METHOD AND DEVICE FOR ASSISTING IN FORMING OPENINGS IN A CONCRETE

WALL DURING CASTING

RELATED APPLICATION/S

This application claims the benefit of priority of Israel Patent Application No. 297647 filed on 25 October 2022, the contents of which are incorporated herein by reference in their entirety.

FIELD AND BACKGROUND OF THE INVENTION

The present invention, in some embodiments thereof, relates to a method and device for generating a concrete wall having an aperture. More specifically, this application relates to a method of using a bracing member in order to place a window or door of any size or shape in any location within a concrete wall.

Building of structures having windows positioned within formed concrete walls, the window frames or surrounds, if unsupported during forming of the walls, are frequently collapsed or deformed such that a window cannot be properly installed therein. In the past, it has been common for builders to reinforce such window frames against crushing by installing plywood panels or other wood bracing to extend between oppositely positioned window frame members. Such bracing is specially formed for each window and is usually destroyed when it is subsequently removed. While satisfactory in that they generally provide sufficient reinforcing strength to prevent the frame from collapsing, these specially built forms require a great deal of time to build, cannot be reused, and usually do not allow for easy insertion therethrough of wire support ties for the concrete forms being used.

Box-out formworks (also referred to as window negatives) have been used in the construction of openings in concrete buildings. However, during casting of the walls, the concrete activates pressure on the sides of the negative and hardens around them. The normal end-result is that the negative remain as a part of the cast after dismantling the formwork plates and further steps need to be taken to remove the negative.

In order to overcome this problem, an “angled negative” has been proposed in which all four faces are angled to one side creating a conical shape. Using this type of format, the cavity it creates in the concrete is bigger on one side (inner) and smaller on the other side (outer) as all the facets are angled. In order to extract the negative, it must be hammered out towards the larger side. This hammering often creates a lot of damage to the window cavity surroundings, especially in “Baranovich” systems where the cavity and surrounding areas are lined with tiles. The second form of "negatives "are collapsing ones in which the negative shrinks or dismantles for extraction. This allows for much easier extraction of the window formwork but in a lot of cases those elements are composed from many parts making their depreciation very high as parts are typically bent or lost.

Additional Background Art includes US Patent No. 3,995,843 and US Patent No. 7,587,868 and US Patent Application No. 2004/0004174.

SUMMARY OF THE INVENTION

According to an aspect of some embodiments of the present invention there is provided a system for use in the construction of a concrete wall with a quadrangle opening, the system comprising:

(a) four individual corner-bracing elements having right-angled side plane; and

(b) a central assembling element for positioning the side planes of the comer bracing elements, so as to define a perimeter of the quadrangle opening.

According to an aspect of some embodiments of the present invention there is provided a method for preparing a formwork used for constructing a concrete wall with a quadrangle opening comprising:

(a) securing the central assembling element to the four individual corner-bracing elements of the system described herein, to generate a bracing apparatus such that it is of a size that defines the quadrangle opening;

(b) securing the bracing apparatus to the outer sheet of the formwork; and

(c) installing a frame over the bracing apparatus, the frame being of a size that defines the quadrangle opening, each comer bracing element of the bracing apparatus being flush with a corner of the frame, thereby preparing the formwork used for constructing the concrete wall with a quadrangle opening.

According to an aspect of some embodiments of the present invention there is provided a method of constructing a cladded wall having a quadrangle opening comprising:

(a) preparing a formwork according to the method any one of claims 38-44;

(b) securing the inner sheet and the outer sheet of formwork with a formwork securing element;

(c) applying cementitious material into the formwork;

(d) allowing the cementitious material to harden with the cementitious material engaging element penetrating therein. According to some embodiments of the invention, the central assembling element comprises four diagonally extending arms.

According to some embodiments of the invention, the each of the four individual comerbracing elements comprises at least two walls which comprise the right-angled side planes and are for biasing a corner of a frame defining the quadrangle opening against cementitious material applied into a formwork.

According to some embodiments of the invention, the each of the four individual comerbracing elements comprises at least four walls, wherein two of the four walls comprise the right- angled side planes and are for biasing a corner of a frame defining the quadrangle opening against cementitious material applied into a formwork, a third of the four walls is for contacting an inner sheet of the formwork and a fourth of the four walls is for contacting an outer sheet of the formwork.

According to some embodiments of the invention, an inner face of a first of the at least two walls comprises at least one reinforcement bar.

According to some embodiments of the invention, an inner face of a first of the at least two walls comprises a plurality of reinforcement bars being parallel to a second of the at least two walls and an inner face of a second of the at least two walls comprises a plurality of reinforcement bars being parallel to a first of the at least two walls.

