EARLIEST PRIORITY DATE

This Application claims priority from a Complete patent application filed in India having Patent Application No. 202241034813, filed on June 17, 2022, and titled “WALL COMPONENT FORMWORKS AND A METHOD THEREOF”.

FIELD OF INVENTION

Embodiments of a present disclosure relate to construction methodologies, and more particularly to a plurality of wall component formworks and a method thereof.

BACKGROUND

Construction refers to the process of making buildings such as residential buildings, infrastructures, industrial facilities, and the like. Conventionally, the construction of buildings is carried out using bricks. Upon laying the foundation, a superstructure is created, and then brick masonry work is started, followed by several other steps, and then finally the building gets constructed. Such an approach, basically, requires external plastering, internal plastering, de-shuttering of temporary formworks, guided reinforcement bars, waterproofing, and skilled labor, thereby making such an approach time-consuming, less flexible, and labor-intensive.

Furthermore, such an approach also requires the curing of concrete, a huge capital investment, proper maintenance, and damage protection, thereby making such an approach expensive, less stable, and can cause steel corrosion.

Hence, there is a need for an improved plurality of wall component formworks and a method thereof which addresses the aforementioned issues.

BRIEF DESCRIPTION

In accordance with one embodiment of the disclosure, a plurality of wall component formworks is provided. The plurality of wall component formworks includes a plurality of wall panel fragments. Each of the plurality of wall panel fragments includes at least two wall pieces. Each of the at least two wall pieces includes at least three protrusions positioned on a corresponding inner surface of the corresponding at least two wall pieces with a predefined spacing between each other. Each of the at least two wall pieces also includes a first edge shaped into a first type of a predetermined receptacle connector. Each of the at least two wall pieces further includes a second edge shaped into a first type of a predetermined locking extension. The second edge is parallel to the first edge. Each of the plurality of wall panel fragments also includes at least three web members. Each of the at least three web members includes at least two parallel edges shaped into a second type of the predetermined receptacle connector. The at least two parallel edges are adapted to receive the corresponding at least three protrusions, upon sliding the corresponding at least three web members between the corresponding at least two wall pieces. The at least two parallel edges are also adapted to enable each of the at least three web members to connect the corresponding at least two wall pieces with each other, upon receiving the corresponding at least three protrusions, for obtaining a hollow structure for the plurality of wall panel fragments. Each of the at least three web members also includes a plurality of web-member-holes adapted to enable a flow of concrete in the hollow structure and between the plurality of wall panel fragments, when the plurality of wall panel fragments is interlocked with each other, for constructing a wall panel. The plurality of wall panel fragments is interlocked with each other via the first type of the predetermined receptacle connector and the first type of the predetermined locking extension. Each of the at least three web members further includes at least one notch positioned below the corresponding plurality of web-member-holes. The at least one notch is adapted to receive and hold at least one horizontal reinforcing bar in a predefined location, thereby obtaining the plurality of wall panel fragments of the plurality of wall component formworks.

In accordance with another embodiment, a wall panel is provided. The wall panel includes a plurality of wall component formworks. The plurality of wall component formworks includes a plurality of wall panel fragments. Each of the plurality of wall panel fragments includes at least two wall pieces. Each of the at least two wall pieces includes at least three protrusions positioned on a corresponding inner surface of the corresponding at least two wall pieces with a predefined spacing between each other. Each of the at least two wall pieces also includes a first edge shaped into a first type of a predetermined receptacle connector. Each of the at least two wall pieces further includes a second edge shaped into a first type of a predetermined locking extension. The second edge is parallel to the first edge. Each of the plurality of wall panel fragments also includes at least three web members. Each of the at least three web members includes at least two parallel edges shaped into a second type of the predetermined receptacle connector. The at least two parallel edges are adapted to receive the corresponding at least three protrusions, upon sliding the corresponding at least three web members between the corresponding at least two wall pieces. The at least two parallel edges are also adapted to enable each of the at least three web members to connect the corresponding at least two wall pieces with each other, upon receiving the corresponding at least three protrusions, for obtaining a hollow structure for the plurality of wall panel fragments. Each of the at least three web members also includes a plurality of web-member-holes adapted to enable a flow of concrete in the hollow structure and between the plurality of wall panel fragments, when the plurality of wall panel fragments is interlocked with each other, for constructing the wall panel. The plurality of wall panel fragments is interlocked with each other via the first type of the predetermined receptacle connector and the first type of the predetermined locking extension. Each of the at least three web members further includes at least one notch positioned below the corresponding plurality of web-member-holes. The at least one notch is adapted to receive and hold at least one horizontal reinforcing bar in a predefined location, thereby obtaining the plurality of wall panel fragments of the plurality of wall component formworks. The plurality of wall component formworks also includes a plurality of bottom track fragments having a U-shaped structure. The plurality of bottom track fragments is adapted to be fixed to a concrete footing using a first predefined fixing mechanism. The plurality of bottom track fragments is also adapted to create a plurality of channels upon fixing the corresponding plurality of bottom track fragments for fitting the plurality of wall panel fragments, based on a layout drawing corresponding to a construction of an entity. Each of the plurality of bottom track fragments include a plurality of bottom-track-holes. Each of the plurality of bottom-track-holes is adapted to receive at least one vertical reinforcing bar. The corresponding at least one vertical reinforcing bar is fixed to the concrete footing using a second predefined fixing mechanism. The plurality of wall component formworks further includes a plurality of corner panel fragments having a predefined shape. Each of the plurality of corner panel fragments includes a plurality of comer-panel-holes on at least four sides of the corresponding plurality of comer panel fragments. Each of the plurality of corner panel fragments also includes at least four edges shaped into a second type of the predetermined locking extension. The plurality of comer panel fragments is adapted to be applied for initiating construction of the wall panel used for constructing the entity by positioning the plurality of wall panel fragments adjacent to the corresponding plurality of corner panel fragments. The plurality of comer panel fragments is also adapted to affix the corresponding plurality of wall panel fragments to the corresponding plurality of corner panel fragments via the plurality of corner- panel-holes and the second type of the predetermined locking extension, thereby constmcting the wall panel using the plurality of wall component formworks.

