Apparatus and method for forming concrete panels

Abstract

The invention provides a form member for use in forming concrete panels comprising a pair of upright walls connected by a plurality of ribs. Each of the ribs includes an aperture for allowing a fastener through. The fastener passes through each of the ribs into a casting floor to fix the form member to the floor. A plurality of form members can be arranged to define enclosures, concrete is then poured into the enclosures to the level of the upright walls, smoothed and allowed to cure to form concrete panels. The form members of the present invention allow a number of panels to be formed at the same time, with some form members common to more than one concrete panel. The invention provides easy of use and savings in space, time and labour.

1 . An apparatus for use in forming a concrete panel comprising a rigid form member, the form member comprising: 
 a pair of upright walls, having internal surfaces facing one another and external surfaces facing away from one another; and    a plurality of ribs connecting the internal surfaces of the walls, wherein the ribs each include an aperture to allow a fastener shaft therethrough.    
   
   
       2 . The apparatus according to  claim 1 , wherein the form member further includes a base portion including at least one chamfered surface extending outwardly from the exterior surface of one of the walls.  
   
   
       3 . The apparatus according to  claim 2 , wherein the base portion includes two chamfered surfaces, one extending outwardly from each of the exterior surfaces of the walls.  
   
   
       4 . The apparatus according to  claim 2 , wherein each chamfered surface is substantially non-perpendicular to the ribs.  
   
   
       5 . The apparatus according to  claim 1 , wherein the form member is formed in one piece.  
   
   
       6 . The apparatus according  claim 1 , further comprising a bolt having a shaft and a head, wherein, in use, the bolt shaft passes through the apertures and into a floor on which the form member sits.  
   
   
       7 . The apparatus according to  claim 6 , wherein the rib furthest from the floor provides a seat on which the bolt head rests.  
   
   
       8 . The apparatus according to  claim 6 , wherein in use, the upright walls extend above the extent of the bolt head.  
   
   
       9 . The apparatus according to  claim 6 , further including a cap, adapted to cover the bolt head.  
   
   
       10 . The apparatus according to  claim 9 , wherein in use, the cap does not extend above the upright walls.  
   
   
       11 . The apparatus according to  claim 9 , wherein the cap rests on the rib furthest from the floor.  
   
   
       12 . The apparatus according to  claim 1 , further including an extension piece, adapted to fit on the rigid form member at the opposite end to a base portion, the extension member comprising a pair of walls connected by a plurality of rib members.  
   
   
       13 . The apparatus according to  claim 12 , wherein the rib members of the extension piece each include an aperture to allow a fastener shaft therethrough.  
   
   
       14 . The apparatus according to  claim 1 , wherein the form member is formed from an aluminium alloy.  
   
   
       15 . The apparatus according to  claim 12 , wherein the extension piece is formed from an aluminium alloy.  
   
   
       16 . The apparatus according to  claim 1 , wherein an end of the form member is sealed between the upright walls.  
   
   
       17 . The apparatus according to  claim 1 , further comprising an end cap, wherein the end cap covers an end of the form member to prevent concrete entering a space between the upright walls.  
   
   
       18 . A kit for forming concrete panels comprising a plurality of form members in accordance with any one of the preceding claims and a plurality of exterior form members, wherein each exterior form member comprises a first wall, and a second wall, wherein the second wall is substantially perpendicular to the first wall and connected to the first wall to form a corner, wherein the second wall is substantially shorter than the first wall and wherein each of the first and second walls include apertures therethrough.  
   
   
       19 . The kit according to  claim 18 , wherein the exterior form members are formed from aluminium alloy.  
   
   
       20 . The kit according to  claim 18 , wherein the exterior form members are each formed in two parts.  
   
   
       21 . A method of forming a concrete panel, comprising the steps of: 
 arranging a plurality of form members or a kit of form members in accordance with any one of the preceding claims on a casting floor to define an enclosure;    fastening the form members to the floor using fasteners passed through the apertures; and    pouring concrete into the enclosure.    
   
   
       22 . The method according to  claim 21 , wherein the form members form a plurality of enclosures, with at least one form member being common to two enclosures.  
   
   
       23 . The method according to  claim 21 , further including the steps of: 
 allowing the concrete to set to form a panel; and    lifting the panel into a desired position.    
   
   
       24 . The method according to  claim 23 , further including the step of unfastening at least one of the form members defining the enclosure from the floor and removing those form members prior to the step of lifting the panel.  
   
   
       25 . The method according to  claim 21 , wherein the step of arranging further comprises placing exterior form members in two parallel lines and placing form members extending between the parallel lines to define enclosures.  
   
   
       26 . The method according to  claim 21 , wherein the step of arranging comprises placing form members in a grid pattern to define enclosures.  
   
   
       27 . The method according to  claim 21 , wherein the step of pouring concrete into the enclosure comprises pouring concrete up to the level of the upright walls.