According to some embodiments of the invention, an inner face of a third of the four walls is connected to an inner face of a fourth of the four walls via at least one reinforcement bar.

According to some embodiments of the invention, an inner face of a third of the four walls is connected to an inner face of a second of the two fourth of the four walls via a plurality of reinforcement bars, at least one of the reinforcement bars being parallel to a first of the four walls and another of the reinforcement bars being parallel to a second of the four walls.

According to some embodiments of the invention, each of the four individual comerbracing elements further comprises a connecting element, the connecting element being attached to the at least two walls.

According to some embodiments of the invention, the connecting element bisects the corner bracing element.

According to some embodiments of the invention, the corner bracing element is integrally formed.

According to some embodiments of the invention, the connecting element comprises at least one first member of a securing structure and each of the four diagonally extending arms comprises at least one second member of a securing structure, whereby the first member of the securing structure and the second member of the securing structure are selected compatible for the positioning the side planes of the comer bracing elements, so as to define a perimeter of the quadrangle opening.

According to some embodiments of the invention, the first member and the second member of the securing structure comprises an element selected from the group consisting of a hole, an indentation, a protrusion, a ratchet mechanism a bolt, a screw and any analog or combination thereof.

According to some embodiments of the invention, a position of the at least one second member of the securing structure on the central assembling element is such that, upon system assembly, it aligns with the at least one first member of the securing structure.

According to some embodiments of the invention, the first member and the second member of the securing structure is a hole.

According to some embodiments of the invention, the hole is a slit.

According to some embodiments of the invention, upon system assembly, each arm of the central assembling element forms an acute angle with the side planes of the comer-bracing elements.

According to some embodiments of the invention, the acute angle is 45 °.

According to some embodiments of the invention, the central assembling element is of a cross shape.

According to some embodiments of the invention, the central assembling element comprises a square- shaped mount, wherein each of the four arms diagonally extends from a corner of the square- shaped mounting element.

According to some embodiments of the invention, the four comer-bracing elements and the central assembling element are fabricated from a metal.

According to some embodiments of the invention, the metal is steel.

According to some embodiments of the invention, the steel is stainless steel.

According to some embodiments of the invention, at least one of the four comer-bracing elements comprises an additional securing stmcture member for securing to a formwork.

According to some embodiments of the invention, the central assembling element comprises an additional securing stmcture for securing to a formwork.

According to some embodiments of the invention, the system is for use in firmly positioning a frame defining the quadrangle opening and firmly securing the frame defining the quadrangle opening onto a formwork. According to some embodiments of the invention, the system is for biasing a frame defining the quadrangle opening against cementitious material applied into a formwork.

According to some embodiments of the invention, the frame comprises four members connected there amongst at right angles, so as to form a quadrangular structure defining the opening.

According to some embodiments of the invention, the each the corner-bracing elements is designed to firmly support an angle and a part of associated two-gones defining the angle without any counter support from any of the four members of the frame adding to the securing of the system to a formwork.

According to some embodiments of the invention, the frame is fabricated from a water- resistant material.

According to some embodiments of the invention, the water-resistant material is selected from the group consisting of ceramic, porcelain, stone and a cement board.

According to some embodiments of the invention, the frame is a blind frame.

According to some embodiments of the invention, a portion of the frame serves as a window sill.

According to some embodiments of the invention, the frame comprises at least one external hole.

According to some embodiments of the invention, the at least one external hole is blunt ended formed in an outer surface of the frame and does not traverse a thickness of the frame.

According to some embodiments of the invention, the at least one hole is an undercut hole.

According to some embodiments of the invention, the system further comprises a plurality of cementitious material engaging elements.

According to some embodiments of the invention, the quadrangle opening is a window opening.

According to some embodiments of the invention, the quadrangle opening is a door opening.

According to some embodiments of the invention, the method further comprises attaching a cementitious material engaging element to at least one outer surface of the frame.

According to some embodiments of the invention, the method further comprises arranging a plurality of end cladding elements onto the formwork such that at least a portion thereof directly surround the frame. According to some embodiments of the invention, the method further comprises securing the plurality of end-cladding elements onto the formwork with securing plates and removable end cladding element securing agent.

According to some embodiments of the invention, the method further comprises waterproofing the frame.

According to some embodiments of the invention, the method further comprises removing the bracing element once the cementitious material is hardened.

Unless otherwise defined, all technical and/or scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which the invention pertains. Although methods and materials similar or equivalent to those described herein can be used in the practice or testing of embodiments of the invention, exemplary methods and/or materials are described below. In case of conflict, the patent specification, including definitions, will control. In addition, the materials, methods, and examples are illustrative only and are not intended to be necessarily limiting.