In accordance with yet another embodiment, a method for constructing a wall panel using a plurality of wall component formworks is provided. The method includes assembling a plurality of wall panel fragments of the plurality of wall component formworks using a predefined assembly technique, wherein the each of the plurality of wall panel fragments includes at least two wall pieces including a first edge shaped into a first type of a predetermined receptacle connector and a second edge shaped into a first type of a predetermined locking extension. The method also includes providing a plurality of bottom track fragments having a U-shaped structure, upon assembling, wherein each of the plurality of bottom track fragments includes a plurality of bottom- track-holes. The method further includes enabling a fixing of the corresponding plurality of bottom track fragments to a concrete footing using a first predefined fixing mechanism. Furthermore, the method also includes receiving at least one vertical reinforcing bar, upon fixing the corresponding plurality of bottom track fragments. The method also includes fixing the corresponding at least one vertical reinforcing bar to the concrete footing using a second predefined fixing mechanism. Moreover, the method also includes providing a plurality of corner panel fragments having a predefined shape upon fixing the corresponding at least one vertical reinforcing bar, wherein the each of the plurality of corner panel fragments includes a plurality of corner-panel-holes and at least four edges shaped into a second type of the predetermined locking extension. Additionally, the method also includes positioning at least one of the plurality of corner panel fragments into the corresponding plurality of bottom track fragments. The method also includes positioning the plurality of wall panel fragments into the corresponding plurality of bottom track fragments, and adjacent to the at least one of the plurality of corner panel fragments for initiating the construction of the wall panel. Further, the method also includes affixing the corresponding plurality of wall panel fragments to the corresponding at least one of the plurality of comer panel fragments via the plurality of comer-panel-holes and the second type of the predetermined locking extension. Subsequently, the method also includes interlocking the plurality of wall panel fragments with each other, upon positioning the corresponding plurality of wall panel fragments adjacent to each other. The method further includes receiving at least one of a plurality of horizontal reinforcing bars and a plurality of vertical reinforcing bars, upon interlocking the plurality of wall panel fragments with each other. Additionally, the method includes enabling an arrangement of at least one of the plurality of horizontal reinforcing bars and the plurality of vertical reinforcing bars in a predefined manner. The method also includes providing support to the corresponding plurality of wall panel fragments using one or more panel bracings, upon arranging at least one of the plurality of horizontal reinforcing bars and the plurality of vertical reinforcing bars. Further, the method also includes pouring concrete inside of the plurality of wall component formworks, thereby constmcting the wall panel using the plurality of wall component formworks.

To further clarify the advantages and features of the present disclosure, a more particular description of the disclosure will follow by reference to specific embodiments thereof, which are illustrated in the appended figures. It is to be appreciated that these figures depict only typical embodiments of the disclosure and are therefore not to be considered limiting in scope. The disclosure will be described and explained with additional specificity and detail with the appended figures.

BRIEF DESCRIPTION OF THE DRAWINGS

The disclosure will be described and explained with additional specificity and detail with the accompanying figures in which:

FIG. 1 (a) is a schematic representation of an isometric view of a plurality of wall panel fragments of a plurality of wall component formworks in accordance with an embodiment of the present disclosure; FIG. 1 (b) is a schematic representation of a top view of the plurality of wall panel fragments of the plurality of wall component formworks of FIG. 1 (a) in accordance with an embodiment of the present disclosure;

FIG. 2 is a schematic representation of an isometric view of a plurality of bottom track fragments of the plurality of wall component formworks in accordance with an exemplary embodiment of the present disclosure;

FIG. 3 is a schematic representation of an isometric view of a plurality of corner panel fragments of the plurality of wall component formworks in accordance with an exemplary embodiment of the present disclosure;

FIG. 4 is a schematic representation of an isometric view of one or more panel connector fragments of the plurality of wall component formworks in accordance with an exemplary embodiment of the present disclosure;

FIG. 5 (a) is a schematic representation of an isometric view of one or more junction track-male fragments of the plurality of wall component formworks in accordance with an exemplary embodiment of the present disclosure;

FIG. 5 (b) is a schematic representation of an isometric view of one or more junction track-female fragments of the plurality of wall component formworks in accordance with an exemplary embodiment of the present disclosure;

FIG. 6 is a schematic representation of an isometric view of one or more corner stop fragments of the plurality of wall component formworks in accordance with an exemplary embodiment of the present disclosure;

FIG. 7 is a schematic representation of an isometric view of one or more top cap fragments of the plurality of wall component formworks in accordance with an exemplary embodiment of the present disclosure;

FIG. 8 is a schematic representation of an isometric view of one or more edge flashing fragments of the plurality of wall component formworks in accordance with an exemplary embodiment of the present disclosure; FIG. 9 is a schematic representation of an isometric view of a wall panel in accordance with an embodiment of the present disclosure;

FIG. 10 is a schematic representation of an exemplary embodiment of a top view of at least two wall panels of FIG. 9, interlocked with each other in accordance with an embodiment of the present disclosure;

FIG. 11 is a schematic representation of an exemplary embodiment of a side view of the wall panel of FIG. 9, supported with one or more panel bracings in accordance with an embodiment of the present disclosure;

FIG. 12 (a) is a flow chart representing steps involved in a method for constructing a wall panel using a plurality of wall component formworks in accordance with an embodiment of the present disclosure; and

FIG. 12 (b) is a flow chart representing continued steps involved in the method of FIG. 12 (a) in accordance with an embodiment of the present disclosure.

