent strength in compression. In addition, it can provide thermal mass, thus reducing the energy consumption of the resulting buildings once in operation. For these reasons, concrete is a very popular choice of building material, particularly where speed of construction is a factor.

Methods of preparation of concrete sections or elements for use in construction are well known and first involve the assembly of a formwork. Such a formwork comprises a temporary mould into which concrete is poured and formed. One such conventional formwork comprises shuttering which is often constructed on site using timber and plywood. Such formworks or temporary moulds are typically assembled on-site as it would be prohibitively expensive and difficult to transport large pre-formed concrete elements from the point of manufacture to the constructions site perse.

Formworks known as battery moulds are suitable for the vertical production of multiple slab elements. Such battery moulds are assembled on-site and used to cast multiple wall structures of single thickness and provide a relatively large mould area on a relatively small base area. This makes them particularly suitable for use on-site where space may be limited. One limitation, however, is that once assembled, the shuttering accommodates the casting of walls of fixed thickness.

Where wall panels of different thicknesses are required, a separate concrete battery casting mould is required for casting each thickness of wall panel. Thus, structural engineers, when designing a concrete building, are faced with the budgetary limitation of restricting the number of different thickness wall panels in a design of a building structure, in an effort to reduce the number of battery casting moulds required. Consequently, concrete building design is either significantly limited by these requirements or very expensive where these requirements are ignored. Further, having numerous battery casting moulds to accommodate multiple different wall thicknesses requires space, which is itself often limited at a construction site. Thus, spatial limitations also act to restrict the number of battery casting moulds that can be present on-site, thereby constraining building design, even if budgetary constraints are a lesser issue.

There is therefore a need for an adjustable concrete battery casting mould for forming concrete structures on-site, that can be used to produce concrete wall panels of differing wall thickness, thereby providing greater design freedom for structural engineers without the conventional increase in costs and space on-site to accommodate multiple battery moulds.

SUMMARY OF THE INVENTION

The present invention seeks to address the problems of the prior art.

Aspects of the present invention are set out in the attached claims.

According to an aspect of the present invention, there is provided a battery mould for casting concrete, the battery mould comprising a plurality of leaf elements, each leaf element comprising an L-shaped body defining a first planar leg element defining a first plane x, and a second planar leg element defining a second plane y, the second planar leg element extending from the first planar leg element in a direction transverse to the first plane x, the first planar leg element defining a first end surface distal to the second planar leg element and the second planar leg element defining a second end distal to the first planar leg element, each of the first and second end surfaces having a capture locking bolt engagement portion; a plurality of capture bolt assemblies, each capture bolt assembly comprising a substantially planar capture base plate defining a leaf element engagement portion for engagement with a respective locking bolt engagement portion, a locking bolt retaining plate extending from the body, the locking bolt retaining plate defining an aperture for receiving a locking bolt therethrough, a locking bolt dimensioned to extend through the aperture, and locking bolt engagement portion extending from the capture base plate, the locking bolt engagement portion configured to receive a portion of the locking bolt therethrough; and a plurality of discrete removable spacers, each spacer having a body defining a predetermined distance (d); and wherein, in use, the leaf elements are aligned with one another such that i) respective first planar leg elements are parallel to one another; ii) respective second planar leg elements are parallel to one another; iii) respective first end surfaces are aligned along a first common plane; iv) respective second end surfaces are aligned along a second common plane; v) at least a portion of a spacer is located between adjacent leaf elements to space adjacent leaf elements distance (d) apart from one another; vi) the leaf element engagement portion of each capture bolt assembly is engaged with a respective locking bolt engagement portion so as to mount each capture bolt assembly on a respective leaf element such that the locking bolt extends in a direction parallel to the plane of the planar captive base plate; and vii) where there are adjacent leaf elements, a portion of the locking bolt of one capture bolt assembly is securely received within the locking bolt engagement portion of an adjacent capture bolt assembly.

Thus, when concrete is poured between the leaf elements, the resulting structure will be L-shaped with a wall thickness of distance (d).

