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Title:
A CORRUGATED CEMENT SLAB PROVIDED WITH STRUCTURAL MOLDS
Document Type and Number:
WIPO Patent Application WO/2010/135795
Kind Code:
A1
Abstract:
The present invention is concerned with a corrugated cement slab provided with structural molds consisting of metal profiles (a, a1, a2) intertwined with filling elements (b), in such a way that the unidirectional (L) or bidirectional (L1) corrugated cement slabs can be implemented, and that the structural molds (a, al, a2) are incorporated to the cement slab (L, L1) after the concrete is cast, thus working as a positive frame.

Inventors:
GOMES DANILO MAGALHAES (BR)
Application Number:
PCT/BR2010/000165
Publication Date:
December 02, 2010
Filing Date:
May 24, 2010
Export Citation:
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Assignee:
TUPER S A (BR)
GOMES DANILO MAGALHAES (BR)
International Classes:
E04C2/06; E04B5/40
Foreign References:
US4507901A1985-04-02
EP1258574A22002-11-20
Attorney, Agent or Firm:
GONÇALVES, Maria Aparecida Pereira (Bairro América, -250 Joinville - Santa Catarina, BR)
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Claims:
Claims

1. A corrugated cement slab provided with structural molds, characterized by being comprised of structural molds of metal profiles (a, al, a2) intertwined with filling elements (b) , in order to cover a span area for forming the cement slab (L, Ll) ; said structural molds

(a, al, a2) being incorporated to the cement slab when it is implemented, thus acting as positive steel. 2. The corrugated cement slab provided with structural molds according to claim 1, characterized in that the structural molds (a, al, a2) comprise side ribs (g, i) and tabs (d) that support the filling elements (b) .

3. The corrugated cement slab provided with structural molds according to claim 1, characterized in that the structural molds (a, al, a2) and filling elements

(b) form unidirectional (c2) and bidirectional (c3) corrugated cement slabs.

4. The corrugated cement slab provided with structural molds according to claim 1, characterized in that the filling elements (b) have a height that corresponds to the height of the beam (c2) except for the thickness of the table (cl) of the cement slab (L, Ll) .

5. The corrugated cement slab provided with structural molds according to claim 1, characterized in that the structural mold (a) comprises a central channel (h) formed by ribs (g) in a metal fold, and at least one rib (i), along the channel (h) .

6. The corrugated cement slab provided with structural molds according to claim 1, characterized in that the structural mold (al) comprises a central channel (h) formed by ribs (g) in a metal fold, and at least one rib (i) that defines channels (hi) along the central channel (h) . 7. The corrugated cement slab provided with structural molds according to claim 1, characterized in that the structural mold (a2) comprises a central channel (i) formed by widened ribs (g) in the shape of inverted channels ( j ) . 8. The corrugated cement slab provided with structural molds according to claim 5, characterized in that the rib (i) of the structural mold (a) has a triangular cross-section.

9. The corrugated cement slab provided with structural molds according to claim 6, characterized in that the rib (i) of the structural mold (al) has a trapezoidal cross-section.

10. The corrugated cement slab provided with structural molds according to any of claims 5 or 6 or 7, characterized in that the structural molds (a, al, a2) comprise anchoring notches (m) distributed throughout the upper surface thereof.

11. The corrugated cement slab provided with structural molds according to claim 6, characterized in that the structural mold (al) has notches (ml) along one of the walls of the ribs (i) and/or (g) .

12. The corrugated cement slab provided with structural molds according to claim 6 or 7, characterized in that the notches (ml) of the rib (i) and (g) of the structural molds (al, a2), respectively, receive support clamps (n) for hangers (o) .

13. The corrugated cement slab provided with structural molds according to claim 1, characterized in that the filling element (b) is chosen among expanded polystyrene (EPS), extractable rigid plastics, ceramics, and metal .

