AU2019101738A4

AU2019101738A4 - A void forming module and system therefor

Info

Publication number: AU2019101738A4
Application number: AU2019101738A
Authority: AU
Inventors: Alex Bowen; Nigel Mark Green; Nikola Quiel; Antonio Bruno Tigani
Original assignee: Neumann Steel Pty Ltd
Current assignee: Neumann Steel Pty Ltd
Priority date: 2018-07-02
Filing date: 2019-04-08
Publication date: 2020-07-16
Anticipated expiration: 2027-04-08
Also published as: AU2019202446A1; AU2019101738B4

Abstract

A void forming module including at least one hollow body with at least one upper surface and a lower abutment perimeter, and at least one shaped support extending from the at least one upper surface and terminating at a level coplanar with the lower abutment perimeter.

Description

I A VOID FORMING MODULE AND SYSTEM THEREFOR TECHNICAL FIELD

[0001] The present invention relates generally to a void forming module and more specifically to a void forming module configured to obviate the use of EPS void forming modules in concrete slab construction.

BACKGROUND ART

[0002] Expanded polystyrene void formers are currently in use to allow operators to form a concrete slab reducing the amount of concrete that is used. Normally, once a site is levelled, one or more operators will set up outside edge boards and completely cover the area in plastic sheeting, and working from one corner, lay out the expanded polystyrene void formers separated by a number of block spacers in a grid pattern within the formwork, as specified in the footing design.

[0003] Reinforcement bars are positioned on the void former spacers between the expanded polystyrene blocks. Top mesh can then be laid on top of the expanded polystyrene blocks, following design specifications and supported and spaced by mech chairs or rails.

[0004] The concrete is then poured over the top of the construction and vibrated well, ensuring intersecting ribs are fully filled and there is a minimum cover achieved as per engineer's specifications on void formers.

[0005] It is well known that expanded polystyrene blocks are an environmental hazard as well as having a relatively low fire rating. Prior art replacements for expanded polystyrene void formers have been developed. One of these is a system including a number of modules of domed bodies which are made of plastic material and which are suitable for being placed in position in a construction site with an own concavity turned towards the construction site itself and in conformity with modules of at least one domed body arranged laterally in relation to each other; a number of channels which are formed by the modules of the adjacent domed bodies and which are suitable for being filled with aggregating material in order to form bearing beams; and a number of interconnecting elements which are arranged in an intermediate position between at least two adjacent modules of domed bodies in order to connect the adjacent modules of domed bodies to each other.

[0006] This system however still uses multiples of two components namely the modules of at least one domed body and the number of interconnecting elements.

[00071 It will be clearly understood that, if a prior art publication is referred to herein, this reference does not constitute an admission that the publication forms part of the common general knowledge in the art in Australia or in any other country.

SUMMARY OF INVENTION

[00081 The present invention is directed to a void forming module, which may at least partially overcome at least one of the abovementioned disadvantages or provide the consumer with a useful or commercial choice.

[0009] With the foregoing in view, the present invention in one form, resides broadly in a void forming module including at least one hollow body with at least one upper surface and a lower abutment perimeter, and at least one shaped support extending from the at least one upper surface and terminating at a level coplanar with the lower abutment perimeter.

[0010] Preferably, the void forming module of a preferred embodiment will include at least one integrated bar support, preferably formed integrally with the remainder of the module.

[0011] Preferably, the hollow body tapers inwardly from the lower abutment perimeter as it extends upwardly towards the at least one upper surface. Preferably, this forms a hollow body which is generally frustum shaped. In a particularly preferred configuration wherein the hollow body is substantially rectangular, the void forming module overall has a frustopyramidal shape, although as will become clear from the discussion below, the dimensions of the body can differ.

[0012] In a preferred form, the module of the present invention will also include at least one attachment assembly to attach a module to or relative to at least one and preferably a number of other modules which have the same configuration. In a most preferred form, the at least one attachment assembly is or is a part of at least one bar support provided at or relative to the perimeter of the module.

[0013] The void forming module of the present invention will normally be used with other void forming modules of the same or a similar type in order to form one or more voids in a concrete slab construction setting. Multiple void forming modules will be provided, typically in a regular array. Normally, at least a portion of the multiple void forming modules will abut or engage one another in use in order to maintain the position of the modules during formation of the slab.

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[00141 The void forming module of a preferred embodiment is generally rectangular although any shape could be used.