The battery mould may be a right-hand casting mould to produce right-handed L- shaped concrete panels i.e., the short leg of the L-shaped panel is on the right hand side of the long leg of the L-shaped panel when viewed from the end of the long leg. Alternatively, the battery mould may be a left-hand casting mould to produce left-handed L-shaped concrete panels i.e., where the short leg of the L- shape panel is on the left hand side of the long leg of the L-shaped panel when viewed from the end of the long leg.

All buildings built with L-shaped panels will be comprised of approximately 50% right hand panels and approximately 50% left hand panels. Therefore, two mirror image battery moulds may be located adjacent one another along their respective long legs with a central walkway provided therebetween to allow a user access to pour each set of panels sequentially. It is important to note that the spacers are discrete i.e., not integral with, for example, the leaf element or the capture bolt assembly. Instead, it is to be appreciated that the spacers are releasably secured in place between leaf elements, when in use. For example, one or more spacers may be releasably secured to one or both adjacent leaf elements to maintain a desired distance between them.

As the spacers are not integral with the capture bolt assembly, it is clear that spacers of differing body sizes, thereby defining differing predetermined distances (d), may be used without having to swap the capture bolt assembly for another of differing dimension. The only consideration is that the locking bolt used in the capture bolt assembly is of sufficient length to engage with an adjacent capture bolt when the spacer of largest distance (d) is used, thereby allowing a range of differently dimensioned spacers to be used with the same capture bolts. Also, it is to be appreciated that all spacers located between a single pair of adjacent leaf elements should have a body defining an identical distance (d) in order to define a distance (d) between the adjacent leaf elements.

In one embodiment, each capture bolt assembly is mounted in the opposite orientation to each adjacent capture bolt assembly and each locking bolt extends away from its respective planar capture base plate in a common direction to the locking bolts of adjacent capture bolt assemblies. In other words, the leaf engagement portions of adjacent capture bolt assemblies are oriented about 180° relative to adjacent capture bolt assemblies. This allows identical capture bolt assemblies to be used without the locking bolt extending through the aperture of a first capture bolt assembly fouling with the locking bolt of an adjacent capture bolt assembly that is received within the locking bolt engagement portion of the first capture bolt assembly. By using opposing orientations for adjacent capture bolt assemblies, the aforementioned fouling of locking bolts is avoided whilst retaining alignment of adjacent locking bolts, such that all locking bolts extend parallel to one another. This contributes to strengthening the structure of the battery mould.

In a further embodiment, each of the first and second end surfaces comprises a pair of capture locking bolt engagement portions spaced apart from one another and wherein, in use, each capture locking bolt engagement portion is engaged with a respective leaf element engagement portion such that two capture bolt assemblies are mounted on each of the first and second end surfaces. Again, this contributes to strengthening the structure of the battery mould as well as stabilising the position of each leaf element relative to adjacent leaf elements.

In a further embodiment, each spacer comprises a first leaf element engagement member for engaging with a leaf element and a second leaf element engagement member for engaging with an adjacent leaf element, such that, in use, the spacer is located between adjacent leaf elements and engages with both said leaf elements to maintain a predetermined distance (d) between adjacent leaf elements.

It is to be appreciated that the first and second leaf element engagement members may comprise abutment surfaces and the spacer is located between adjacent leaf elements which are then pushed together, thereby holding the spacers in place between adjacent leaf elements. However, it is preferred that the battery mould is further provided with securing means to retain the spacers in place between adjacent leaf elements to retain adjacent leaf elements at a maximum distance (d) apart. Such securing means preferably comprise a bolting arrangement to facilitate bolting of the spacer to one or both of the first and second leaf elements. However, it is to be appreciated that other forms of securing, such as releasable fastenings, catches, clips, or frictional fit may be used in addition to, or as an alternative to, bolting arrangements.