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS

Some embodiments of the invention are herein described, by way of example only, with reference to the accompanying drawings. With specific reference now to the drawings in detail, it is stressed that the particulars shown are by way of example and for purposes of illustrative discussion of embodiments of the invention. In this regard, the description taken with the drawings makes apparent to those skilled in the art how embodiments of the invention may be practiced.

In the drawings:

FIG. 1A is a drawing of an example of a corner bracing element according to embodiments of the invention.

FIG. IB is a drawing of an example of a corner bracing element according to embodiments of the invention.

FIG. 1C is a drawing of an example of a corner bracing element according to embodiments of the invention.

FIG. ID is a drawing of a cross-shaped central assembling element according to embodiments of the invention.

FIG. IE is a drawing of a central assembling element comprising a rectangular mounting element, according to embodiments of the invention. FIG. 2A is a drawing of four corner bracing elements (as depicted in FIG. IB) connected with the central assembling element (as depicted in FIG. ID).

FIG. 2B is a drawing of four corner bracing elements (as depicted in FIG. 1C) connected with the central assembling element (as depicted in FIG. ID).

FIG. 3 is a drawing of four comer bracing elements (as depicted in FIG. 1C) connected with a central assembling element (as depicted in FIG. IE) according to embodiments of the invention.

FIG. 4 is a drawing of a frame according to embodiments of the invention.

FIG. 5 is a front view of an open formwork which is prepared for casting a wall having an opening. The opening is defined by a frame which is braced using four corner bracing elements according to embodiments of the invention.

FIG. 6 is a side view of an open formwork which is prepared for casting a wall having an opening. The opening is defined by a frame which is braced using four corner bracing elements according to embodiments of the invention.

FIG. 7 is a drawing of a cement wall having a non-cladded surface, generated according to embodiments of the invention, before the bracing elements are removed.

FIG. 8 is a drawing of a cement wall having a cladded surface, generated according to embodiments of the invention, before the bracing elements are removed.

FIG. 9 is a drawing of a cement wall, generated according to embodiments of the invention, after the bracing elements are removed. The frame remains within the wall.

DESCRIPTION OF SPECIFIC EMBODIMENTS OF THE INVENTION

The present invention, in some embodiments thereof, relates to a method of generating a concrete wall having an aperture. More specifically, this application relates to a method of using a bracing member in order to place a window or door of any size or shape in any location within a concrete wall.

Before explaining at least one embodiment of the invention in detail, it is to be understood that the invention is not necessarily limited in its application to the details set forth in the following description or exemplified by the Examples. The invention is capable of other embodiments or of being practiced or carried out in various ways.

Whilst conceiving embodiments of the present invention, the present inventors have developed a system which can be used for creating apertures in concrete walls using a formwork in a quick and efficient manner. The system is reusable and thus extremely cost efficient. Furthermore, the system allows for casting a complete, waterproofed frame which is ready to receive a window without the need for insertion of a blind frame. The system relies on the use of corner bracing elements which may be temporarily connected via a central element prior to pouring of the concrete in the formwork. This allows for the generation of a bracing system which is strong enough to withstand lateral forces exerted by the concrete on the frame during construction. Once casting has been completed, the central element is disconnected and the bracing elements may be removed.

FIG. 1A shows a single corner bracing element 10 according to embodiments of the invention. The comer bracing element 10 comprises at least two walls 32 and 34 being at right angles to one another. The two walls are for biasing a corner of a frame defining a quadrangle opening against cementitious material applied into a formwork. The width (w) of single corner bracing element may be between 100 - 1000 mm, more preferably between 100-500 mm and even more preferably between 200-300 mm, for example about 250 mm. The height (h) of a single bracing element may be between 100 - 1000 mm, more preferably between 100-500 mm and even more preferably between 200-300 mm, for example about 250 mm. The depth (d) of single comer bracing element may be between 100-500 mm, more preferably between 200-400 mm, and even more preferably between 300-350 mm, for example about 320 mm. The depth of the bracing element may be adjusted according to the thickness of the wall being constructed.

FIG. IB shows a single comer bracing element 10 according to additional embodiments of the invention. The corner bracing element 10 comprises at least two walls 32 and 34 being at right angles to one another. The thickness of the walls is typically between 4-20 mm e.g. between 8- 15 mm.

Optionally, comer bracing element 10 comprises another wall 12 which contacts an inner sheet of a formwork (e.g. is placed flush against the inner face of the outer formwork) and an additional, oppositely facing wall 14 which contacts an outer of sheet of a formwork (e.g. is placed flush against the outer sheet of the formwork). Wall 12 and wall 14 are parallel to one another and may be of any shape - e.g. square, triangular, rectangular etc.

