FIELD OF INVENTION The present invention relates to formwork structure, and more particularly to a solid and rigid formwork structure for use in the construction of concrete walls.

BACKGROUND ART Existing methods for constructions of walls have several disadvantages. Construction uses concrete blocks, clay bricks or stone have been used for ages to build walls. This requires skilled labor and supervision. After the walls have been built, electrical and plumbing elements are installed by scoring channels in the masonry resulting in blemishes that must later be patched. The exterior perimeter needs to be caulked and maintained.

Construction systems using prefabricated panels made of concrete which are factory built and assembled on site have the disadvantages that this requires skilled labor, administration, logistics, and planning. They also require a factory, specialized machinery, technical personnel, and a market absorbing the planned production. Another very popular construction system usually for industrial buildings involves producing concrete panels on site.

This invention provides a solution to the problems of the existing wall construction methods.

SUMMARY OF INVENTION

This invention provides a formwork structure for a wall, comprising: a framework of rectangular section formed by inter-engaging flat based channel members having elongate slots extending lengthwise along their base; an expanded metal sheet attached to the each side of the framework, a column structure and a beam structure. The column structure and the beam structure are formed by using a plurality of rebars, arranged vertically and horizontally passing through the elongate slots of the inter- engaging flat based channel members.

Preferably, the formwork structure further includes a plurality of slotted channel members arranged at spaced distance within the rectangular framework for providing support to the rebars extending along the length of the rectangular framework. Preferably, the column structure is formed by the vertically arranged rebars positioned in the elongate slots of top and bottom inter-engaging flat based channel members of the rectangular framework.

Preferably, the beam structure is formed by the horizontally arranged rebars, extends through the elongate slots of the slotted channel members and the inter-engaging flat based channel members of the rectangular framework.

Preferably, the slotted channel members and the inter-engaging flat based channel members are formed from light-weight steel.

Preferably, a wall panel formed using the formwork structure, wherein the formwork structure is filled with concrete material.

This invention also provides a method to form the formwork structure, comprises steps to: form a framework of a rectangular section by using inter-engaging flat based channel members having elongate slots extending lengthwise along their base; arrange plurality of slotted channel members at spaced distance within the rectangular framework; form a column structure using plurality of rebars by arranging the rebars vertically within the rectangular framework on at least one side; form a beam structure by arranging the rebars horizontally within the rectangular framework; and, attach an expanded metal sheet to the sides of the rectangular framework. Preferably, the column structure is formed, by arranging the rebars vertically in a position connecting top and bottom inter-engaging flat sided channel members of the rectangular framework

Preferably, the beam structure is formed, by arranging the rebars horizontally in position extending through the elongate slots of the slotted channel members and the inter-engaging flat sided channel members of the rectangular framework.

Preferably, the method to form a wall comprises steps to fill concrete material within the formwork.

DESCRIPTION OF PREFERRED EMBODIMENT

The invention will now be described in greater detail with reference to the drawings in which

Figure 1 illustrates one form of the formwork structure, according to the invention;

Figure 2a and 2b illustrates column structure formed on sides of the formwork structure, according to the invention;

Figure 3 a illustrates beam structure formed in the formwork structure, according to the invention; and,

Figure 3b illustrates side view of the beam structure, according to the invention.

As shown in figure 1, the formwork structure (100) is a light weight formwork structure comprises: inter-engaging flat based channel members (110a, 110b, 110c, and llOd), plurality of slotted channel members (120), rebars (160) and structural mesh (130). The inter-engaging flat based channel members (110a, 110b, 110c, and HOd) has elongate slots along their base. A framework of rectangular section is formed by using four inter engaging flat sided channel members (110a, 110b, 110c, and HOd). The slotted channel members (120) are arranged vertically at equally spaced distance within the rectangular framework, such that it connects top and bottom channel members (110c, 110a) of the framework. The channel members are made from light weight steel.

Further, the light weight formwork structure (100) includes column structure (140) and beam structure (150) arranged within the rectangular framework. The column structure (140) is formed vertically anywhere within the rectangular framework to carry compressive load. The beam structure (150) is formed longitudinally is supported by the column structures (140) and the internal slotted channel members (120) to carry bending load. The arrangement of the column - beam structure (140, 150) is in such a way that the formwork structure (100) is simultaneously able to carry both compressive and bending load.

Referring to figure 1, the structural mesh (130) is attached on the both sides of the formwork structure (100). The channel members (120) are connected to the structural mesh (130) using a plug, screw, nail, bolt or any other means of connection in such a way that the formwork structure (100) is able to receive the concrete or cement mixture through the slots. The concrete is poured into the formwork structure (100), in which the mesh would attach to the concrete to form the wall. The structural mesh (130) has minute opening that the poured concrete is contained within the formwork structure (100) without flowing freely through the apertures. Further, the concrete is plastered or applied with a plasterwork to smoothen the structure.

As shown in figure 2a and 2b, the column structure (140) formed within the rectangular framework using the plurality of rebars (160). The column structure (140) is formed by the arrangement of the rebars (160) vertically, which connects the bottom and top channel members (110a, 110c). The rebars (160) are arranged vertically in the elongated slots of the bottom channel member (110a) and extends through the elongate slots in the top channel member (110c). The vertically arranged rebars (160) are held together in position using ties (170) at pre-determined location across its length. This arrangement forms the column structure (140) with stability, strength and able to carry compressive load. As shown in figure 3a and 3b, the beam structure (150) is formed near the top channel member (110c) of the rectangular framework using the rebars (160). The rebars (160) are arranged horizontally connects the sides of the rectangular framework parallel to the top channel member (110c) of the rectangular framework. Where, these horizontally arranged rebars (160) passes through the elongate slots of the internal slotted channel members (120) arranged within the rectangular framework. The horizontal rebars (160) are held together in position using the ties (170) at the predetermined location across it to form the beam structure (150) and is able to carry bending load. The method to form a formwork structure (100), comprises steps: form the rectangular section of a framework by using inter-engaging flat based channel members (110a, 110b, 110c, HOd) having elongate slots extending lengthwise along their base; arrange the plurality of slotted channel members (120) at spaced distance within the rectangular framework; form the column structure (140) using plurality of rebars (160) by arranging the rebars (160) vertically within the rectangular framework on at least one side; form the beam structure (150) by arranging the rebars (160) horizontally within the rectangular framework; and, attach an expanded metal sheet to the sides of the rectangular framework. The column structure (140) is formed, by arranging the rebars (160) vertically in a position connecting top and bottom inter- engaging flat based channel members (110a, 110c) of the rectangular framework. The beam structure (150) is formed, by arranging the rebars (160) horizontally in position connecting the sides of the framework and passing through the elongate slots of the slotted channel members (120). A wall panel is formed using the formwork structure (100), where the concrete material is poured into the formwork structure (100). Further, a layer of plaster is layered over the concrete wall panel. The configuration and assembly method for formwork structure (100) has great effects in the quality and construction work. The pre-punch holes or purlins will allow the concrete or mortar flow better to both sides and provides better performance on strength of the wall built using the formwork structure (100). The formwork structure (100) is built to be user friendly installation, eco-friendly, no timber products are needed, therefore it's easy to handle in terms of delivery or logistic, lesser time and requires less manpower. Further, the formwork structure (100) does not need the use of additional support members and is convenient to be installed on site, has reasonable design and is stable for practical applications. It further able to connect a various components and eliminate accumulated errors that accrued during the installation work.