Further, those skilled in the art will appreciate that elements in the figures are illustrated for simplicity and may not have necessarily been drawn to scale. Furthermore, in terms of the construction of the device, one or more components of the device may have been represented in the figures by conventional symbols, and the figures may show only those specific details that are pertinent to understanding the embodiments of the present disclosure so as not to obscure the figures with details that will be readily apparent to those skilled in the art having the benefit of the description herein.

DETAILED DESCRIPTION

For the purpose of promoting an understanding of the principles of the disclosure, reference will now be made to the embodiment illustrated in the figures and specific language will be used to describe them. It will nevertheless be understood that no limitation of the scope of the disclosure is thereby intended. Such alterations and further modifications in the illustrated system, and such further applications of the principles of the disclosure as would normally occur to those skilled in the art are to be construed as being within the scope of the present disclosure. The terms "comprises", "comprising", or any other variations thereof, are intended to cover a non-exclusive inclusion, such that a process or method that comprises a list of steps does not include only those steps but may include other steps not expressly listed or inherent to such a process or method. Similarly, one or more devices or sub-systems or elements or structures or components preceded by "comprises... a" does not, without more constraints, preclude the existence of other devices, sub-systems, elements, structures, components, additional devices, additional sub-systems, additional elements, additional structures or additional components. Appearances of the phrase "in an embodiment", "in another embodiment" and similar language throughout this specification may, but not necessarily do, all refer to the same embodiment.

Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by those skilled in the art to which this disclosure belongs. The system, methods, and examples provided herein are only illustrative and not intended to be limiting.

In the following specification and the claims, reference will be made to a number of terms, which shall be defined to have the following meanings. The singular forms “a”, “an”, and “the” include plural references unless the context clearly dictates otherwise.

Embodiments of the present disclosure relate to a plurality of wall component formworks. As used herein, the term “form work” refers to temporary or permanent molds into which concrete or similar materials are poured. Therefore, the plurality of wall component formworks may refer to multiple formworks having the same or different structures, which are interlocked with each other for constructing a wall, wherein the wall thus constructed can be used to construct an entity. The entity may be a building such as a residential building, a commercial building, an industrial building, or the like. Further, the plurality of wall component formworks described hereafter in FIG. 1 is the plurality of wall component formworks.

FIG. 1 (a) is a schematic representation of an isometric view of a plurality of wall panel fragments (10) of a plurality of wall component formworks in accordance with an embodiment of the present disclosure. FIG. 1 (b) is a schematic representation of a top view of the plurality of wall panel fragments (10) of the plurality of wall component formworks of FIG. 1 (a) in accordance with an embodiment of the present disclosure. In a specific embodiment, the plurality of wall component formworks may be permanent formworks. In one embodiment, the plurality of wall component formworks may be composed of predefined material such as, but not limited to, polyvinyl chloride (PVC) based polymer components, glass fibers, electronic waste, High-density polyethylene (HDPE), HDPE waste, Polyphenylene Ether (PPE) of recycled components, or a combination thereof. The plurality of wall component formworks includes the plurality of wall panel fragments (10). In one exemplary embodiment, each of the plurality of wall panel fragments (10) may have one or more first predefined dimensions such as a width of about 300 millimeters (mm), a thickness of about 100 mm to about 350 mm, and the like.

Each of the plurality of wall panel fragments (10) includes at least two wall pieces (20). In one embodiment, the at least two wall pieces (20) may be flat and have a square shape, a rectangular shape, or the like. Therefore, in an embodiment, the plurality of wall panel fragments (10) may have a cubic shape, a cuboid shape, or the like. Each of the at least two wall pieces (20) includes at least three protrusions (30) positioned on a corresponding inner surface (40) of the corresponding at least two wall pieces (20) with a predefined spacing between each other. In one embodiment, the predefined spacing may be constant or may be variable. Each of the at least two wall pieces (20) also includes a first edge (50) shaped into a first type of a predetermined receptacle connector. As used herein, the term “receptacle connector” refers to a female connector that receives and holds a male connector. Each of the at least two wall pieces (20) further includes a second edge (60) shaped into a first type of a predetermined locking extension. As used herein, the term “locking extension” refers to a male connector that is pushed into a female connector. The second edge (60) is parallel to the first edge (50).

Each of the plurality of wall panel fragments (10) also includes at least three web members (70). Each of the at least three web members (70) includes at least two parallel edges (80) shaped into a second type of the predetermined receptacle connector. In one embodiment, the second type of the predetermined receptacle connector may be the same as the first type of the predetermined receptacle connector. In another embodiment, the second type of the predetermined receptacle connector may be different from the first type of the predetermined receptacle connector. The at least two parallel edges (80) are adapted to receive the corresponding at least three protrusions (30), upon sliding the corresponding at least three web members (70) between the corresponding at least two wall pieces (20). The at least two parallel edges (80) are also adapted to enable each of the at least three web members (70) to connect the corresponding at least two wall pieces (20) with each other, upon receiving the corresponding at least three protrusions (30), for obtaining a hollow structure for the plurality of wall panel fragments (10).

Basically, in an embodiment, each of the at least three web members (70) is connected to the corresponding at least two wall pieces (20) using a predefined connecting mechanism. In one exemplary embodiment, the predefined connecting mechanism may include a snap-lock mechanism. As used herein, the term “snap-lock mechanism” refers to a device or component which is fastened automatically when pushed into position. Therefore, when the corresponding at least three protrusions (30) may be pushed into the second type of the predetermined receptacle connector, the corresponding at least three web members (70) may get connected to the corresponding at least two wall pieces (20).