In one embodiment, the inner face of wall 32 comprises at least one reinforcement bar 16. Additionally, or alternatively, the inner face of wall 34 comprises at least one reinforcement bar 18. Reinforcement bars 16 or 18 may be a ridge, a protmsion. Reinforcement bar 16 connects the inner face of wall 12 with the inner face of wall 14. Reinforcement bar 16 is parallel to wall 34 and perpendicular to wall 32. Reinforcement bar 18 connects the inner face of wall 12 with the inner face of wall 14. Reinforcement bar 18 is parallel to wall 32 and perpendicular to wall 34. FIG. 1C shows a single comer bracing element 10 according to additional embodiments of the invention. The comer bracing element 10 comprises at least two walls 32 and 34 being at right angles to one another. The two walls are for biasing a comer of a frame defining a quadrangle opening against cementitious material applied into a formwork.

In one embodiment, the inner face of wall 32 comprises at least one reinforcement bar 16. Additionally, or alternatively, the inner face of wall 34 comprises at least one reinforcement bar 18. Reinforcement bar 16 is parallel to wall 34 and perpendicular to wall 32. Reinforcement bar 18 is parallel to wall 32 and perpendicular to wall 34.

Comer bracing element 10 as depicted in Figures IB and 1C, may further comprise a connecting element 20, which is attached to the inner facing side of wall 32 and the inner facing side of wall 34. Connecting element 20 may be of any shape (e.g. square, as in Figure IB, or triangular as in Figure 1C). Connecting element 20 is typically a planar element and may be parallel to wall 12 and 14 (i.e. comprise the same right angle connection as walls 12 and 14). In one embodiment, connecting element bisects comer bracing element 10 - i.e. is positioned at an equal distance from wall 12 as it is from wall 14. The thickness of the connecting element is typically between 4-20 mm e.g. between 8-15 mm.

Connecting element 20 may comprise at least one member of a securing stmcture. Exemplary members of securing stmctures include, but are not limited to a hole, an indentation, a protmsion, a ratchet mechanism a bolt, a screw and any analog or combination thereof. According to a particular embodiment, the securing stmcture is a hole 22 or a slit 30. Thus, for example connecting element may comprise at least two holes 22, as depicted in Figure IB or at least one hole 22 and one slit 30, as depicted in Figure 1C. Holes 22 or slit 30 are for securing the central assembling element 40 to comer bracing element 10, or additional non-comer bracing elements, as further described herein below.

Connecting element 20 may comprise additional members of a securing structure to allow for securing to an outer sheet of a formwork. Such additional members may include holes, indentations and or protrusions. According to a particular embodiment the additional member of the securing stmcture to allow for securing to a formwork is a hole 24. In one embodiment, each corner bracing element 10 comprises at least two holes 24 to allow for securing to a formwork. Hole 24 may also serve as a member of a securing structure for securing to a crane so that the bracing element 10 may be lifted to the appropriate height whilst preparing the formwork. Alternatively, bracing element 10 may comprise a dedicated hole 26 for allowing connection to a crane. Connecting element 20 may further comprise alignment bars 28 so as to allow alignment (i.e. guiding) of the corner bracing element 10 with the central assembling element 40.

In one embodiment, comer bracing element 10 (comprising walls 32 and 34, connecting element 10 and reinforcement ridge 16 and 18) is integrally formed.

FIG. ID shows an exemplary central assembling element 40, according to embodiments of the invention. Central assembling element 40, has at least four diagonally extending arms 44 each serving to position the side planes of one corner bracing element 10.

When each arm of the four arms of the central assembling element 40 is connected to one corner bracing element 10, the perimeter of a quadrangle opening is defined. Each arm 44 of central assembling element 40 forms an acute angle (e.g. 45 °) with the side planes of cornerbracing elements 10.

The distance from point (w) to point (x) may be between 200-1000 mm, more preferably between 200-600 mm and more preferably between 300-500 mm, for example 450 mm. Similarly, the distance from point (y) to point (z) may be between 200-1000 mm, more preferably between 200-600 mm and more preferably between 300-500 mm, for example 450 mm.

Another exemplary central assembling element 40, is illustrated in FIG. IE. In this embodiment, central assembling element 40 comprises a square or rectangular shaped mount 46 and four diagonally extending arms 44. The distance from point (w) to point (y) may be between 500-1000 mm, more preferably between 600-900 mm, for example about 850 mm. Similarly, the distance from point (z) to point (z) may be between 500-1000 mm, more preferably between 600-900 mm, for example about 850 mm. The distance from point (a) to point (b) may be between 300-600 mm and more preferably between 400-500 mm.

