A CASTING MOULD

The present invention relates to a casting mould for use in the construction industry and in particular to a casting mould for protruding components of a building.

The conventional method of casting a mould for a protruding component of a building such as a wall capping, a chimney capping or a parapet is to construct a mould box around and on the masonry using a number of different wooden profiles. This method is time consuming as the forms have to be constructed and can not be removed for a minimum of three to four days after pouring the concrete. The second and most common method of implementing such protruding components of a building is to use pre-cast concrete products. These pre-cast concrete products often require cranes or similar mechanical lifting apparatus to move them into place due to their extreme weight. Furthermore, such concrete products are produced in standardised sizes and are therefore unsuitable for bespoke applications. It is an object of the present invention to obviate or mitigate the problems outlined above.

Accordingly, the present invention provides a casting mould comprising an open profile member having a mounting edge mountable to masonry and a free edge, the free edge of the open profile member having means for receiving stabilising means. Preferably, the casting mould is a permanent fixture left as an element of the finished structure.

Advantageously, the casting mould is light in weight so that no mechanical lifting machinery is required making the casting mould user friendly. Furthermore, the casting mould significantly reduces the time taken to implement a mould onto a building. The casting mould is manufactured in a range of shapes and sizes and is therefore suitable for a wide range of applications unlike conventional pre-cast products. The casting mould of the present invention is suitable for both existing and new builds and can be used in the pre-cast fabrication industry to create new mould boxes with various designs and shapes.

Preferably, the open profile member of the casting mould is manufactured from weather proof material such as fibre reinforced plastics materials.

Ideally, the open profile member is an elongate member. Preferably, the open profile member is an angle member.

Ideally, the casting mould comprises at least one open profile angle member and at least one open profile elongate member.

Preferably, the casting mould comprises a plurality of open profile angle members and a plurality of open profile elongate members. Ideally, means are provided for releasably connecting an open profile angle member and an elongate open profile member together.

Preferably, means are provided for fixing an open profile angle member to the masonry.

Ideally, means are provided for fixing an elongate open profile member to the masonry.

In a first embodiment of casting mould, there is provided four open profile angle members and four open profile elongate members.

In the first embodiment, the open profile angle members and the open profile elongate members comprise a base portion having a perforated edge for receiving masonry fixing members for fixing the open profile members to the structure of the chimney.

In the first embodiment, an inclined portion of the open profile members extends at an obtuse angle from the opposite end of the base portion to the perforated edge and terminates with a top wall portion folding back over the top of the inclined portion toward the perforated edge substantially parallel to the base portion. In the first embodiment, an elongate top wal l portion ridge extends from the underside of the top wall portion and together with the folded over portion between the inclined portion and the top wall portion defines a top wall portion elongate cavity formed for receiving top

wall portion jointing dowels for connecting and holding adjacent open profile members together

In the first embodiment, the base portion has a base portion elongate ridge and a spaced apart L-shape flange extending from the upper surface of the base portion and defining an elongate base portion cavity there between for receiving base portion jointing dowels for connecting and holding adjacent open profile members together

In the first embodiment, the open profile angle members comprise two elongate open profile members mitred together It will also be appreciated that the open profile angle members may have an included angle of greater than or less than ninety degrees The end face profiles of the open profile members are identical although it is envisaged that non identical end face profiles can be used

In the first embodiment, a stabilising means can be used between apertures of opposing and/or adjacent open profile members to provide additional stability

Ideally, a second embodiment of casting mould comprises open profile members mountable along the surface of the masonry of a wall

In the second embodiment, one edge of the open profile member is fixable to the masonry via apertures and a free edge of the open profile members has apertures for receiving stabilising members The casting mould is a permanent fixture left as an element of the cast wall capping In the second embodiment of casting mould, there is provided two opposing open profile elongate members and a T-shaped ancho r member being centrally mounted on the top of the wall between the two opposing open p rofile elongate members

In the second embodiment, the T-shaped anchor member has three perforated edges Ideally, the T-shaped anchor member lies upside down on its head with its central leg protruding into the air, and the perforated edges define anchor member apertures

In the second embodiment, the open profile elongate members comprise a base portion having a perforated edge for receiving masonry fixing members for fixing the open profile members to the structure of the wall

In the second embodiment, an upright portion of the open profile members extends substantially orthogonally from the opposite end of the base portion to the perforated edge and terminates with a top wall portion folding back over the top of the upright portion toward the perforated edge substantially parallel to the base portion and terminates with a downwardly depending lip substantially parallel to the upright portion.