Each of the at least three web members (70) also includes a plurality of web-member- holes (90) adapted to enable a flow of concrete in the hollow structure and between the plurality of wall panel fragments (10), when the plurality of wall panel fragments (10) is interlocked with each other, for constructing a wall panel. The plurality of wall panel fragments (10) is interlocked with each other via the first type of the predetermined receptacle connector and the first type of the predetermined locking extension.

Each of the at least three web members (70) further includes at least one notch (100) positioned below the corresponding plurality of web-member-holes (90). The at least one notch (100) is adapted to receive and hold at least one horizontal reinforcing bar in a predefined location, thereby obtaining the plurality of wall panel fragments (10) of the plurality of wall component formworks. Basically, in an embodiment, the at least one notch (100) may be adapted to receive and hold the at least one horizontal reinforcing bar to prevent a movement of the corresponding at least one horizontal reinforcing bar. In one exemplary embodiment, the at least one notch (100) may have a diameter of about 25 mm. FIG. 2 is a schematic representation of an isometric view of a plurality of bottom track fragments (110) of the plurality of wall component formworks in accordance with an exemplary embodiment of the present disclosure. Basically, in an embodiment, the plurality of wall component formworks may also include the plurality of bottom track fragments (110) having a U-shaped structure. The plurality of bottom track fragments (110) may be adapted to be fixed to a concrete footing using a first predefined fixing mechanism. As used herein, the term “first predefined fixing mechanism” is defined as a mechanism which uses one or more fasteners for performing a fixing operation. In one embodiment, the one or more fasteners may include one or more screws, one or more bolts, one or more nuts, and the like.

The plurality of bottom track fragments (110) may also be adapted to create a plurality of channels upon fixing the corresponding plurality of bottom track fragments (110) for fitting the plurality of wall panel fragments (10), based on a layout drawing corresponding to a construction of an entity. In one embodiment, the entity may be a building such as a residential building, a commercial building, an industrial building, a low-rise building, a high-rise building, or the like.

Each of the plurality of bottom track fragments (110) may include a plurality of bottom-track-holes (120). Each of the plurality of bottom-track-holes (120) may be adapted to receive at least one vertical reinforcing bar. The corresponding at least one vertical reinforcing bar may be fixed to the concrete footing using a second predefined fixing mechanism. As used herein, the term “second predefined fixing mechanism” is defined as a mechanism in which adhesive material is used for performing a fixing operation. In one embodiment, the adhesive material may be concrete.

In one exemplary embodiment, each of the plurality of bottom track fragments (110) may have one or more second predefined dimensions such as a width of about 100 mm to about 350 mm, a height of about 50 mm, and the like.

FIG. 3 is a schematic representation of an isometric view of a plurality of corner panel fragments (130) of the plurality of wall component formworks in accordance with an exemplary embodiment of the present disclosure. In one embodiment, the plurality of wall component formworks may also include the plurality of corner panel fragments (130) having a predefined shape. In one embodiment, the predefined shape may include a cubic shape, a cuboid shape, or the like. Each of the plurality of comer panel fragments (130) may include a plurality of comer-panel-holes (140) on at least four sides (150) of the corresponding plurality of comer panel fragments (130). Each of the plurality of corner panel fragments (130) may also include at least four edges (160) shaped into the second type of the predetermined locking extension.

The plurality of comer panel fragments (130) may be adapted to be applied for initiating the constmction of the wall panel used for constructing the entity by positioning the plurality of wall panel fragments (10) adjacent to the corresponding plurality of corner panel fragments (130). The plurality of comer panel fragments (130) may also be adapted to affix the corresponding plurality of wall panel fragments (10) to the corresponding plurality of comer panel fragments (130) via the plurality of corner-panel-holes (140) and the second type of the predetermined locking extension. In one embodiment, the plurality of corner-panel-holes (140) may be adapted to receive the at least one horizontal reinforcing bar.

In one exemplary embodiment, each of the plurality of corner panel fragments (130) may have one or more third predefined dimensions for a cross-sectional view of the corresponding plurality of comer panel fragments (130) such as a length of about 100 mm to about 350 mm, a breadth of about 100 mm to about 350 mm, and the like.

FIG. 4 is a schematic representation of an isometric view of one or more panel connector fragments (170) of the plurality of wall component formworks in accordance with an exemplary embodiment of the present disclosure. In one embodiment, the plurality of wall component formworks may also include the one or more panel connector fragments (170) having an I-shaped stmcture. The one or more panel connector fragments (170) are adapted to slide down and affix between at least two of the plurality of wall panel fragments (10), thereby filling in a gap of a preferred dimension between the corresponding plurality of wall panel fragments (10). In one embodiment, the one or more panel connector fragments (170) may have one or more panel-connector-holes (180) for receiving the at least one horizontal reinforcing bar.

In one exemplary embodiment, each of the plurality of panel connector fragments (170) may have one or more fourth predefined dimensions such as a width of about 100 mm, a thickness of about 100 mm to about 350 mm, and the like. FIG. 5 (a) is a schematic representation of an isometric view of one or more junction track-male fragments (190) of the plurality of wall component formworks in accordance with an exemplary embodiment of the present disclosure. FIG. 5 (b) is a schematic representation of an isometric view of one or more junction track-female fragments (200) of the plurality of wall component formworks in accordance with an exemplary embodiment of the present disclosure. In one embodiment, the plurality of wall component formworks may also include one or more junction track fragments. Basically, the one or more junction track fragments may be adapted to be affixed to a corner of a first wall panel laterally using the first predefined fixing mechanism. The one or more junction track fragments may also be adapted to receive and interlock a second wall panel, wherein the second wall panel may be perpendicular to the first wall panel.