Each diagonally extending arm 44 of central assembling element 40 comprises at least one member of a securing structure which is compatible with a securing structure on the corner bracing element 10. Examples of securing structures include, but are not limited to a hole, an indentation, a protrusion, a ratchet mechanism a bolt, a screw and any analog or combination thereof. According to a particular embodiment, each diagonally extending arm 44 of central assembling element 40 comprises at least one hole 42. Hole 42 may be round or a slit.

Comer bracing element 10 and central assembling element 40 are typically fabricated from a material that can withstand lateral pressure exerted by cement in a formwork. Typically, the material is a metal, including for example steel, such as stainless steel.

In order to define the perimeter of a quadrangular opening, four corner bracing elements 10 are connected with a single central assembling element 40. Typically, the connection between the comer bracing elements 10 and the central assembling element 40 is temporary such that after the cement is poured in the formwork and left to dry, the single central assembling element may be easily removed. In one embodiment, at least one securing structure (e.g. hole 42) of central assembling element 40 is aligned with at least one securing structure (e.g. hole 22) of corner bracing element 10. Since it is contemplated that the corner bracing elements 10 comprises a number of securing structures and further the central assembling element 40 also comprises a number of securing structures, the selection of the particular securing structure on both elements for alignment is dependent upon the size of the quadrangular opening being defined. Small adjustments to the size of the quadrangular opening may be made by using slits for one of the holes 22 or 42. In the embodiment, where both the securing structure of central assembling element 40 is a hole and the securing structure of the corner bracing element is a hole, a screw and bolt can be used to fix the connection and prevent relative movement between the two. It will be appreciated that each of the four comer bracing elements 10 are connected to one another through the central assembling element 40 and are not connected along the perimeter of the quadrangular opening. Thus, the entire length perimeter of the quadrangular opening is never fully supported by bracing elements, thus allowing for easy dismantling.

FIG. 2A illustrates an exemplary system for use in the construction of a concrete wall with a quadrangle opening 38. The system comprises:

(a) four individual corner-bracing elements 10 having a right-angled side plane; and

(b) a central assembling element 40 for positioning the side planes of the corner bracing elements, so as to define a perimeter of the quadrangle opening 38. The corner bracing element of FIG. 2A is similar to the one shown in FIG. IB. Holes 22 of comer bracing element 10 are aligned with holes 42 of each arm 44 of central assembling element 40 and a screw and bolt 36 is used to firmly connect the two and prevent them from moving relative to one another.

FIG. 2B illustrates an exemplary system for use in the construction of a concrete wall with a quadrangle opening 38. The system comprises:

(a) four individual corner-bracing elements 10 having right-angled side plane; and

(b) a central assembling element 40 for positioning the side planes of the corner bracing elements, so as to define a perimeter of the quadrangle opening 38. The corner bracing element of FIG. 2B is similar to the one shown in FIG. 1C. Optionally, each comer bracing element comprise a comer supporting element 58, which serves to strengthen the stmcture. Slit 30 of corner bracing element 10 is aligned with hole 42 of each arm 44 of central assembling element 40 and a screw and bolt 36 is used to firmly connect the two and prevent them from moving relative to one another. Typically, the cross-shaped central assembling element 40 is used to define a quadrangle having a length of about 500 mm to 1000 mm, when the only bracing elements used are the corner bracing elements, although it will be appreciated that apertures of larger areas may also be constructed depending on the size and strength of the corner bracing element. Typically, at least half of the length of the perimeter is supported by the comer bracing elements. More preferably, three fifths of the length of the perimeter is supported by the comer bracing elements. In another embodiment, at least four fifths of the length of the perimeter is supported by the corner bracing elements. In still another embodiment, at least five sixths of the length of the perimeter is supported by the comer bracing elements. In another embodiment, no more than four fifths of the length of the perimeter is supported by the comer bracing elements. In still another embodiment, no more than five sixths of the length of the perimeter is supported by the comer bracing elements.

FIG. 3 illustrates an exemplary system for use in the construction of a concrete wall with a quadrangle opening 38. The system comprises:

(a) four individual corner-bracing elements 10 having right-angled side plane; and

(b) a central assembling element 40 having a square or rectangular shaped mount 46 for positioning the side planes of the comer bracing elements, so as to define a perimeter of the quadrangle opening 38. The corner bracing element of FIG. 3 is similar to the one shown in FIG. 1C. Slit 30 of comer bracing element 10 is aligned with hole 42 of each arm 44 which extends diagonally out from square shaped mount 46 of central assembling element 40. A screw and bolt 36 is used to firmly connect the two and prevent them from moving relative to one another.