[0015] The void forming module of the present invention includes at least one hollow body. The hollow body will preferably be generally rectangular and frustum shaped.

[0016] The void forming module of the present invention may be divided into a number of submodules. Preferably, one or more of the submodules may be separable from one another, usually by cutting between the submodules but it is anticipated within the scope of the present invention that a line of weakness may be provided to allow an operator to separate the submodules using an appropriate cutting implement.

[00171 The submodules may have any configuration within the module. Particularly preferred configurations have three submodules provided, one submodules which is approximately half the dimension of the module and the other two submodules which are each approximately one quarter of the dimension of the module. This allows the separation of the submodules to form a submodule which is half the dimension of the void forming module, or to remove one of the quarter submodules which will necessarily form a one quarter submodule and a three-quarter module made from the one-half submodule and one of the quarter submodules. This will allow minimisation of waste by giving an operator more options for using the module, for example using the module as a complete full-size module, a three-quarter size module, a half size module and 1/4size module, in order to fit the modules into a specific dimension for a slab.

[00181 Preferably, the submodules are arranged linearly, that is, each of the two quarter size modules are the full width of the module but a quarter of the length of the module rather than dividing one half of the module into two side-by-side half-width and half-length submodules.

[0019] The submodules typically each have at least one upper surface and 4 sidewalls which depend from the upper wall and at least one laterally extending flange provided about a lower side of each of the 4 sidewalls forming a part of the lower abutment perimeter for the submodule but also for the module as a whole. The submodules are typically joined to one another by the at least one laterally extending flange extending therebetween.

[0020] A ridge or similar may be provided between adjacent submodules, extending at least partially along the preferred laterally extending flange between the adjacent submodules. The ridge will preferably act to strengthen the laterally extending flange. Preferably, the ridge will be formed through the provision of a hollow, raised portion. Typically, the raised portion is concave or hollow on a bottom side thereof. An additional advantage of the provision of a high raised

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portion is that the underside of the hollow raised portion can provide a guide for the separation of the submodules, for example for receiving a cutting implement.

[0021] The hollow body will normally have one or more shaped supports, typically a plurality of shaped supports provided within or partially within a hollow volume formed by the at least one upper surface and at least one sidewall. The number of sidewalls provided on the hollow body will typically depend upon the shape desired or required of the hollow body. In a preferred embodiment, the hollow body will be rectangular and include four sidewalls. The shaped support may be formed at least partially in or as a part of one or more of the sidewalls.

[0022] At least one shaped support is provided on each void forming module extending from the at least one upper surface and terminating at a level coplanar with the lower abutment perimeter.

[0023] Preferably, each module is provided with a number of shaped supports with the number and layout of the shaped supports largely being determined by the shape and configuration of the module itself.

[0024] The shaped supports may have any shape but a particularly preferred shape is circular when viewed in plan. Each shaped support will preferably taper from a larger dimensioned upper end to a smaller dimensioned lower end. Each of the shaped supports will typically be hollow. The lower end of each shaped support will typically be open.

[0025] The shaped supports will typically be integrally with the upper surface, preferably with an arcuate transition zone between the preferred substantially planar upper surface and the depending shaped support. The shaped support in a preferred embodiment will typically be a hollow, frustoconical shape.

[0026] The shaped supports will typically be provided in a regular array relative to the at least one upper surface of each module. As mentioned above, any number of shaped supports may be provided depending upon the shape and configuration of the module.

[00271 One or more partial supports may be provided. A partial support is typically configured as a part only of the preferred shape support. For example, a partial support of the hollow frustoconical shaped supports would be an arcuate or semicircular, frustoconical shaped support rather than an enclosed frustoconical shape. Typically, more than one partial support may be provided at a periphery of the at least one upper surface and extend at least partially into one or more of the sidewalls. The provision of partial support may allow the module to be cut to different sizes and then at least partially overlap portions of the cut module with a full module in order to fit into the available space. The provision of the partial supports may also provide additional strength to the periphery of the module.

[0028] A lower end of each of the shaped supports will typically terminate at a level which is coplanar with the lower abutment perimeter. One or more radially extending foot portions may be provided but preferably, a lower end edge of each of the shaped supports simply terminates at a level coplanar with the lower abutment perimeter. As mentioned, the lower end of each of the shaped supports (and partial supports) will typically be open.