In one exemplary embodiment, the one or more junction track fragments may include the one or more junction track-male fragments (190) and the one or more junction track-female fragments (200). In one embodiment, the one or more junction trackmale fragments (190) may have a third type of the predetermined locking extension on at least two edges of the corresponding one or more junction track-male fragments (190). Similarly, in an embodiment, the one or more junction track-female fragments (200) may have a third type of the predetermined receptacle connector on at least two edges of the corresponding one or more junction track-female fragments (200).

Further, in one exemplary embodiment, each of the one or more junction track-male fragments (190) may have one or more fifth predefined dimensions such as a width of about 100 mm to about 350 mm, a thickness of about 12 mm, and the like. Similarly, in one exemplary embodiment, each of the one or more junction track-female fragments (200) may have one or more sixth predefined dimensions such as a width of about 100 mm to about 350 mm, a thickness of about 16 mm, and the like

FIG. 6 is a schematic representation of an isometric view of one or more comer stop fragments (210) of the plurality of wall component formworks in accordance with an exemplary embodiment of the present disclosure. In one embodiment, the plurality of wall component formworks may also include the one or more comer stop fragments (210). The one or more corner stop fragments (210) may have a L- shaped structure. Further, in an embodiment, the one or more corner stop fragments (210) may be adapted to be used when the wall panel may be ending at a corner in the entity.

In one exemplary embodiment, each of the one or more comer stop fragments (210) may have one or more seventh predefined dimensions such as a width of about 100 mm to about 350 mm, a thickness of about 50 mm, and the like.

FIG. 7 is a schematic representation of an isometric view of one or more top cap fragments (220) of the plurality of wall component formworks in accordance with an exemplary embodiment of the present disclosure. In one embodiment, the plurality of wall component formworks may also include the one or more top cap fragments (220). In one embodiment, the one or more top cap fragments (220) may have a U-shaped structure. Basically, in an embodiment, the one or more top cap fragments (220) may be used, when the wall panel may have at least one of one or more one door segments and one or more window segments.

The one or more top cap fragments (220) may be adapted to be fixed to at least one of a corresponding top portion of at least one of the one or more one door segments and the one or more window segments, and a corresponding bottom portion of at least one of the one or more one door segments and the one or more window segments. The one or more top cap fragments (220) may also be adapted to enable at least one of the corresponding one or more one door segments and the corresponding one or more window segments to withstand a concrete pour, upon fixing the corresponding one or more top cap fragments (220).

In one exemplary embodiment, each of the one or more top cap fragments (220) may have one or more eighth predefined dimensions such as a width of about 100 mm to about 350 mm, a height of about 50 mm, and the like.

FIG. 8 is a schematic representation of an isometric view of one or more edge flashing fragments (230) of the plurality of wall component formworks in accordance with an exemplary embodiment of the present disclosure. In one embodiment, the plurality of wall component formworks may also include one or more edge flashing fragments (230). Each of the one or more edge flashing fragments (230) may have at least two edges including a first-flashing edge (240) and a second-flashing edge (250). The first-flashing edge (240) may be extended perpendicularly to a first predefined extent, and towards a first side of the first-flashing edge (240). The second-flashing edge (250) may be extended perpendicularly to a second predefined extent, and towards both the first side of the first-flashing edge (240) and a second side of the first-flashing edge (240). In one exemplary embodiment, the first predefined extent may be about 50 mm. Similarly, in one exemplary embodiment, the second predefined extent may be about 100 mm. In one exemplary embodiment, each of the one or more edge flashing fragments (230) may have one or more ninth predefined dimensions such as a width of about 100 mm to about 350 mm, and the like.

Further, the one or more edge flashing fragments (230) may be adapted to seal a concrete slab laterally, wherein the concrete slab may be positioned between two floors of the entity. For example, the concrete slab may be positioned between a first floor and a second floor of a building, thereby acting as a ceiling for the first floor and a flooring for the second floor.

FIG. 9 is a schematic representation of an isometric view of a wall panel (260) in accordance with an embodiment of the present disclosure. The wall panel (260) includes a plurality of wall component formworks. The plurality of wall component formworks includes the plurality of wall panel fragments (10). Each of the plurality of wall panel fragments (10) includes the at least two wall pieces (20). Each of the at least two wall pieces (20) includes the at least three protrusions (30) positioned on the corresponding inner surface (40) of the corresponding at least two wall pieces (20) with the predefined spacing between each other. Each of the at least two wall pieces (20) also includes the first edge (50) shaped into the first type of the predetermined receptacle connector. Each of the at least two wall pieces (20) further includes the second edge (60) shaped into the first type of the predetermined locking extension. The second edge (60) is parallel to the first edge (50).

Each of the plurality of wall panel fragments (10) also includes the at least three web members (70). Each of the at least three web members (70) includes the at least two parallel edges (80) shaped into the second type of the predetermined receptacle connector. The at least two parallel edges (80) are adapted to receive the corresponding at least three protrusions (30), upon sliding the corresponding at least three web members (70) between the corresponding at least two wall pieces (20). The at least two parallel edges (80) are also adapted to enable each of the at least three web members (70) to connect the corresponding at least two wall pieces (20) with each other, upon receiving the corresponding at least three protrusions (30), for obtaining the hollow structure for the plurality of wall panel fragments (10).