Typically, the central assembling element 40 having a square shaped mount 46 may be used to define a quadrangle having a length of about 800 mm to 1500 mm, when the only bracing elements used are the comer bracing elements. Typically, at least half of the length of the perimeter is supported by the four comer bracing elements. More preferably, three fifths of the length of the perimeter is supported by the four comer bracing elements. In another embodiment, at least four fifths of the length of the perimeter is supported by the four corner bracing elements. In still another embodiment, at least five sixths of the length of the perimeter is supported by the four corner bracing elements. In another embodiment, no more than four fifths of the length of the perimeter is supported by the four corner bracing elements. In still another embodiment, no more than five sixths of the length of the perimeter is supported by the four corner bracing elements. In order to construct walls having larger openings, the present inventors further contemplate using additional bracing elements. Such bracing elements may be connected to the central assembling element 40 via additional securing mechanisms. Thus, for example, central assembling element 40 may comprise a central hole 48, as illustrated in FIG. ID and FIG. IE.

As mentioned, the system described herein can be used for firmly positioning a frame defining a quadrangle opening and firmly securing the frame onto a formwork. The system serves to bias the frame against cementitious material applied into a formwork.

FIG. 4 illustrates an exemplary frame according to embodiments of the invention. Frame 50 comprises four members (i.e. sides) connected there amongst at right angles, so as to form a quadrangular structure defining the opening. Each side of the frame may be connected to another side of the frame with a connector e.g. connector 56.

Frame 50 is typically fabricated from a water-resistant material, examples of which include, but are not limited to ceramic, porcelain, stone and a cement board. The sides of frame 50 may have a wide range of thicknesses less than 3 cm, e.g., 1 cm - 3 cm, less than 2 cm, e.g., 1.9 cm, or 1.5 cm or less, or even 9-12 mm.

The outer facing walls of frame 50 have cementitious material engaging elements 54 connected thereto. The outer walls of frame 50 may comprise at least one hole (e.g. a blind hole or an undercut hole) into which an undercut anchor is secured. Typically, each outer wall of frame 50 comprises a plurality of holes - for example at least four, one in each comer, at least 6, at least 8, at least 12. Depending on the size of the frame, more holes may be drilled.

The hole does not traverse the entire thickness of the walls, such that the inside of the frame is continuous and does not comprise a hole. The undercut anchor is flared using a flaring element, which is attachable to, or comprised of the cementitious material engaging element.

Cementitious material engaging element 54 has an elongated structure, a length, a cement embedding end and an undercut anchor attaching end. In one embodiment, cementitious material engaging element 54 is a metal pin. According to a particular embodiment, cementitious material engaging element 54 has a normal vector component in the cement embedding end which, during service, is positioned parallel to the side of the frame to which it is attached.

According to exemplary aspects of some embodiments of the invention, the normal vector component is formed, at least in part, by selecting cement embedding end of the cementitious material engaging element 54 with a bend.

According to exemplary aspects of some embodiments of the invention, cementitious material engaging element 54 is threaded at the cement embedding end and wherein the normal vector component is formed at least in part by a threaded surface of the cement embedding end. The cementitious material engaging element 54 may be the same or similar to the metal pins described in section 2378 Part 2 of the Israeli building standard, may be the same or similar to the metal pins described in section 2378 Part 5 of the Israeli building standard. In some exemplary embodiments of the invention the engaging element may be formed from a metal such as steel (e.g., a stainless steel rod) that has a diameter of at least 3 mm - 4 mm, e.g., 3.5 mm. According to some exemplary embodiments, larger diameter engaging elements may be used. The length of the part of the cementitious material engaging element 54 that actually engages the cement or concrete may be between 50-100 mm for example, between 60-80 mm.

In one embodiment, the flaring element may include a first portion of a connecting structure for connecting with a second portion of a connecting structure positioned at the undercut anchor attaching end of the cementitious material engaging element 54. According to some exemplary embodiments, the connection is defined to be loose so that engaging element 54 can wobble and/or move with respect to the flaring element. Flaring element may be a screw, bolt, or stud that is configured to flare undercut anchor with a screwing or bolting motion. According to some exemplary embodiments, first portion of the connecting structure is a head of the screw, bolt or stud. The connecting structure comprises first portion of flaring element directly or indirectly connected to second portion of cementitious material engaging element 54. The tightness or looseness of the connection between the first portion and second portion of the connecting structure (when in service), is physically determined by the relative sizes of the inner portion of the undercut anchor, the length of the flaring element, the size of the first portion, the size of the second portion and the decision of the assembler, as to what tightness or looseness to engage the parts together.

Further details concerning cementitious material engaging elements are described in PCT Application No. IL2022/050515, the contents of which are incorporated herein within.