[0029] In a preferred form, a partial support will preferably be provided along one of the longer side edges, and preferably along each of the longer side edges of the module and/or each sub module. Typically, in this form, each partial support will be a half support and where a longer side edge of a sub-module faces a longer side edge of an adjacent sub module, it is preferred that a partial support is provided in each longer side edge of each sub module.

[0030] Typically, a single partial support is provided approximately halfway along the length of a sidewall.

[0031] The shorter length side walls of a sub module may not need a support to be provided because of the shorter length and therefore, a support or partial support may not be provided on a shorter length side wall of sub module.

[0032] Each hollow body is provided with at least one upper surface, and preferably, a single upper surface is provided. Each of the sidewalls provided preferably extend from the at least one upper surface. Preferably each of the sidewalls will extend from the upper surface at an angle relative thereto. The angle of the sidewalls relative to the upper surface or is close to perpendicular, but preferably slightly out of perpendicular. According to a particularly preferred embodiment, the at least one sidewall will preferably be angled at approximately 88.5 relative to the plane of the at least one upper surface. Providing sidewalls at a slight angle out of perpendicular relative to the at least one upper surface will preferably form the taper of the preferred frustum shape. The taper will typically allow multiple void forming modules to be stacked one on top of one another for a reduction in space, particularly during transport.

[0033] An arcuate transition zone is typically provided at the corners between the at least one upper surface and each of the at least one side walls in order to increase the strength of the module and/or between the adjacent sidewalls.

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[00341 It is preferred that the at least one upper surface be substantially planar. A surface texture or finish is preferably provided to the at least one upper surface to increase friction.

[0035] Each hollow body also includes a lower abutment perimeter. The lower abutment perimeter may be formed from the bottom edge of at least one sidewall but preferably, at least one laterally extending flange is provided, extending from each at least one sidewall. It is preferred that the at least one laterally extending flange is provided substantially parallel to, but spaced from the at least one upper surface. A laterally extending flange is preferably provided about the perimeter of the module and/or about each sub-module if provided.

[0036] In the preferred configuration of a rectangular module with four sidewalls, a laterally extending flange will preferably be provided from each of the sidewalls.

[00371 Each laterally extending flange preferably has at least a part of a bar support to allow placement of a reinforcing bar thereon to position the reinforcing bar relative to the void forming module. Preferably, each module will include a pair of bar supports spaced apart on each of the laterally extending flanges at the perimeter of the module. In the preferred rectangular embodiment, each module will preferably have eight bar supports, two on each side.

[0038] The bar supports are preferably provided between a sidewall of the body and one of the preferred laterally extending flanges, but preferably formed integrally therewith.

[0039] The bar support may take any form. The bar support may have any shape but is preferably configured as a cradle with at least one support surface spaced above the lower abutment perimeter. In a particularly preferred form, the bar support will have a pair of support surfaces oriented at an obtuse angle relative to one another to form an angled depressed junction or cradle or valley to support a bar thereon. Preferably, the inner angled support surface nearer to the sidewall of the module is longer than the outer angled support surface which will space the junction or cradle or valley, and therefore the bar, from the sidewall of the module. The bar supports will preferably orient the bar substantially parallel to at least one of the sidewalls of the module.

[0040] In a particularly preferred embodiment, each bar support will be substantially V shaped or U-shaped when viewed from the side. Each bar support will preferably be substantially V-shaped or U-shaped when viewed from the front. In the most preferred form, the bar support will be substantially V-shaped or U-shaped from both the side and the front as this shape will preferably spread the load of the bar more effectively and also act to locate the bar in the depressed junction or cradle or valley of the bar support.

[00411 A locating formation, preferably in the form of a locating flange will preferably be provided on an elevated central portion of the bar support extending substantially perpendicularly to the sidewall of the module. Each locking flange will typically have an upper edge which is angled downwardly away from the wall. The upper edge of each of the locking flange is will preferably act to guide the bar into the depressed junction or cradle or valley.

[0042] Each locating flange will typically have an outer edge which is substantially vertical.

[0043] As mentioned above, it is preferred that the junction or cradle or valley of the bar support is spaced from the sidewall of the module and preferably, an outer edge of the locking flange will be positioned adjacent to but slightly spaced from the bottom of the valley, typically approximately half of the width of the preferred bar which the bar support is adapted to support.