In the second embodiment, the base portion has a base portion elongate ridge, also acting as a rain water break and a spaced apart L-shape flange extending from the upper surface of the base portion and defining an elongate base portion cavity there between for receiving base portion jointing dowels for connecting and holding adjacent open profile members together.

In the second embodiment, a stabilising means can be used between apertures of opposing open profile members and/or between apertures of open profile members and apertures of the perforated end of the central leg of the inverted T-shaped anchor member to provide additional stability. Concrete is poured into the casting mould and allowed to set with the casting mould remaining in place after the concrete sets. The open profile members and anchor members of the casting mould are manufactured from weather proof material such as fibre reinforced plastics material. The end face profiles of the open profile members are fitted with end caps (not shown) to complete the decorative appearance.

A third embodiment of casting mould comprises open profile members mountable along the vertical surface of the masonry of a wall for forming a decorative parapet mould. In the third embodiment, an upright portion of the open profile member is fixable to the masonry via apertures and a free edge of the open profile members has apertures for receiving stabilising means. The casting mould is a permanent fixture left as an element of the cast window sill. In the third embodiment, there is provided an open profile elongate member and end caps to be fitted onto the end face of the open profile elongate member.

In the third embodiment, the open profile elongate members comprise an upright portion having a perforated edge defining apertures for receiving masonry fixing members for fixing the open profile member to the structure of the wall

In the third embodiment, a base portion extends substantially orthogonally from the opposite end of the upright portion to the perforated edge and terminates with an inclined portion

In the third embodiment, the inclined portion of the open profile member extends at an obtuse angle from the opposite end of the base portion to the upright portion and terminates with a top wall portion folding back over the top of the inclined portion toward the perforated edge substantially parallel to the base portion

In the third embodiment, an elongate top wall portion ridge extends from the underside of the top wall portion and together with the folded over portion between the inclined portion and the top wall portion defines a top wall portion elongate cavity formed for receiving top wall portion jointing dowels for connecting and holding adjacent open profile members together

In the third embodiment, the free end of the top wall portion has top wall portion apertures

In the third embodiment, the base portion has a base portion elongate ridge extending out of the base portion defining a groove therein which acts as a rain water break In the third embodiment, an elongate flange exten ds from the upright portion proximal to the apertures and the free edge of the elongate flange is perforated with apertures

In the third embodiment, a stabilising means can be used between apertu res of the elongate flange and between top wall portion apertures of the open profile member to provide additional stabili ty Concrete is poured into the casting mould and allowed to set with the casting mould remaining in place after the concrete sets

In a fourth embodiment, there is provided a casting mould for casting a window sill comprising a first elongate open profile member and a second elongate open profile member

In the fourth embodiment, the second elongate open profile member has a base portion and an elongate upright lip extending substantially orthogonally from one elongate edge of the base portion

In the fourth embodiment, an upright elongate portion extends substantially orthogonally from the other elongate edge of the base portion in the same direction as the upright lip and has a window sill supporting platform portion extending substantially orthogonally from the upright portion towards the upright lip

In the fourth embodiment, the free edge of the window sill supporting platform portion and the free edge of the upright lip is perforated with apertures The invention will now be described with reference to the accompanying drawings which show by way of example only five embodiments of a casting mould in accordance with the invention In the drawings -

Figure 1 is a partial vertical sectional view of a chimney supporting a conventional wooden mould box, Figure 2 is a partial vertical sectional view of a building supporting a conventional wooden mould box,

Figure 3 is partial vertical sectional view of a chimney supporting a first embodiment of casting mould of the present invention,

Figure 4 is a plan view of the first embodiment of casting mould supported on a chimney, Figure 5 is an end elevational view of an elongate open profile member of the first embodiment of casting mould,

Figure 6 is a perspective view of the elongate open profile member of Figure 5,

Figure 7 is a partially cutaway perspective view of a pair of elongate open profile members of

Figures 5 and 6 and an open profile angle member, Figure 8 is a partial perspective view of a second embodiment of casting mould,

Figure 9 is a vertical sectional view of the casting mould of Figure 8,

Figure 10 is a second vertical sectional view of the casting mould of Figure 8,

Figure 1 1 is an end elevational view of an elongate component of the second embodiment of casting mould,

Figure 12 is a partial perspective view of an elongate component of the second embodiment of casting mould, Figure 13 is a partial vertical sectional view of a third embodiment of casting mould,

Figure 14 is a partial perspective view of the third embodiment of casting mould of Figure 13, Figure 15 is a partial perspective view of a fourth embodiment of casting mould, Figure 16 is a second partial perspective view of the fourth embodiment of casting mould, Figure 17 is an end elevational view of a second elongate component of the fourth embodiment of casting mould of Figures 15 and 16,