A load dispersion element 52 may be used when attaching cementitious material engaging element 54 to the sides of frame 50 in accordance with some exemplary embodiments. The load dispersion element 52 may be used to disperse load over a surface area of the load dispersion element 52, so as to reduce load imposed by the flared undercut anchor on walls defining the hole on outer surface the wall of frame 50.

The load dispersion element 52 is placed tightly against the outer surface of the side of the frame to relieve lateral forces and blows by spreading the force over a larger surface area. The load dispersion element 52 may be a plate and/or a washer that is according to exemplary embodiments made of metal, e.g., steel. According to some exemplary embodiments of the invention, the load dispersion element is about 40 mm in diameter. Other examples of load-dispersing elements and methods of using same are described in PCT Application No. IL2022/050515, the contents of which are incorporated herein within.

The system described herein may be used in a method for preparing a formwork used for constructing a concrete wall with a quadrangle opening (e.g. a window opening or a door opening). The method comprises:

(a) securing the central assembling element to the four individual corner-bracing elements of the system of as described herein above to generate a bracing apparatus such that it is of a size that defines said quadrangle opening;

(b) securing the bracing apparatus to the outer sheet of the formwork; and

(c) installing a frame over the bracing apparatus, the frame being of a size that defines the quadrangle opening, each comer bracing element of the bracing apparatus being flush with a corner of the frame, thereby preparing the formwork used for constructing the concrete wall with a quadrangle opening.

Securing the bracing apparatus to the outer sheet of the formwork can be carried out using a securing apparatus - e.g. a threaded rod 66 or a screw and a bolt. Typically, the securing apparatus penetrates a hole 24 of connecting element 20 of comer bracing element 10. In one embodiment, each corner bracing element 10 is attached to the formwork via two screws or rods, each penetrating a hole 24 situated in connecting element 20 and a hole in the outer formwork.

A frame is constructed which defines the perimeter of the quadrangle.

Examples of frames are provided herein above and an exemplary frame that can be used according to the methods described herein is illustrated in FIG. 4. The frame comprises four members connected there amongst at right angles, so as to form a quadrangular stmcture defining said opening.

Preferably, the frame is constmcted such cementitious material engaging elements are connected to the outer surface thereof. The frame is installed over the bracing apparatus. The frame is not physically connected to the bracing apparatus with a connecting element (e.g. screw, rod etc.), but fits snugly over it. Thus, the bracing apparatus positions the frame on the outer sheet of the formwork and serves to firmly secure the frame onto the formwork. The bracing apparatus further serves to bias the frame against cementitious material applied into the formwork. When the frame is placed over the bracing apparatus, the corner-bracing elements firmly support an angle of the frame (e.g. right angle of the frame) and a part of associated two- cones defining the angle. The walls of the frame are not sufficiently strong to withstand the pressure of the concrete and rely on the bracing elements to prevent their collapse. If not already connected, the present invention contemplates connecting the cementitious material engaging elements to the outer surface of the frame following installation over the bracing apparatus.

End cladding elements (e.g. tiles) 60 may be arranged on the outer formwork so that they surround the frame, as illustrated in FIG. 5. Additional end-cladding elements may be arranged on the formwork so that the entire outer surface of the wall is cladded. The back surface of endcladding element 60 is attached to cementitious material engaging elements 52.

According to some exemplary embodiments, end-cladding elements used for cladding an exterior facing surface of a wall are porcelain or ceramic tiles. Such end-cladding elements may be fabricated from other man-made (i.e., synthetic) materials (such as high pressure laminate (HPL), concrete, Corian®, Caesarstone®), glass, clay, brick or with slate. According to some exemplary embodiments of the invention, the end-cladding element may have a water absorption of less than 0.5 %.

According to some exemplary embodiments, the end-cladding elements for cladding the exterior facing surface of the wall are spaced with spacers on the outer sheet of the formwork.

According to some exemplary embodiments, the end-cladding elements are secured against the outer sheet of the formwork with securing plates. According to some exemplary embodiments, the securing plates are arranged on the back surface of the end-cladding elements.

According to some exemplary embodiments, securing plates are rectangular plates with a bore through which a securing element is received. Securing element may extend through an outer sheet of a formwork and may be fixed with a nut element that engages securing element with a threaded connection. According to some exemplary embodiments, the threaded connection resists leakage of cementitious material through bore during casting and thereby provides a cleaner finish. In some exemplary embodiments, the securing plates are used in place of the tying method used in the Baranovich system.

Securing plates may be metal or may be another material that resists rust. According to some exemplary embodiments, securing plates is formed with Delrin®. According to some exemplary embodiments, securing plates are square with a width and height of 30 mm - 90 mm, e.g., about 60 mm. According to some exemplary embodiments the bore is 5 mm 15 mm, e.g., 7 mm, in diameter.