14. The corrugated cement slab provided with structural molds according to claim 13, characterized in that the filling element (b) is expanded polystyrene (EPS) .

15. The corrugated cement slab provided with structural molds according to claim 1, characterized in that the filling element (b) comprises a plurality of transversal cuts (bl) distributed longitudinally in such a way that, when of the concrete is cast, they are filled up with concrete, forming a bidirectional corrugated cement slab (Ll) .

Description:
"A CORRUGATED CEMENT SLAB PROVIDED WITH STRUCTURAL MOLDS" Disclosure of the Invention

The present invention is directed to a corrugated cement slab provided with structural molds consisting of metal profiles used as a support and mold for implementing the cement slabs, particularly unidirectional and bidirectional corrugated cement slabs . Background of the Invention For the cement slab implementation in civil construction it is necessary to use molds and supportive centering templates that are kept in their place until the concrete is cured, when the cement slab is then removed from the center, and the struts and molds are removed therefrom. Among the several types of cement slabs, mention may be made to the massive cement slab which is produced by using wood molds supported on metal or wood struts. In this case, the concrete is cast after the steel meshes are assembled and electric and hydraulic tubes are passed therethrough. This procedure, besides being extremely time and labor consuming, involves a large number of workers for carrying out same, its final effect as a function of the impreciseness of the wood mold is hardly satisfactory, and also requires a high consumption of concrete, thus requiring a more strengthened structure, increasing the labor cost.

This issue has been partially solved by providing pre- molded cement slabs that are produced industrially. They comprise a plurality of reinforced concrete beams and ceramic hollowed tiles, said beams being assembled in a staggered arrangement, the side fittings of the ceramic tiles being placed on the beam tabs and the whole assembly being placed on wood or metal struts before a layer of concrete is cast thereon.

Even when the procedure for assembling the cement slab in situ and its removal from the centre is made easy in this type of cement slab, and the final aspect is of a better quality than that of the massive cement slab, the problem caused by the interventions for implementing electric and hydraulic tubes still remains. This is because the tubes should not pass through the compression area of the cement slab that is called compression table, which is reduced in the region where the ceramic tiles are present, what would compromise the resistance of the cement slab, in view of the reduction that would be caused to the useful section of the compression table. Moreover, since the beams are made by the manufacturer of the cement slab, the constructor does not control both the quality and guarantee as to the strength thereof.

Also, there are cement slabs cast on metal molds that extend all over the lower surface thereof. Indeed, this system consumes a large number of molds and concrete, when compared to the corrugated cement slab of the proposed invention. Moreover, there are a few restrictions for such cement slabs as to the passage of tubes through the compression table of the cement slab that, in order not to compromise the resistance thereof, increase its height, thus implying disadvantageously in a higher consumption of concrete and increasing the weight of the cement slab itself, thus requiring a more robust superstructure and foundation. Object of the Invention

Therefore, an object of the present invention is a corrugated cement slab provided with structural molds that may be easily assembled, with a reduced consumption of labor and struts.

Another object of the present invention is a corrugated cement slab provided with structural molds that makes it possible to install tubes and ducts without breaking the elements that make out the cement slab, thus preventing structural or aesthetic damages to the construction.

Another object of the present invention is a corrugated cement slab provided with structural molds that makes it possible to mold same with desirable structural characteristics, that is, mechanical resistance to efforts and loads, also providing an improved functional effect.