[0044] In use, the bar supports of adjacent modules will preferably be overlapped with one another during the layout of the modules. An operator will typically overlap the edges of adjacent modules such that the bar supports of the respective adjacent modules aligned with one another and the junction or cradle or valley of the respective bar supports on the adjacent modules are also aligned. This will typically form a bar opening between the outer edges of the respective locking flanges of the overlapped bar supports. In use, once a bar is inserted into the bar opening, the respective locking flanges will either abuts the bar on each side locking the adjacent modules together or alternatively, if forces are applied to try to separate the adjacent modules, then the bar will typically abut the respective locking flanges, resisting separation.

[0045] The void forming module the present invention will preferably include at least one, and typically a number of bar chairs relative to the at least one upper surface of each of the modules and/or submodules. Typically, the bar chair will be or include a raised portion or protrusion which extends above the upper surface of the module.

[0046] Preferably, each of the bar chairs is elongate. Normally, the bar chairs will be spaced from one another over the module in order to provide an enlarged support area. Typically, each of the bar chairs is generally triangular in cross-sectional shape with an arcuate upper surface to provide increased strength.

[00471 In a preferred embodiment, each of the bar chairs will typically be located adjacent to a side edge of the upper surface. Typically, a pair of bar chairs are provided on one lateral side of the module or submodule and a pair of bar chairs are provided on an opposite lateral side of the module or submodule.

[00481 The bar chairs do not have to have the same dimension as one another and indeed, a pair of larger bar chairs may be provided and a pair of smaller bar chairs may be provided on each module or submodule.

[0049] A number of openings may be provided in the upper surface of the module in order to locate bar rails relative to the module if required. In a preferred configuration, a bar rail support may be used for thicker slabs in order to position a layer of reinforcing mesh or bar above the height of the module. In one particularly preferred embodiment, a bar rail support may be provided with a pair of spiked engagement portions which may be located into the openings on the upper surface of the module in order to positively locate the bar rail support relative to the module and to retain the bar rail support in a particular orientation relative to the module.

[0050] Generally, a pair of openings is provided substantially parallel to but spaced from each of the side edges of the module and/or submodule.

[0051] The location of modules in the preferred layout forms a number of channels between the adjacent modules and which are suitable for being filled with aggregate material such as concrete or similar in order to form bearing beams. In another form, the present invention resides in a plurality of modules laid out in a regular array in this way.

[0052] The module of the preferred embodiment will typically be formed in a single piece and be of unitary construction. Typically, the module will be manufactured of a plastic material but other materials may be used if appropriate or if they have material characteristics that are required or desired in the module. Portions of the module may be formed from one or more different materials.

[0053] Any of the features described herein can be combined in any combination with any one or more of the other features described herein within the scope of the invention.

[0054] The reference to any prior art in this specification is not, and should not be taken as an acknowledgement or any form of suggestion that the prior art forms part of the common general knowledge.

BRIEF DESCRIPTION OF DRAWINGS

[0055] Preferred features, embodiments and variations of the invention may be discerned from the following Detailed Description which provides sufficient information for those skilled in the art to perform the invention. The Detailed Description is not to be regarded as limiting the scope of the preceding Summary of the Invention in any way. The Detailed Description will make reference to a number of drawings as follows:

[0056] Figure 1 is an isometric view from above of a void forming module according to a first preferred embodiment of the present invention.

[00571 Figure 2 is an isometric view from below of the void forming module illustrated in Figure 1.

[0058] Figure 3 is a view from above of the void forming module illustrated in Figure 1.

[0059] Figure 4 is a view from below of the void forming module illustrated in Figure 1.

[0060] Figure 5 is a side view of the void forming module illustrated in Figure 1.

[0061] Figure 6 is a section view of the void forming module illustrated in Figure 4 along line B-B.

[0062] Figure 7 is a sectional view of the void forming module illustrated in Figure 3 along line A-A.

[0063] Figure 8 is a detailed view of the circled portion illustrated in Figures 7 and

[0064] Figure 9 is a detailed view of an edge area of a pair of void forming modules as illustrated in Figure 1 and particularly the bar supports, when the void forming modules are stacked.

[0065] Figure 10 is a detailed view of an overlap of the bar supports of a pair of adjacent void forming modules in use.

[0066] Figure 11 is an isometric view from above of a void forming module according to a second preferred embodiment of the present invention.

[00671 Figure 12 is an isometric view from below of the void forming module illustrated in Figure 11.

[0068] Figure 13 is a view from above of the void forming module illustrated in Figure 11.