In one embodiment, the battery mould further comprises mechanical or hydraulic compression means to bias the adjacent leaf members towards one another to securely retain the distance (d) between adjacent leaf members. This securely locates and retains the assembled battery mould in place prior to the pouring of concrete between adjacent leaf elements to form L-shaped walls of predetermined thickness corresponding to the predetermined distance (d) defined by the body of the spacer(s) located between adjacent leaf elements.

It is to be appreciated that the spacers are removable, such that they can be interchanged with other spacers defining a different dimension (d) when a different wall thickness is to be cast between adjacent leaf elements.

In one embodiment, the plurality of spacers define a selection of predetermined distances (d). This allows a single concrete battery casting mould to be used with a selection of spacers defining specifically selected distances (d) to produce a plurality of L-shaped wall structures, each of which can be of an individually predetermined wall thickness. Thus, a single battery mould may be used to produce a plurality of identical L-shaped walls, or the same battery mould may employ a variety of stop members defining different distances (d) to produce a plurality of L-shaped wall structures with differing wall thicknesses (d).

In a further embodiment, a group of two or more spacers are located between adjacent leaf elements to space them apart from one another a predetermined distance (d) wherein each group of two or more spacers define the same predetermined distance (d). This ensures a consistent wall thickness throughout the resulting cast concrete wall panel.

Each group of two or more spacers located between a pair of adjacent leaf elements may differ in predetermined distance (d) from one or more other groups of spacers located between a different pair of adjacent leaf elements in order that a single battery mould may produce cast concrete wall structures of different thicknesses.

In one embodiment, the battery mould further comprises a track on which leaf elements are slidably mounted. As the individual leaf elements are extremely heavy and unwieldy, having the leaf elements mounted on the track facilitates the movement of adjacent leaf elements relative to one another, both when moving adjacent leaf elements closer to one another to assemble the battery mould for the production of L-shaped wall structure of desired wall thicknesses, and when moving adjacent leaf elements apart from one another after poured concrete between leaf elements has cured, in order to release the cast wall panels from the battery moulds. One of the leaf elements is preferably fixed relative to the track and the remaining leaf elements are all independently movable along the track.

The battery mould may further comprise a soffit plate arrangement for releasable engagement with each respective leaf element. The position of the soffit plate arrangement relative to each respective leaf element is selected based on the height of the desired resultant concrete panel.

A second aspect of the present invention provides a first battery mould in accordance with a first aspect of the present invention, and a second battery mould, the second battery mould being a mirror-image of the first battery mould, wherein the first and second battery moulds are arranged adjacent one another to form a T-shaped battery mould assembly.

In one embodiment, two such T-shaped battery mould assemblies are arranged adjacent one another to form an X-shaped battery mould assembly.

A walkway may be provided between adjacent battery moulds.

The battery mould assembly is capable of producing multiple L-shaped wall structures of a variety of predetermined thicknesses (d), the predetermined thickness of each wall structure being determined by the predetermined distance defined by the body of the selected spacers located between the adjacent leaf members that form the mould for each respective wall structure.

Before concrete pouring and casting takes place, the soffit plates referred to above are set to the required height of the panel to be cast on each respective leaf element.

The moulds are then set sequentially starting with the first panel mould or cell. The first leaf element is typically provided fixed in place relative to the adjacent leaf element. The adjacent leaf element is brought to within a lm to 2 m distance from the first leaf element. A steel reinforcement, required to be incorporated in the finished concrete wall panel, is then placed on top of the soffit plate. Once the reinforcement is in place, vertical stop ends are positioned between the adjacent leaf elements and spaced a selected distance from the edge of contact between the first and second leg elements so as to define the horizontal dimensions of the subsequently cast walls. Thus, concrete poured between adjacent leaf elements can only expand horizontally between adjacent leaf elements as far as each of the respective vertical stop ends. In this way, the location of the respective vertical stop ends determines the length of each leg of each of the respective resulting cast concrete wall panels.

