Amorphous Formwork

Abstract

The invention disclose a method and formwork for casting concrete or concrete like elements where said elements may have an amorphous shape, wherein the method comprises the following steps: —in a block of formable material having a size larger than the element to be cast, a model of the element is cut out, thereby creating an inner formwork; —an outer load bearing support structure having an inner size corresponding to the outer dimensions of the block is created; —the parts of the block not representing the model are arranged in the interior of the load bearing support structure, thereby creating a cavity corresponding to the model; —optionally reinforcement is arranged in the cavity; fresh concrete or other concrete like material is poured into the cavity and allowed to cure; —the outer load bearing support structure and the inner formwork are removed.

1 . Method for casting concrete or concrete like elements ( 5 ), where said elements may have an amorphous shape, wherein the method comprises the following steps:
 in a formable material ( 10 ) having a size larger than the element to be cast, a model of the element is cut out, thereby creating an inner formwork ( 18 , 19 , 20 , 30 , 31 , 41 , 42 , 44 , 45 );   an outer load bearing support structure ( 21 , 50 ) having an inner size corresponding to the outer dimensions of the formable material ( 51 ) is created;   the parts ( 18 , 19 , 20 , 30 , 31 , 41 , 42 , 44 , 45 ) of the formable material not representing the model are arranged in the interior of the load bearing support structure ( 21 , 50 ), thereby creating a cavity corresponding to the model;   a release agent ( 54 , 47 , 53 ) either in liquid form or as a foil or membrane is arranged covering the cavity ( 52 ) in the inner formwork ( 51 ); optionally reinforcement is arranged in the cavity;   fresh concrete or other concrete like material is poured into the cavity and allowed to cure;   the outer load bearing support structure ( 21 , 50 ) and the inner formwork ( 51 ) are removed and where the elements ( 5 ) are sections of a larger structure, and where templates ( 13 , 14 , 32 , 43 , 46 ) defining end surfaces of the elements to be joined are used, such that surfaces of two adjacent elements to be joined, use the same template when the model is being cut out of the formable material.   
     
     
         2 . Method according to  claim 1  wherein the formable material is a block made from a polystyrene based product, and that a hot wire is used for cutting the model. 
     
     
         3 . Method according to  claim 1  wherein the inner formwork is pre-manufactured, and optionally allowed to remain in contact with the concrete during the hardening process, whilst another set of inner formwork is arranged inside the outer load bearing support structure. 
     
     
         4 . Method according to  claim 1  wherein a suitable release agent is applied to the formwork before casting, where the release agent is a liquid which is selected among one or more of the following: retarder, vegetable oil, oilbased wax, Vaseline, PE glue, latex, synthetic rubber, silicone. 
     
     
         5 . Method according to  claim 1  wherein a suitable release agent is applied to the formwork before casting, where the release agent is a membrane or foil, where the foil is flexible and made from latex, or synthetic rubber, where said membrane or foil optionally is preformed. 
     
     
         6 . Formwork for casting concrete or concrete like elements in the method according to  claim 1 , where said elements may have an amorphous shape, wherein the formwork comprises:
 an outer load bearing support structure ( 21 , 50 ), which support structure has means allowing the structure to be disassembled, thereby freeing   an inner formable structure ( 18 , 19 , 20 , 30 , 31 , 41 , 42 , 44 , 45 ), which inner structure defines the outer shape of the element to be cast, where said element has at least two surfaces, and where at least one surface is manufactured by cutting along a template, whereby the inner formable structure has a corresponding shape;   a liquid, foil or membrane release agent, covering the inner structure.   
     
     
         7 . Formwork according to  claim 6  wherein the inner formable structure is made from a polymer-based lightweight foam material. 
     
     
         8 . Formwork according to  claim 6  wherein the inner formable structure is made from a castable material, and that the inner formwork is created by casting the castable material around a model of the element to be cast.