[0069] Figure 14 is a view from below of the void forming module illustrated in Figure 11.

[00701 Figure 15 is a side view of the void forming module illustrated in Figure 11.

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[00711 Figure 16 is a section view of the void forming module illustrated in Figure 14 along line D-D.

[0072] Figure 17 is a sectional view of the void forming module illustrated in Figure 13 along line C-C.

[0073] Figure 18 is a detail view of the portion illustrated in Figure 15 and identified using reference letter E.

DESCRIPTION OF EMBODIMENTS

[0074] According to two particularly preferred embodiments of the present invention, a void forming module 10 is provided.

[00751 Two preferred embodiments are illustrated in the Figures namely, a first preferred embodiment illustrated in Figures 1 to 7 and a second preferred embodiment illustrated in Figures 11 to 18. Figures 8 to 10 show features that are applicable to both preferred embodiments.

[0076] The void forming module 10 of both embodiments includes at least one hollow body with an upper surface 11 and a lower abutment flange 12 about the perimeter of the module 10, and at least one shaped support 13 extending from the upper surface 11 and terminating at a level coplanar with the lower abutment flange 12.

[00771 The void forming module 10 includes a number of integrated bar supports 14, formed integrally with the remainder of the module 10.

[0078] As illustrated, the hollow body tapers inwardly from the lower abutment perimeter flange 12 as it extends upwardly towards the upper surface 11 to form a hollow body which is generally frustum shaped. In a particularly preferred configuration wherein the hollow body is substantially rectangular, the void forming module 10 overall has a frustopyramidal shape, although as will become clear from the discussion below, the dimensions of the body of the module can differ.

[00791 In the preferred forms illustrated, the module 10 includes a number of attachment assemblies to attach a module 10 to or relative to a number of other modules 10 which have the same configuration. In a most preferred form, the attachment assembly is or is a part of each of the bar supports provided at or relative to the perimeter of the module 10.

[00801 The void forming module 10 is normally used with other void forming modules of the same or a similar type in order to form one or more voids in a concrete slab construction setting. Multiple void forming modules are provided, typically in a regular array. Normally, at least a portion of the multiple void forming modules to abut or engage one another in use in order to maintain the position of the modules during formation of the slab.

[0081] As illustrated, the void forming module 10 is generally rectangular although any shape could be used.

[0082] The void forming module of the present invention includes at least one hollow body. The hollow body will preferably be generally rectangular and frustum shaped, having a number of sidewalls 15 that are angled relative to the upper surface 11.

[0083] As shown in Figures 11 to 18, the void forming module 10 may be divided into a number of submodules 16. The submodules may be separable from one another, usually by cutting between the submodules but it is anticipated within the scope of the present invention that a line of weakness may be provided to allow an operator to separate the submodules by hand, for example by snapping along the line of weakness.

[0084] The submodules may have any configuration within the module 10. The particularly preferred configuration illustrated in Figures 11 to 18 has three submodules provided, one submodule 16 which is approximately half the dimension of the module 10 and the other two submodules 17 which are each approximately one quarter of the dimension of the module 10. This allows the separation of the submodules 16, 17 to form a submodule which is half the dimension of the void forming module 10, or to remove one of the quarter submodules 17 which will necessarily form a one quarter submodule and a three-quarter module made from the one half submodule and one of the quarter submodules. This will allow minimisation of waste by giving an operator more options for using the module, for example using the module as a complete full-size module, a three-quarter size module, a half size module and 1/4size module, in order to fit the modules into a specific dimension for a slab.

[00851 Preferably, the submodules 16, 17 are arranged linearly as shown, that is, each of the two quarter size modules 17 are the full width of the module 10 but a quarter of the length of the module 10 rather than dividing one half of the module into two side-by-side half-width and half length submodules.

[00861 The submodules 16, 17 typically each have an upper wall 11 and four sidewalls 15 which depend from the upper wall 11 and a laterally extending flange 12 provided about a lower

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side of each of the sidewalls 15 forming a part of the lower abutment perimeter for the submodule but also for the module 10 as a whole. The submodules 16, 17 are typically joined to one another by the laterally extending flange 12 extending therebetween.