The next step is to locate the spacers in position between the adjacent leaf elements. This is done by screwing the respective spacers in place relative to the first leaf element. Once this has been securely achieved, the second leaf element is moved towards the first leaf element as close as the spacers allow. The capture bolts of the first leaf element are then fastened in place i.e., the locking bolt of each capture bolt assembly of the first leaf element is securely fastened in place within the locking bolt engagement portion of the adjacent capture bolt assembly.

It is to be noted that when assembling the battery moulds in preparation for producing walls of desired thickness, the spacers are selected to provide the desired predetermined distance (d) between adjacent leaf elements.

As this point, the cell is described as being 'set'. This process is then repeated sequentially until all cells of the battery mould are set. For example, where there are 7 panels to be cast, there will be 8 leaf elements, the first of which may be fixed in place relative to the frame, and the other 7 of which will be slidable relative to one another.

If the battery mould assembly comprises more than one battery mould, then the whole process is repeated for each battery mould in the assembly until all cells are set.

Once all cells are set, the hydraulics are pressurised to bias adjacent leaf elements towards one another, locking bolts are checked for tightness and long ties are fastened to retain the cells in position.

Concrete can then be poured sequentially into the cells of the battery mould until all cells are full. A walkway may be provided between adjacent battery moulds in a battery mould assembly comprising more than one battery mould. A user would simply use the walkway for access to pour concrete sequentially into each cell of one battery mould, before turning and repeating the concrete pouring process with the adjacent battery mould.

Once the concrete has sufficient set, the resultant concrete panels are released from the cells by reversing the assembly process so as to separate adjacent leaf elements.

BRIEF DESCRIPTION OF THE DRAWINGS

Figure 1 is a perspective view of an embodiment of a battery mould in accordance with a first aspect of the present invention;

Figure 2 is a perspective view of a capture bolt assembly of the battery mould of figure 1; Figure 3 is a perspective view of a portion of the battery mould of figure 1;

Figure 4 is an enlarged perspective view of a portion of the battery mould of figure 1;

Figure 5 is an end elevation of a portion of the battery mould of figure 1; and

Figure 6 is a view of an embodiment of a battery mould assembly in accordance with a second aspect of the present invention comprising two of the battery moulds of figure 1.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

Figure 1 shows a battery mould 10 for casting concrete structures, the battery mould 10 comprising a plurality of aligned leaf elements 12. One leaf element (indicated with an 'F' in the figures) is fixed in place, with the remaining leaf elements 12 being slidably mounted on track 14 via mounting elements 16 e.g., wheel and rack and pinion assemblies, located at the base of each leaf element 12

Each leaf element 12 comprises an L-shaped body defining a first leg element 18 defining a first plane (x) and a second leg element 20 defining a second plane (y). Second leg element 20 extends away from first leg element 18 in a direction transverse to first plane (x). First leg element 18 defines a first end surface 22 distal to second leg element 20 and second leg element 20 defines a second end surface 24 distal to first leg element 18. A pair of capture bolt assemblies 26 is provided on each of the first and second end surfaces 22, 24 of each leaf element 12.

Figure 2 shows a capture bolt assembly 26 comprising a planar capture base plate 28 defining a leaf element engagement surface 30 provided with apertures through which headed bolts 32 extend to secure the capture bolt assembly 25 to a leaf element 12. A first locking bolt retaining plate 34 extends from planar capture base plate 28 in a transverse direction to leaf element engagement surface 30, first locking bolt retaining plate defining aperture 36 through which a locking bolt 38 extends in a direction parallel to the plane of leaf element engagement surface 30. Locking bolt 38 has length (I) as indicated in Figure 2. A second locking bolt retaining plate 40 also extends from planar capture base plate 28 in a transverse direction to leaf element engagement surface 30.

Second locking bolt retaining plate 40 comprises an open channel arranged to receive the locking bolt 38 of an adjacent capture bolt assembly 26 (not shown in figure 2) therethrough during use. Once received within the open channel of the second locking bolt retaining plate 40, locking bolt 38 is retained in place by applying a securing nut 39 to the end of locking bolt 38 and tightening it to securely fasten adjacent leaf elements together (see Figure 5).