Each of the at least three web members (70) also includes the plurality of web- member-holes (90) adapted to enable the flow of the concrete in the hollow structure and between the plurality of wall panel fragments (10), when the plurality of wall panel fragments (10) is interlocked with each other, for constructing the wall panel (260). The plurality of wall panel fragments (10) is interlocked with each other via the first type of the predetermined receptacle connector and the first type of the predetermined locking extension. Each of the at least three web members (70) further includes the at least one notch (100) positioned below the corresponding plurality of web-member-holes (90). The at least one notch (100) is adapted to receive and hold the at least one horizontal reinforcing bar in the predefined location, thereby obtaining the plurality of wall panel fragments (10) of the plurality of wall component formworks.

The plurality of wall component formworks also includes the plurality of bottom track fragments (110) having the U-shaped structure. The plurality of bottom track fragments (110) is adapted to be fixed to the concrete footing using the first predefined fixing mechanism. The plurality of bottom track fragments (110) is also adapted to create the plurality of channels upon fixing the corresponding plurality of bottom track fragments (110) for fitting the plurality of wall panel fragments (10), based on the layout drawing corresponding to the construction of the entity. Each of the plurality of bottom track fragments (110) includes the plurality of bottom-track-holes (120). Each of the plurality of bottom-track-holes (120) is adapted to receive the at least one vertical reinforcing bar. The corresponding at least one vertical reinforcing bar is fixed to the concrete footing using the second predefined fixing mechanism.

The plurality of wall component formworks further includes the plurality of corner panel fragments (130) having the predefined shape. Each of the plurality of comer panel fragments (130) includes the plurality of corner-panel-holes (140) on the at least four sides (150) of the corresponding plurality of corner panel fragments (130). Each of the plurality of comer panel fragments (130) also includes the at least four edges (160) shaped into the second type of the predetermined locking extension. The plurality of comer panel fragments (130) is adapted to be applied for initiating the construction of the wall panel (260) used for constructing the entity by positioning the plurality of wall panel fragments (10) adjacent to the corresponding plurality of corner panel fragments (130). The plurality of corner panel fragments (130) is also adapted to affix the corresponding plurality of wall panel fragments (10) to the corresponding plurality of corner panel fragments (130) via the plurality of corner-panel-holes (140) and the second type of the predetermined locking extension, thereby constructing the wall panel (260) using the plurality of wall component formworks.

In one exemplary embodiment, each of the plurality of wall component formworks may be manufactured in advance. Further, in an embodiment, the plurality of wall panel fragments (10) may be assembled at a site of the construction of the entity using a predefined assembly technique. In one embodiment, the predefined assembly technique may include performing a plurality of steps onto the at least two wall pieces (20) and the at least three web members (70) using an assembly machine.

In one embodiment, the assembly machine may include one or more loading units, one or more flat pack units, one or more tracks, and one or more conveyor rollers arranged in a predefined way. In one embodiment, the predefined way may refer to positioning the one or more flat pack units, the one or more tracks, and the one or more conveyor rollers alternatively and adjacent to each other. Further, the one or more loading units may be a crane-like structure hanging on top of the arrangement of the one or more flat pack units, the one or more tracks, and the one or more conveyor rollers.

In one exemplary embodiment, one or more prerequisites needed to be maintained prior to using the assembly machine may include at least one of a requirement of a three-phase power connection, a covered shed for covering the assembly machine, a plain cement concrete (PCC) for the covered shed to ensure an alignment of the assembly machine, and the like. Basically, the covered shed may be needed to avoid damage to the assembly machine due to rain or heat. An alternative for the covered shed may be a plastic cover, an impermeable material, or the like. Upon maintaining the one or more prerequisites, the plurality of steps may be implemented, and the plurality of wall panel fragments (10) may be obtained. FIG. 10 is a schematic representation of an exemplary embodiment of a top view of at least two wall panels (270) of FIG. 9, interlocked with each other in accordance with an embodiment of the present disclosure. In an embodiment, upon interlocking the plurality of wall panel fragments (10) with each other, at least one of a plurality of horizontal reinforcing bars (280) and a plurality of vertical reinforcing bars (290) may be passed through the plurality of wall component formworks.

Further, at least one of the plurality of horizontal reinforcing bars (280) and the plurality of vertical reinforcing bars (290) may be arranged in a predefined manner. The predefined manner may correspond to the plurality of horizontal reinforcing bars (280) and the plurality of vertical reinforcing bars (290) placed perpendicular to each other and crossing each other. Furthermore, in an embodiment, the plurality of horizontal reinforcing bars (280) may be bent (300) at a corner, and inside of the plurality of corner panel fragments (130). In such embodiment, at least one of the plurality of vertical reinforcing bars (290) may be passed through the bent (300), and inside of the corresponding plurality of vertical reinforcing bars (290) for locking the corresponding plurality of horizontal reinforcing bars (280) as shown in FIG. 10.

Moreover, in an embodiment, a corresponding top end of each of the plurality of vertical reinforcing bars (290) may be tied to the corresponding plurality of horizontal reinforcing bars (280) using a wire, thereby enabling the corresponding plurality of horizontal reinforcing bars (280) and the corresponding plurality of vertical reinforcing bars (290) to remain in a proper position during the concrete pour.

FIG. 11 is a schematic representation of an exemplary embodiment of a side view of the wall panel (260) of FIG. 9, supported with one or more panel bracings in accordance with an embodiment of the present disclosure. In one embodiment, the wall panel (260) may be supported with the one or more panel bracings to ensure that the plurality of wall component formworks is properly installed, located, aligned, and firm. In one embodiment, the one or more panel bracing may include at least one of one or more corner metal strips, one or more wooden logs (310), one or more aluminum angels (320), and the like.