[00871 A ridge 18 or similar is preferably provided between adjacent submodules, as shown in Figures 11, 14 and 18 extending at least partially along the laterally extending flange 12 between the adjacent submodules. The ridge 18 preferably acts to strengthen the laterally extending flange 12. As shown, the ridge 18 is formed through the provision of a hollow, raised portion and the ridge 18 is hollow on a bottom side thereof as shown in Figure 12. An additional advantage of the provision of a hollow ridge 18 is that the underside of the hollow raised portion can provide a guide for the separation of the submodules, for example for receiving a cutting implement.

[0088] The hollow body of the module or submodule will normally have one or more shaped supports 13, typically a plurality of shaped supports 13 provided within or partially within a hollow volume formed by the upper wall 11 and sidewalls 15 as shown in Figure 2. The number of sidewalls 15 provided on the hollow body will typically depend upon the shape desired or required of the hollow body. In a preferred embodiment, the hollow body will be rectangular and include four sidewalls 15. The shaped support 13 may be formed at least partially in or as a part of one or more of the sidewalls 15.

[0089] The embodiment illustrated in Figures 1 to 7 has one, central shaped support 13 provided extending from the at upper wall 11 and terminating at a level coplanar with the lower abutment perimeter.

[0090] The shaped supports 13 may have any shape but a particularly preferred shape is recctangular when viewed in plan. Each shaped support 13 will preferably taper from a larger dimensioned upper end to a smaller dimensioned lower end. Each of the shaped supports 13 is normally hollow and the lower end of each shaped support can be open or closed.

[0091] The shaped supports will typically be integrally formed with the upper surface, with an arcuate transition zone between the substantially planar upper surface and the depending shaped support 13. The shaped support 13 in a preferred embodiment will typically be a hollow, frustopyrimidal shape.

[0092] One or more partial supports 19 may be provided. A partial support 19 is typically configured as a part only of the preferred shaped support. For example, a partial support of the hollow frustopyrimidal shaped supports is be a triangular, frustopyrimidal shaped support rather

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than an enclosed frustopyrimidal shape. Typically, more than one partial support 19 may be provided at a periphery of the at least one upper surface and extend at least partially into one or more of the sidewalls 15 as shown in the embodiment illustrated in Figures 1 to 7.

[0093] A lower end of each of the shaped supports 13 will typically terminate at a level which is coplanar with the lower abutment perimeter. One or more radially extending foot portions may be provided but preferably, a lower end edge of each of the shaped supports simply terminates at a level coplanar with the lower abutment perimeter.

[0094] In a preferred form, a partial support 19 is provided along one of the longer side edges, and preferably along each of the longer side edges of the module 10 (as shown in Figures I to 7) and/or each submodule 16, 17 (as shown in Figures 11 to 18). Typically, in this form, each partial support 19 will be a half support and where a longer side edge of a sub-module 16, 17 faces a longer side edge of an adjacent sub module 16, 17, a partial support is provided in each longer side edge of each sub module 16, 17.

[0095] As illustrated in Figures 11 to 17, the shorter length side walls of a sub module 16, 17 may not need a support 13 or partial support 19 to be provided because of the shorter length and therefore, a support 13 or partial support 19 may not be provided on a shorter length side wall of the submodule 16, 17.

[0096] Each hollow body is provided with at least one upper wall with an upper surface, and preferably, a single upper wall and surface is provided. Each of the sidewalls 15 provided preferably extend from the at least one upper surface at an angle. The angle of the sidewalls relative to the upper surface or is close to perpendicular, but preferably slightly out of perpendicular. According to a particularly preferred embodiment, the sidewalls are angled at approximately 88.5 relative to the plane of the upper surface. Providing sidewalls at a slight angle out of perpendicular relative to the upper surface to form the taper of the frustum shaped module 10. The taper will typically allow multiple void forming modules 10 to be stacked one on top of one another for a reduction in space, particularly during transport.

[00971 An arcuate transition zone is typically provided at the corners between the at least one upper surface and each of the at least one side walls in order to increase the strength of the module and/or between the adjacent sidewalls.

[0098] It is preferred that the at least one upper surface be substantially planar. A surface texture or finish is preferably provided to the at least one upper surface to increase friction.

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[0099] The lower abutment perimeter is preferably formed from the bottom edge of at least one sidewall 15 but preferably, at least one laterally extending flange 12 is provided, extending from each sidewall 15. It is preferred that the laterally extending flange 12 is provided substantially parallel to, but spaced from the upper surface 11. A laterally extending flange 12 is preferably provided about the perimeter of the module 10 and/or about each sub-module 16, 17 if provided.