There are a number of advantages provided by the present invention, amongst which we have: - the possibility of implementing the corrugated cement slabs without the need to use wood molds;

- the possibility of implementing the corrugated cement slabs without using steel bar cuts or folds;

- the system for supporting the corrugated cement slab provided with structural mold requires a low consumption of struts compared to the traditional massive cement slab;

- the structural molds of the corrugated cement slab are light, easy to handle and may be conveyed horizontally or vertically in the worksite; - the cement slab implementation steps are reduced, and there is no need to precast the concrete as required for pre- manufactured cement slabs, and no need to use wood molds as required for the massive cement slab, as well as steel folding and cutting; - the structural molds are made of thin plates and make it possible to overlay same, thus providing optimization of space for storing same;

- the molds have a device that makes it easy to install hangers for fixing linings, without the need to perforate holes in the cement slab;

- several types of filling elements, such as rigid or semi-flexible plastics, ceramic, metals, among others, that possess sufficient resistance characteristics to support work loads during the concrete casting may be used;

- the corrugated cement slabs provided with structural molds made of metal profiles and filling elements, for example, EPS, provide a lower consumption of concrete and steel compared to the cooperative massive metal molds; - the steps for manufacturing and transporting materials are reduced, as well as implementation and assembly time, thus saving labor; the corrugated cement slabs implemented with the structural molds of the present invention make it possible to place a covering directly on the inner part of the cement slab;

- also, the present invention makes it possible to pass the tubes therethrough without compromising the structure of the cement slab.

Brief Description of the Invention The present invention is directed to a corrugated cement slab provided with structural molds that consist of metal profiles that are positioned parallel to one another, and interspersed filling elements that are supported on the tabs of the structural molds . The filling element is made of any material that can support the concrete of the cement slab, such as expanded polystyrene, or any other material having equivalent characteristic and/or having the same function. The present corrugated cement slab provided with structural molds makes it easy to assemble same, since it uses a minimum of struts in view of the fact that the structural molds are provided with a dual function. In the first stage for implementing the cement slab, the molds function is to support the work loads (workers, equipment) during the assembly and while the concrete is cast. After the concrete is cured, it is removed from the centre, and the molds remain incorporated to the cement slab, thus performing its second function, that is, as the "positive" steel of the cement slab. The ribs are formed on the structural molds, and among the filling elements, for example, EPS (expanded polystyrene) . This constructive disposal makes it possible to cut the filling element for the passage of electric and hydraulic tubes therethrough without compromising the resistance of the compression table.

The present invention makes it possible to implement the work in a short time, at a lower cost compared to the conventional options of the implementation of cement labs molded "in situ" (massive cement slab) or pre-manufactured cement slab. Also, the present invention provides the advantage of dispensing with the use of additional steel bars, thus eliminating the work of cutting and folding the bars, such as required for the traditional techniques; thus saving both material and labor and reducing the steps for implementing the cement slab, resulting in a abbreviated work timetable. Brief Description of the Figures

In order to have a clear view of the structural mold of the present invention, illustrative drawings are shown hereinbelow, to which reference is made in order to better elucidate the following detailed description, without excluding any other equivalent embodiment, wherein: figure 1 represents a schematic cut view of a unidirectional corrugated cement slab (L) provided with structural molds (a) and filling elements (b) ; figure 2 represents a schematic cut view of a corrugated cement slab (L) having a constructive variant (al) of the structural mold (a) ;

- figure 3 represents a schematic perspective view of a bidirectional corrugated cement slab (Ll) provided with the structural mold (al) of figure 2 in a direction and one filling element (b) in the other direction;

- figure 4 represents a schematic amplified cut view of the structural mold (a) ; - figure 5 represents a schematic amplified cut view of the constructive variant (al) of the structural mold (a) ;

- figure 6 represents a schematic amplified cut view of another constructive variant (a2) of the structural mold (a);

- figure 7 represents a schematic perspective view of the structural mold (al) provided with notches (m and ml) distributed along the surface thereof;

- figure 8 represents a schematic perspective view of the structural mold (a) provided with notches (m) distributed along the surface thereof; - figure 9 represents a schematic perspective view of the structural mold (a2) provided with notches (m) distributed along the surface thereof; figure 10 represents a schematic cut view of the structural mold (al) with a hanger (p) for hanging linings or objects. Detailed Description of the Invention

As illustrated in the accompanying figures, the present invention is concerned with a corrugated cement slab provided with structural molds (a, al, a2) consisting of metal profiles of filling elements (b) that are positioned in a staggered arrangement, in such a way to cover a cement slab span area for casting the concrete when the corrugated cement slabs (L, Ll) are formed, the filling elements (b) having a height that corresponds to the height of the beam (c2) of the rib except for the thickness of the table (cl) of the cement slab (L, Ll) .