Figure 18 is an end elevational view of an elongate component of the second embodiment of casting mould,

Figure 19 is a perspective view of an open profile angle member of a fifth embodiment of casting mould, Figure 20 is a partial perspective view of a house detailing the location of the five embodiments of casting mould of the present invention

Referring to the drawings and initially to Figure 1 , there is shown a brickwork/block work of a structure of a chimney 8 having a chimney pot 1 The chimney 8 supports face timber moulds 3 fillet timber moulds 4, soffit timber moulds 5 and soffit support timber moulds 6 which enclose the four faces of the chimney to provide a wooden mould for receiving concrete 2 which is poured there into This method of forming a chimney capping is time consuming as the wooden moulds 3, 4, 5 and 6 have to be constructed onto the chimney 8 using masonry fixings 7 and can not be removed for a minimum of three to four days after pouring the concrete 2 Figure 2 shows a brickwork/ block work wall 8 of a building such as a conservatory onto which a soffit support timber 6 is fixed using masonry fixings 7 A soffit timber 5 supports a face timber 3 and together with end pieces they define a mould for a sill into which concrete 2 is poured to form the sill This method of forming a window sill is also time consuming for the same reason that the wooden moulds 3, 5 and 6 have to be

constructed onto the wall 8 using masonry fixings 7 and can not be removed for a minimum of three to four days after pouring the concrete 2

Referring now to Figures 3 to 7, there is shown a first embodiment of casting mould indicated generally by the reference numeral 51 comprising open profile members 59, 61 mountable along the surface of the masonry 58 of a chimney One edge 55 of the open profile members 59, 61 is fixed to the masonry 58 via apertures 60 and a free edge 52 of the open profile members 59, 61 has apertures 53, see especially Figure 6 for receiving stabilising members, not shown The casting mould 51 is a permanent fixture left as an element of the cast chimney capping Figure 3 and Figure 4 show the brickwork/block work 58 of the chimney and a chimney pot 11

Advantageously, the casting mould 51 is light in weight so that no mechanical lifting machinery is required making the casting mould 51 user friendly Furthermore, the casting mould 51 significantly reduces the time taken to implement a mould onto a building The casting mould 51 is manufactured in a range of shapes and sizes and is therefore suitable for any application unlike conventional pre-cast products The casting mould 51 is suitable for both existing and new builds and can be used in the pre-cast fabrication industry to create new mould boxes with various designs and shapes

The first embodiment of casting mould 51 comprises four open profile angle members 59 and four open profile elongate members 61 Referring especially now to Figures 5 and 6, the open profile angle members 59 and the open profile elongate members 61 comprise a base portion 62 having a perforated edge 55 for receiving masonry fixing members 64 for fixing the open profile members 59, 61 to the brickwork/blockwork 58 of the chimney An inclined portion 65 of the open profile members 59, 61 extends at an obtuse angle from the opposite end of the base portion 62 to the perforated edge 55 and terminates with a top wall portion 67 folding back over the top of the inclined portion 65 toward the perforated edge 55 substantially parallel to the base portion 62 An elongate top wall portion ridge 69 extends from the underside of the top wall portion 67 and together with the folded over portion between the inclined portion 65 and the top wall portion 67 defines a top wall portion

elongate cavity 71 formed for receiving top wall portion jointing dowels 73 for connecting and holding adjacent open profile members 59, 61 together The base portion 62 has a base portion elongate ridge 75 and a spaced apart L-shape flange 76 extending from the upper surface of the base portion 62 and defining an elongate base portion cavity 77 there between for receiving base portion jointing dowels 78 for connecting and holding adjacent open profile members 59, 61 together The open profile angle members 59 comprise two elongate open profile members 61 mitred together It will also be appreciated that the open profile angle members 59 may have an included angle of greater than or less than ninety degrees The end face profiles of the open profile members 59, 61 are identical although it is envisaged that non identical end face profiles can be used