In one exemplary embodiment, the one or more aluminum angels (320) may be fixed to the wall panel (260) using the first predefined fixing mechanism. Then, in an embodiment, the one or more wooden logs (310) are positioned by enabling the corresponding one or more wooden logs (310) to lean on the wall panel (260) by making a predefined angle with the concrete footing (330). In one embodiment, the predefined angle may include about 50 degrees to about 60 degrees. The one or more aluminum angels (320) are adapted to receive and hold the one or more wooden logs (310), when the corresponding one or more wooden logs (310) lean on the wall panel (260).

FIG. 12 (a) is a flow chart representing steps involved in a method (340) for constructing a wall panel using a plurality of wall component formworks in accordance with an embodiment of the present disclosure. FIG. 12 (b) is a flow chart representing continued steps involved in the method (340) of FIG. 12 (a) in accordance with an embodiment of the present disclosure. The method (340) includes assembling a plurality of wall panel fragments of the plurality of wall component formworks using a predefined assembly technique, wherein the each of the plurality of wall panel fragments includes at least two wall pieces including a first edge shaped into a first type of a predetermined receptacle connector and a second edge shaped into a first type of a predetermined locking extension in step 350.

The method (340) also includes providing a plurality of bottom track fragments having a U-shaped structure, upon assembling, wherein each of the plurality of bottom track fragments includes a plurality of bottom-track-holes in step 360.

The method (340) further includes enabling a fixing of the corresponding plurality of bottom track fragments to a concrete footing using a first predefined fixing mechanism in step 370.

Furthermore, the method (340) also includes receiving at least one vertical reinforcing bar, upon fixing the corresponding plurality of bottom track fragments in step 380. In one embodiment, receiving the at least one vertical reinforcing bar may include receiving the at least one vertical reinforcing bar via the plurality of bottom-track- holes.

The method (340) also includes fixing the corresponding at least one vertical reinforcing bar to the concrete footing using a second predefined fixing mechanism in step 390. Moreover, the method (340) also includes providing a plurality of corner panel fragments having a predefined shape upon fixing the corresponding at least one vertical reinforcing bar, wherein the each of the plurality of corner panel fragments includes a plurality of corner-panel-holes and at least four edges shaped into a second type of the predetermined locking extension in step 400.

Additionally, the method (340) also includes positioning at least one of the plurality of comer panel fragments into the corresponding plurality of bottom track fragments in step 410.

The method (340) also includes positioning the plurality of wall panel fragments into the corresponding plurality of bottom track fragments, and adjacent to the at least one of the plurality of comer panel fragments for initiating the constmction of the wall panel in step 420.

Further, the method (340) also includes affixing the corresponding plurality of wall panel fragments to the corresponding at least one of the plurality of comer panel fragments via the plurality of corner-panel-holes and the second type of the predetermined locking extension in step 430.

Subsequently, the method (340) also includes interlocking the plurality of wall panel fragments with each other, upon positioning the corresponding plurality of wall panel fragments adjacent to each other in step 440. In one embodiment, interlocking the plurality of wall panel fragments with each other may include interlocking the plurality of wall panel fragments with each other via the first type of the predetermined receptacle connector and the first type of the predetermined locking extension.

The method (340) further includes receiving at least one of a plurality of horizontal reinforcing bars and a plurality of vertical reinforcing bars, upon interlocking the plurality of wall panel fragments with each other in step 450.

Additionally, the method (340) includes enabling an arrangement of at least one of the plurality of horizontal reinforcing bars and the plurality of vertical reinforcing bars in a predefined manner in step 460. The method (340) also includes providing support to the corresponding plurality of wall panel fragments using one or more panel bracings, upon arranging at least one of the plurality of horizontal reinforcing bars and the plurality of vertical reinforcing bars in step 470.

Further, the method (340) also includes pouring concrete inside of the plurality of wall component formworks, thereby constructing the wall panel using the plurality of wall component formworks in step 480. In one embodiment, pouring the concrete may include pouring the concrete via a concrete pouring unit. In one exemplary embodiment, the concrete pouring unit may include a boom pump.

In one exemplary embodiment, assembling the plurality of wall panel fragments using the predefined assembly technique may include assembling the plurality of wall panel fragments using the predefined assembly technique, wherein the predefined assembly technique may include performing a plurality of steps onto the at least two wall pieces and the at least three web members using an assembly machine. In such embodiment, the plurality of steps may include providing the at least two wall pieces including a first wall piece and a second wall piece, wherein the first wall piece includes at least three first protrusions positioned on a first inner surface of the first wall piece, wherein the second wall piece includes at least three second protrusions positioned on a second inner surface of the second wall piece.

In an embodiment, the plurality of steps may also include inspecting each of the at least two wall pieces for including the first edge shaped into the first type of the predetermined receptacle connector and the second edge shaped into the first type of the predetermined locking extension. In such embodiment, inspecting each of the at least two wall pieces may include inspecting each of the at least two wall pieces via an inspection unit of the assembly machine.

Further, the plurality of steps may include providing the at least three web members upon inspecting each of the at least two wall pieces, wherein each of the at least three web members may include the at least two parallel edges (80) shaped into the second type of the predetermined receptacle connector.

Further, in one embodiment, the plurality of steps may also include loading the at least three web members vertically into a track associated with the assembly machine. In such an embodiment, loading the at least three web members vertically into the track may include loading the at least three web members vertically into the track via a loading unit of the assembly machine.

Furthermore, in an embodiment, the plurality of steps may include loading the first wall piece on a first surface of the track having the corresponding at least three web members loaded, wherein the at least three first protrusions are facing the first surface of the track. In such an embodiment, loading the first wall piece on the first surface of the track may include loading the first wall piece on the first surface of the track via the loading unit of the assembly machine.