After the concrete is cured, the structural molds (a, al, a2) start to be cooperative with the concrete of the cement slab (L, Ll), acting as a frame or positive steel, dispensing with the usual steel bars.

Figures 1 and 2 represent schematically a cut view of unidirectional corrugated concrete slabs (L) laid on a plurality of structural molds (a, al) consisting of metal profiles positioned parallel to one another and intertwined with filling elements (b) .

Besides acting as a mold, the filling element (b) also comprises such a geometry that creates the desired aspect for the cement slab (L) , and thus the dimension and geometry thereof depend on the structural need of the cement slab (L) that, as illustrated in this example, is corrugated in one direction. The filling materials may be EPS (expanded polystyrene) compounds, rigid ceramic materials, plastics or any material that can provide the resistance needed to support the weight of the concrete (c) . Figure 3 illustrates a perspective view of a bidirectional corrugated cement slab (Ll) that comprises structural molds (al) positioned in one direction, wherein filling elements (b) intertwined with structural molds (al) are provided with transversal cuts (bl) on the upper face thereof, in the form of channels, and steel bars (e) positioned in the channels (bl) before the cement slab (Ll) is implemented which, when filled up with concrete, form the transversal ribs (c3) , thus providing bidirectional corrugated cement slabs (Ll) .

Figure 4 illustrates a cross-section of the structural mold (a) that is provided with side tabs (d) for supporting the filling element (b) . Said structural mold (a) comprises a cross- section in the shape of a channel (h) surrounded by ribs (g) formed by folds, and a rib (i) in the central portion of the channel (h) that extends longitudinally, said channel (h) being provided with notches (m) that increase the adhesion of the structural mold (a) to the concrete (c) . In this illustrated example the rib (i) has a triangular cross-section.

Figure 5 illustrates a constructive variant (al) of the structural mold (a) illustrated in figures 1, 4 and 8. In this variant (al), the rib (i) in the channel (h) has a trapezoidal cross-section, forming an inverted channel (il) that splits the channel (h) into two channels (hi) also having a trapezoidal cross-section.

Advantageously, the rib (i) and the ribs (g) provide the structural mold (al) with a higher flexural strength to support work loads while the concrete is cast, and make it possible to have a greater distance between the supporting lines (not illustrated) . Figure 6 illustrates another constructive variant (a2) of the structural mold (a) , wherein the ribs (g) are widened, thus forming inverted channels (j) of a trapezoidal cross-section that make it possible to install hangers (p) .

Figures 7, 8 and 9 illustrate examples of distribution of notches (m) in the structural molds (a, al, a2) that, as illustrated, are distributed along the upper surfaces of the structural molds (a, al, a2), channels (h, hi) and ribs (i, g) .

The aim of the notches (m) is to increase the adhesion of the structural molds (a, al, a2) in the concrete (c) , besides assisting the transfer of stress among same. The notches (m) have a geometry, dimensions and disposition that may change according to a higher or lower anchorage of the assembly.

Figure 7 illustrates the notches (ml) on the sides of the central rib (i) for fastening the support clamps (n) for the supporting hangers (o) provided with oblong holes for fixing the lining (not illustrated) (see figure 10) .

As can be seen in figures 1 and 2, the filling elements (b) are supported on the tabs (d) of the structural molds (a, al) , in such a way that, according to the geometry of the structural molds (a, al) and the filling (b) , the geometry of the cement slab

(L) is attained. By changing the distance between the structural molds (a, al) and the height of filling elements (b) , several geometric characteristic of the cement slab (L) are provided, whose characteristics may vary in accordance with the structural sizing of the cement slab, providing same with the ability to cross over spans and support permanent and/or temporary loads after the concrete is cured.