Further details on securing end-cladding elements to a formwork are provided in PCT Application No. IE2022/050515, the contents of which are incorporated herein within. Optionally, once secured to the formwork, the frame may be waterproofed using a sealant 62 (e.g. sealing strips, caulk or the like) - see for example FIG. 6. This ensures that no water leakages occur after casting and renders waterproofing following casting unnecessary.

According to some exemplary embodiments, the sealing strip is a 1 mm Ethylene Propylene Diene Monomer (EPDM) sheet. EPDM sheets are known to be used to weather-seal roofs and are outdoor and UV rated for over 80 years of use. Sealing strips 62 may be adhered to joins between the walls of the frame and between the frame and the end-cladding elements.

Once the outer sheet of the formwork is prepared, it may be used in a method to construct a cladded wall having a quadrangle opening. The method comprises:

(a) preparing a formwork according to the method described herein above;

(b) securing an inner sheet and the outer sheet of formwork with a formwork securing element;

(c) applying cementitious material into the formwork;

(d) allowing said cementitious material to harden with said cementitious material engaging element penetrating therein.

Reinforcements may be added to the defined volume, e.g., reinforcement metal bars or metal mesh prior to applying the cementitious material into the formwork. According to some exemplary embodiments, the cementitious material engaging elements penetrate holes of the reinforcement metal mesh and engage with the reinforcement metal mesh.

The inner sheet of the formwork and the outer sheet of the formwork may then be secured to one another to define a volume in which the cementitious material may be received. According to some exemplary embodiments, the cementitious material is added to the defined volume of the framework and allowed to dry. In some exemplary embodiments, the cementitious material is added with a pump pumping the cementitious material. In some exemplary embodiments, the cementitious material is added through a funnel to reduce the flow rate of the cementitious material within the volume.

After drying of the cementitious material, the framework may be removed leaving a wall having an aperture, as illustrated in FIG. 7. At least one surface of the wall (e.g. exterior facing surface) is cladded with end-cladding elements 60 as illustrated in FIG. 8. The central assembling element 20 may then be easily removed since the concrete does not harden around the join. Once the central assembling element 20 is dismantled, the corner bracing elements 10 may be removed by gentle tapping, leaving a complete wall having a frame defining an opening, as illustrated in FIG. 9. By utilizing this method corner bracing elements 10 may be reused to create a plurality of apertures making the method cost effective. Additionally because of the sealant that is used, energy losses out of the window are minimized.

The wall may be constructed at a building site or may be a pre-fabricated wall constructed at a worksite.

Once the wall is constructed with frame 50, it may serve as a blind frame. Alternatively, once the wall is constructed with the frame, the bottom portion of frame 50, may serve as a window sill.

Once the wall is constructed, a window pane or door may be inserted into frame 50. A window pane generally has a transparent window and a perimeter. Optionally the bottom member of frame 50 serves as a window sill. The bottom member of frame 50 may be tilted (i.e. at an angle) to allow water (i.e. rain) to run off the sill. Any type of window pane or door may be installed including aluminum, vinyl or wood.

As used herein the term “about” refers to ± 10 %.

The terms "comprises", "comprising", "includes", "including", “having” and their conjugates mean "including but not limited to".

The term “consisting of’ means “including and limited to”.

The term "consisting essentially of" means that the composition, method or structure may include additional ingredients, steps and/or parts, but only if the additional ingredients, steps and/or parts do not materially alter the basic and novel characteristics of the claimed composition, method or structure.

As used herein, the singular form "a", "an" and "the" include plural references unless the context clearly dictates otherwise. For example, the term "a compound" or "at least one compound" may include a plurality of compounds, including mixtures thereof.

Throughout this application, various embodiments of this invention may be presented in a range format. It should be understood that the description in range format is merely for convenience and brevity and should not be construed as an inflexible limitation on the scope of the invention. Accordingly, the description of a range should be considered to have specifically disclosed all the possible subranges as well as individual numerical values within that range. For example, description of a range such as from 1 to 6 should be considered to have specifically disclosed subranges such as from 1 to 3, from 1 to 4, from 1 to 5, from 2 to 4, from 2 to 6, from 3 to 6 etc., as well as individual numbers within that range, for example, 1, 2, 3, 4, 5, and 6. This applies regardless of the breadth of the range. Whenever a numerical range is indicated herein, it is meant to include any cited numeral (fractional or integral) within the indicated range. The phrases “ranging/ranges between” a first indicate number and a second indicate number and “ranging/ranges from” a first indicate number “to” a second indicate number are used herein interchangeably and are meant to include the first and second indicated numbers and all the fractional and integral numerals therebetween. In addition, any priority document(s) of this application is/are hereby incorporated herein by reference in its/their entirety.