In use, four open profile angle members 59, four elongate open profile members 61 , masonry fixing members 64, top wall portion jointing dowels 73, base portion jointing dowels 78 and adhesive are delivered to the chimney region The members 59, 61 are fitted together and an operator fixes the open profile members 59, 61 onto the masonry 58 of the top surface of the chimney by driving the masonry fixing members 64 into the masonry 58 via the apertures 60 Jointing dowels 73, 78 are pushed into the top wall portion elongate cavities 71 and the elongate base portion cavities 77 of predetermined open profile members 59, 61 when these members 59, 61 have been carefully fixed in place with the respective adjacent top wall portion elongate cavities 71 in alignment and the respective adjacent elongate base portion cavities 77 in alignment The jointing dowels 73, 78 are pushed across the gap between adjacent members 59, 61 Adhesive is then applied between the jointing dowels 73, 78 and the adjacent members 59, 61 to fix them in place It will of course be appreciated that any other fastening means such as press fit male and female connectors can be provided on adjacent edges of the open profile members 59, 61 to form an interlocking structure prior to pouring the concrete 12 A stabilising arrangement such as one or more fastening ties can be tied between apertures 53 of opposing and/or adjacent open profile members 59, 61 to provide additional stability Concrete 12 is poured into the casting mould 51 and allowed to set with the casting mould 51 remaining in place after the concrete 12 sets The open profile

members 59, 61 of the casting mould 51 are manufactured from weather proof material such as fibre reinforced plastics material.

Referring to the drawings and now to Figures 8 to 12, there is shown a second embodiment of casting mould indicated generally by the reference numeral 251 comprising open profile members 261 mountable along the surface of the masonry 258 of a wall One edge 255 of the open profile member 261 is fixed to the masonry 258 via apertures 260 and a free edge 252 of the open profile members 261 has apertures 253, see especially Figure 8 for receiving stabilising members 254 see Figure 9 The casting mould 251 is a permanent fixture left as an element of the cast wall capping The second embodiment of casting mould 251 comprises two opposing open profile elongate members 261 and a T-shaped anchor member 259 being centrally mounted on the top of the wall between the two opposing open p rofile elongate members 261 The T-shaped anchor member 259 has three perforated edges The T-shaped anchor member 259 lies upside down on its head 281 with its central leg 282 protruding into the air, and the perforated edges define anchor member apertures 283, see especially Figure 12 The open profile elongate members 261 comprise a base portion 262 , see especially Figure 11 , having a perforated edge 263 for receiving masonry fixing members 264 for fixing the open profile members 261 to the bπckwork/blockwork 258 of the wall An upright portion 265 of the open profile members 261 extends at a right angle from the opposite end of the base portion 262 to the perforated edge 263 and terminates with a top wall portion 267 foldin g back over the top of the upright portion 265 toward the perforated edge 263 substantially parallel to the base portion 262 and terminates with a downwardly depending lip 264 substantially parallel to the upright portion 265 The base portion 262 has a base portion elongate ridge 275, also acting as a rain water break and a spaced apart L-shape flange 276 extending from the upper surface of the base portion 262 and defining an elongate base portion cavity 277 there between for receiving base portion jointing dowels for connecting and holding adjacent open profile members 261 together

In use, elongate open profile members 261 , T-shaped anchor members 259 and masonry fixing members 264 are delivered to the wall region An operator fixes the open profile members 261 onto opposing sides of the top surface of the wall by driving the masonry fixing members 264 into the masonry 258 via the apertures 260 and fixes the T- shaped anchor member 259 between the open profile members 261 by driving masonry fixing members into the masonry via apertures 283 A stabilising arrangement such as one or more fastening ties 254 can be tied between apertures 253 of opposing open profile members 261 and/or between apertures 253 of opposing open profile members 261 and apertures 283 of the perforated end of the central leg 282 of the inverted T-shaped anchor member 259 to provide additional stability Concrete 212 is poured into the casting mould 251 and allowed to set with the casting mould 251 remaining in place after the concrete 212 sets The open profile members 261 and anchor members 259 of the casting mould 251 are manufactured from weather proof material such as fibre reinforced plastics material. The end face profiles of the open profile members 261 are fitted with end caps (not shown) to complete the decorative appearance.

Referring now to Figures 13 and 14, there is shown a third embodiment of casting mould indicated generally by the reference numeral 351 comprising open profile members 361 mountable along the vertical surface of the masonry 358 of a wall for forming a decorative parapet moulding An upright portion 366 of the open profile member 361 is fixed to the masonry 358 via apertures 360 and a free edge 352 of the open profile members 361 has apertures 353, see especially Figure 14 for receiving stabilising members, not shown The casting mould 351 is a permanent fixture left as an element of the cast decorative parapet

The third embodiment of casting mould 351 comprises the open profile elongate member 361 and end caps, not shown to be fitted onto the end face of the open profile elongate member 361 The open profile elongate members 361 comprise upright portion 366 having a perforated edge 363 defining apertures 360 for receiving masonry fixing members 364 for fixing the open profile member 361 to the bπckwork/blockwork 358 of the wall A base

portion 362 extends substantially orthogonally from the opposite end of the upright portion