The structural molds (a, al, a2) perform several functions in accordance with the cement slab implementation phases which include:

1. During the assembly of the cement slab (L, Ll) the structural molds (a, al, a2) consisting of metal profiles perform the function of supporting the filling elements (b) . 2. The structural molds (a, al, a2) perform the function of supporting operating work loads, such as loads of workers, equipment, tools and concrete cast (c) during the assembly and implementation of the cement slab (L, Ll).

3. After the complete cure of the concrete, the molds (a, al, a2) start performing a structural function, working as the positive steel of the cement slab, thus replacing the usual steel bars (rods) .

In bidirectional cement slabs (Ll) (see figure 3), the shield (e) for the secondary rib (c3) is obtained by using steel bars (e) (rods) . The secondary rib (c3) is formed by the filling element (b) provided with transversal channels (bl), forming the secondary ribs (c3) perpendicular to the main ribs (c2).

Also, one may use the same structural molds (a, al, a2) split and distributed in a staggered arrangement and perpendicular to the main beams (c2) to create secondary ribs (c3), said split molds not acting as structural elements.

The cement slab (L, Ll) may receive a covering applied directly to the structural molds (a, al, a2) or then receive a lining through the use of support clamps (n) attached to the ribs (i) or (g) of the structural molds (al, a2), respectively, (see figure 10), thus making it possible to create support lines for the installation of several types of linings, PVC, plaster, EPS, amongst other commercial linings. To implement the present unidirectional and bidirectional cement slab provided with structural molds, first of all use is made of struts made out of longitudinal beams supported on struts

(not illustrated) , whose distance between the support lines is calculated in accordance with the characteristics of the cement slab and the type of concrete casting applied. The support systems may be any system among those known in the prior art, such as wood or metal.

When the unidirectional cement slab (L) is assembled, the structural molds (a, al, a2) are positioned perpendicular to the support lines and parallel to one another, being at a distance in accordance with the one stipulated in the structural design of the cement slab. The ends of the structural molds (a, al, a2) advance on the beams of the structure (not illustrated) , thus being supported thereon. The filling elements (b) are then positioned by being supported on the tabs (d) of the structural molds (a, al, a2), that are moved away sufficiently to allow same to be fitted therein.

In the bidirectional cement slabs (Ll) the assembly is much like the one of the unidirectional cement slab (L) , by taking a filling element provided with transversal channels (bl) that form the secondary ribs (c3) when the cement slab (Ll) is implemented, and using steel bars (e) for reinforcing the rib

(c3) . Said secondary ribs (c3) also may be made with a filling element (b) without a channel (bl) that it is stopped for positioning the segmented structural molds (a, al, a2), supported on the main structural molds (a, al, a2) . In any one of these options the secondary ribs (c3) should be lined up.

Before the concrete is cast, the electric, hydraulic installations, etc., are implemented (not illustrated), and the ancillary hardware and steel meshes of the compression table (cl) of the cement slab (L, Ll) are positioned as well.

The tubes should be located below the compression table

(cl) of the cement slab (L, Ll), in the filling elements (b) so that, when EPS is used, a thermal blower or cutting tools may be used to provide channels in the filling elements (b) for the tubes .

As to the bidirectional cement slab (Ll) the bars (e) of the secondary rib (c3) should be launched before the installation of electric and hydraulic elements.

After the whole installation is performed and the hardware is positioned, the concrete casting process of the cement slab (L, Ll) is started. In the concrete curing period, a time that is determined by the engineer that makes all calculations, the struts should not be removed. After the concrete curing time, the struts are removed and the molds remain attached, thus performing the function of positive steel in the cement slab.

One skilled in the art will readily realize, from the description and the drawings shown, several ways to carry out the invention without departing from the scope of the attached claims.