Figures 3 and 4 show multiple capture bolt assemblies 26 mounted on respective leaf elements 12, showing how the locking bolt 38 of one capture bolt assembly 26 is received within second locking bolt retaining plate 40 of an adjacent capture bolt assembly 26.

A pair of spacers 42 are located between adjacent first leg elements 18 and between adjacent second leg elements 20. Spacers 42 are arranged to space respective leg elements of adjacent leaf elements 12 apart by a specific predetermined distance (d). This distance (d) will correspond to the width of the wall structure subsequently produced by pouring concrete into the space between adjacent leaf elements 12. Adjacent leaf elements 12, once secured in position relative to one another, are described as a cell into which concrete is poured during the wall structure casting process.

It will be appreciated that a single battery mould 10 may be used to produce multiple wall structures of differing thicknesses by locating spacers 42 defining differing distances (d) between different pairs of leaf elements 12. However, it is to be appreciated that the distance (d) defined by spacers 42 located between a single pair of adjacent leg elements must remain the same. This produces a wall structure with walls of a constant thickness.

In the embodiment shown in the figures, one battery mould 10 can produce a plurality of wall structures comprising two panels, one of which may be longer than the other. In the embodiment shown in figure 1, each resulting wall structure is a right-handed panel i.e. when viewed from the end of the longer panel, the shorter panel is on the right-hand side.

In figure 6, a battery mould assembly 44 is shown, comprising two mirror image concrete battery casting moulds 10. One produces right-handed panels and the other produces left-handed panels. Typically, concrete building structures are produced using approximately equal numbers of left-handed and right-handed panels. Therefore, the advantages are clear in being able to cast both left- handed and right-handed panels using a single battery mould assembly 44 as shown in figure 6. Leaf elements 12 indicated by 'F' (see Figure 3) are fixed in place relative to track 14, with each of the remaining leaf elements 12 being slidable with respect to track 14. Adjacent leaf elements 12, once secured in position relative to one another, are described as a cell into which concrete is poured during the wall structure casting process. The two battery moulds 10 are placed back-to-back such that respective first leg elements 18 of fixed leaf elements 12 marked with 'F' are parallel to one another, with a walkway for a user located therebetween.

Figure 6 shows a battery mould assembly 44 comprising a plurality of battery moulds 10 as previously described. The battery mould assembly 44 allows a significant number of wall structures to be produced on-site, using a compact arrangement which can be adjusted to accommodate selected spacers 42 to produce a desired number of wall structures of selected thicknesses.

This is a significant advantage over conventional battery moulds for casting concrete, which can only cast wall structures of a single thickness. If a wall structure of a different thickness is required then, conventionally, a separate battery mould would be required to achieve this. Once assembled in place, conventional battery moulds cannot be adjusted to accommodate the production of wall structures of different thicknesses.

By contrast, it is a simple process to adjust the battery mould of the present application to replace selected spacers 42 with other spacers 42 of selected different dimension defining a different distance (d) to produce wall structures of different predetermined thicknesses. It is also possible to locate spacers 42 defining a first distance (d) between one pair of adjacent leaf elements 12 and spacers 42 defining a second different distance (d) between another pair of adjacent leaf elements 12 within the same battery mould.

Thus, not only can a battery mould 10 in accordance with the present invention produce wall structures of selected wall thickness, such a battery mould 10 can also produce a selection of differing thickness wall structures within the one casting process. This increases the flexibility of a design, whilst reducing the number of concrete battery casting moulds required on-site, which is a major saving in both time and expense during a construction project. Further, the on site space required to produce concrete wall structures is significantly reduced as a single battery mould assembly can be used to produce multiple wall structures with differing thicknesses. This advantage is further extended by connecting multiple battery moulds 10 to provide a compact battery mould assembly 44 in accordance with the present invention which is able to produce a large number of wall structures of varying selected wall thicknesses on-site, and which can be adjusted between casting events to change the selected thicknesses of the wall structures produced, as required.