366 to the perforated edge 363 and terminates with an inclined portion 365 The inclined portion 365 of the open profile member 361 extends at an obtuse angle from the opposite end of the base portion 362 to the upright portion 366 and terminates with a top wall portion 367 folding back over the top of the inclined portion 365 toward the perforated edge 363 substantially parallel to the base portion 362 An elongate top wall portion ridge 369 extends from the underside of the top wall portion 367 and together with the folded over portion between the inclined portion 365 and the top wall portion 367 defines a top wall portion elongate cavity 371 formed for receiving top wall portion jointing dowels (not shown) for connecting and holding adjacent open profile members 361 together The free end of the top wall portion 367 has top wall portion apertures 353 The base portion 362 has a base portion elongate ridge 375 extending out of the base portion 362 defining a groove therein which acts as a rain water break An elongate flange 378 extends from the upright portion 366 proximal to the apertures 360 and the free edge of the elongate flange 378 is perforated with apertures 381

In use, elongate open profile members 361 and masonry fixing members 364 are delivered to the masonry region An operator fixes the open profile members 361 onto the masonry 358 of the vertical surface of the wall by driving the masonry fixing members 364 into the masonry 358 via the apertures 360 A stabilising arrangement such as one or more fastening ties can be tied between apertures 381 of the elongate flange 378 and between top wall portion apertures 353 of the open profile member 361 to provide additional stability Concrete 312 is poured into the casting mould 351 and allowed to set with the casting mould 351 remaining in place after the concrete 312 sets The open profile members 361 of the casting mould 351 are manufactured from weather proof material such as fibre reinforced plastics material

Referring to the drawings and now to figures 15 to 17, there is a shown a fourth embodiment of casting mould indicated generally by the reference numeral 451 for casting a window sill The casting mould 451 comprises an elongate open profile member 261 as

described above and a second elongate open profile member 461 The second elongate open profile member 461 , see especially Figure 17, has a base portion 462 and an elongate upright lip 463 extending substantially orthogonally from one elongate edge of the base portion 462 An upright elongate portion 465 extends substantially orthogonally from the other elongate edge of the base portion 462 in the same direction as the upright lip 463 and has a window sill supporting platform portion 466 extending substantially orthogonally from the upright portion 465 towards the upright lip 463 The free edge of the window sill supporting platform portion 466 and the free edge of the upright lip 463 is perforated with apertures 468 and 469 respectively In use, elongate open profile members 261 and second elongate open profile members 461 are delivered to an opening in a wall A second elongate open profile member 461 is mounted on masonry 478 of a cavity wall having cavity insulation 479 The second elongate open profile member 461 extends across the cavity with the upright portion 465 resting on the inner leaf of the cavity wall and the base portion 462 extending across the cavity An elongate open profile member 261 is mounted on the outer leaf of the cavity wall with its base portion 262 underneath the upright lip 463 of the second elongate open profile member 461 Fastening ties (not shown) are mounted between apertures 468 and 469 to increase the stability of the casting mould 451 and fastening ties (not shown) are mounted between the apertures 253 of elongate open profile member 261 and apertures 468 and/or 469 Concrete 412 is poured into the opening defined by the fourth embodiment of casting mould 451 and allowed to set and the open profile members 261 , 461 remain in place as part of the finished window sill Window 483 is then set into the opening and fixed therein

Figure 18 is an end view of Figure 12 showing T-shaped anchor member 259 Figure 19 shows the open profile angle members 59 of Figures 3 to 8 comprising two elongate open profile members 61 mitred together and two top wall portion jointing dowels 73 extending from the angle member 59 The open profile angle members 59 can be used as a multipurpose decorative external angle corner member

Figure 20 shows a house indicated by the reference numeral 501 The house has a roof 500 with a concrete barge 502 being formed using the second embodiment of casting mould 251 as shown in Figure 10 A chimney 505 has a chimney capping 507 using the first embodiment of casting mould 51 as shown in Figure 3 The house 501 has a parapet and decorative cornice 509 as shown in the detail view of Figure 15 Decorative porch mouldings 511 are shown with corner details as shown in Figure 19 Decorative cornice 514 and decorative lintel 515 are provided by the third embodiment of casting mould as shown in Figure 13 A conservatory 517 has a window sill 519 provided by the fourth embodiment of casting mould 451 as shown in Figure 16 and a garden wall 522 has a wall capping 523 provided by a second embodiment of casting mould 251 as shown in Figure 9

Variations and modifications can be made to the above embodiments without departing from the scope of the invention as outlined above

Variations and other modifications can be made without departing from the scope of the invention described above and as claimed hereinafter