Moreover, in an embodiment, the plurality of steps may also include aligning the at least three first protrusions with a corresponding first parallel edge of the at least two parallel edges of the corresponding at least three web members. In such embodiment, aligning the at least three first protrusions with the corresponding first parallel edge of the at least two parallel edges may include aligning the at least three first protrusions with the corresponding first parallel edge of the at least two parallel edges via the loading unit of the assembly machine.

In addition, in an embodiment, the plurality of steps may include pressing the first wall piece towards the corresponding at least three web members. In such embodiment, pressing the first wall piece may include pressing the first wall piece via a flat pack unit of the assembly machine.

Subsequently, the plurality of steps may also include interlocking the at least three first protrusions with the corresponding second type of the predetermined receptacle connector of the first parallel edge of the at least two parallel edges, upon pressing, thereby obtaining a plurality of partial wall panel fragments.

Later, in an embodiment, the plurality of steps may then include flipping the plurality of partial wall panel fragments for enabling a first outer surface of the first wall piece of each of the plurality of partial wall panel fragments facing the first surface of the track. In such embodiment, flipping the plurality of partial wall panel fragments may include flipping the plurality of partial wall panel fragments via the loading unit of the assembly machine. The plurality of steps may then include loading the second wall piece on the corresponding plurality of partial wall panel fragments, upon flipping. In such embodiment, loading the second wall piece on the corresponding plurality of partial wall panel fragments may include loading the second wall piece on the corresponding plurality of partial wall panel fragments via the loading unit of the assembly machine.

Further, in an embodiment, the plurality of steps may also include aligning the at least three second protrusions with a corresponding second parallel edge of the at least two parallel edges of the corresponding at least three web members. In such embodiment, aligning the at least three second protrusions may include aligning the at least three second protrusions via the loading unit of the assembly machine.

Furthermore, the plurality of steps may include pressing the second wall piece towards the corresponding at least three web members. In such embodiment, pressing the second wall piece may include pressing the second wall piece via the flat-pack unit of the assembly machine.

Moreover, the plurality of steps may finally include interlocking the at least three second protrusions with the corresponding second type of the predetermined receptacle connector of the second parallel edge of the at least two parallel edges, upon pressing, thereby obtaining the plurality of wall panel fragments.

In a specific embodiment, the method (340) may further include enabling a fixing of a plurality of service lines inside of the corresponding plurality of wall component formworks, upon arranging at least one of the plurality of horizontal reinforcing bars and the plurality of vertical reinforcing bars.

Later, in one exemplary embodiment, the method (340) may include providing one or more top cap fragments having a U-shaped structure upon fixing the plurality of service lines, when the wall panel may include at least one of one or more one door segments and one or more window segments. In such embodiment, the method (340) may also include enabling a fixing of the one or more top cap fragments to at least one of a corresponding top portion of at least one of the one or more door segments and the one or more window segments, and a corresponding bottom portion of at least one of the one or more one door segments and the one or more window segments. Further, the method (340) may also include enabling at least one of the corresponding one or more one door segments and the corresponding one or more window segments to withstand a concrete pour, upon fixing the corresponding one or more top cap fragments.

Various embodiments of the present disclosure enable the construction of the wall panel used in the construction of a building using the plurality of wall component formworks. The plurality of wall component formworks serves as a permanent durable finished formwork for encapsulating steel and concrete, thus improving the performance of one or more structural elements of the building. The use of the plurality of wall component formworks eliminates the need for de-shuttering and curing.

The wall panel is erected and filled with the concrete, in situ, to provide a monolithic concrete wall with enhanced curing capacity due to water entrapment, as the polymer encasement does not allow the concrete to dry prematurely with only the top surface of a wall obtained from the wall panel being exposed to potential drying. The polymer encasement provides crack control vertically and horizontally for the concrete and provides vertical tension reinforcement thus increasing the structural strength of the wall. The wall panel thus obtained is unique and provides substantial advantages in terms of structural strength, durability enhancement, weather resistance, seismic resistance, design flexibility, and ease of construction.

The wall obtained from the use of the plurality of wall component formworks is very efficient in terms of acoustic performance, weatherproof and highly resistant to termites’ attack, and is virtually maintenance-free. The plurality of wall component formworks has a specific advantage to use near coastal areas as durability is not affected due to salt-peter action. Further, usage of the plurality of wall component formworks for the construction of the buildings is more advantageous because of the elimination or reduction of usage of brickwork, external plastering, internal plastering, de-shuttering, guided reinforcing bars, waterproofing, and labor. Other construction benefits are the elimination of curing of concrete due to encapsulation, steel erosion, and constraint on the minimum required repetition of designs.

Furthermore, multiple units can be built simultaneously, and the plurality of wall component formworks has a higher thermal resistivity of about 54 percent, thereby making the plurality of wall component formworks energy efficient. Chances of leakages are minimized due to impervious walls, no holes caused by formwork holders, no moisture absorption, and capillary action. Structure life and stability improved significantly with greater structural stability due to the absence of seepage, air voids, steel corrosion, and concrete cancer. While specific language has been used to describe the disclosure, any limitations arising on account of the same are not intended. As would be apparent to a person skilled in the art, various working modifications may be made to the method in order to implement the inventive concept as taught herein.

The figures and the foregoing description give examples of embodiments. Those skilled in the art will appreciate that one or more of the described elements may well be combined into a single functional element. Alternatively, certain elements may be split into multiple functional elements. Elements from one embodiment may be added to another embodiment. For example, order of processes described herein may be changed and are not limited to the manner described herein. Moreover, the actions of any flow diagram need not be implemented in the order shown; nor do all of the acts need to be necessarily performed. Also, those acts that are not dependent on other acts may be performed in parallel with the other acts. The scope of embodiments is by no means limited by these specific examples.