[0100] Each laterally extending flange 12 preferably has a bar support 14 to allow placement of a reinforcing bar (not shown) thereon to position the reinforcing bar relative to the void forming module 10. As shown, each module 10 includes a pair of bar supports 14 spaced apart on each of the laterally extending flanges 12 at the perimeter of the module 10. In the preferred rectangular embodiment, each module 10 typically has eight bar supports 14, two on each side.

[0101] As shown, the bar supports 14 are provided between a sidewall 15 of the body and one of the laterally extending flanges 12, but preferably formed integrally therewith.

[0102] The bar support 14 may take any form. The bar support 14 of the illustrated embodiments, best shown in Figure 8, is configured as a cradle with a pair of support surfaces oriented at an obtuse angle relative to one another to form an angled depressed junction or cradle or valley to support a bar thereon spaced above the lower abutment perimeter. Preferably, the inner angled support surface 20 nearer to the sidewall of the module 10 is longer than the outer angled support surface 21 which spaces the cradle 22, and therefore the bar, from the sidewall 15 of the module 10. The bar supports 14 orient the bar substantially parallel to at least one of the sidewalls 15 of the module 10.

[0103] In the particularly preferred embodiment illustrated, each bar support is substantially V-shaped or U-shaped from both the side and the front as this shape will preferably spread the load of the bar more effectively and also acts to locate the bar in the depressed cradle 22 of the bar support 14.

[0104] As shown in Figures 8 and 9 in particular, a locating flange 23 is provided on an elevated central portion of the bar support 14 extending substantially perpendicularly to the sidewall 15 of the module 10. Each locating flange 23 has an upper edge 24 which is angled downwardly away from the wall 15. The upper edge 24 of each of the locating flanges 23 acts to guide the bar into the depressed cradle 22.

[0105] Each locating flange 23 also has an outer edge 25 which is substantially vertical.

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[01061 As mentioned above, it is preferred that the cradle 22 of the bar support 14 is spaced from the sidewall 15 of the module 10 and the outer edge 25 of the locating flange 23 is positioned adjacent to but slightly spaced from the bottom of the cradle 22, typically approximately half of the width of the preferred bar which the bar support 14 is adapted to support.

[01071 In use, the bar supports 14 of adjacent modules 10 are overlapped with one another as shown in Figure 10 during the layout of the modules 10. An operator will typically overlap the edges of adjacent modules 10 such that the bar supports 14 of the respective adjacent modules 10 align with one another and the cradles 22 of the respective bar supports 14 on the adjacent modules 1Oare also aligned as shown in Figure 10. This forms a bar opening 26 between the outer edges 25 of the respective locking flanges 23 of the overlapped bar supports 14. In use, once a bar is inserted into the bar opening 26, the respective locating flanges 23 either abut the bar on each side, locking the adjacent modules 10 together or alternatively, if force is applied to try to separate the adjacent modules 10, then the bar will abut the respective outer edges 25 of the locating flanges 23, resisting separation of the modules, and holding them in place relative to one another.

[0108] The void forming module 10 of the illustrated embodiments include several bar chairs 27 relative to the upper surface 11 of each module 10 and/or submodules 16, 17. Each bar chair 27 includes a raised portion or protrusion which extends above the upper surface 11 of the module.

[0109] Each of the bar chairs 27 is elongate. Normally, the bar chairs 27 will be spaced from one another over the module 10 in order to provide an enlarged support area. Typically, each of the bar chairs 27 is generally triangular in cross-sectional shape with an arcuate upper surface to provide increased strength.

[0110] In the illustrated preferred embodiment, each of the bar chairs 27 is located adjacent to a side edge of the upper surface 11. Typically, a pair of bar chairs 27 are provided on one lateral side of the module 10 or submodule 16, 17 and a pair of bar chairs 27 are provided on an opposite lateral side of the module 10 or submodule 16, 17.

[0111] The bar chairs 27 do not have to have the same dimension as one another and indeed, as shown in Figure 11 in particular, a pair of larger bar chairs 27 is provided and a pair of smaller bar chairs 27 are provided on each submodule 16, 17.

[0112] A number of openings 28 are provided in the upper surface 11 of the module 10 in order to locate bar rails relative to the module if required. In a preferred configuration, a bar rail support may be used for thicker slabs in order to position a layer of reinforcing mesh or bar above the height of the module. In one particularly preferred embodiment, a bar rail support may be provided with a pair of spiked engagement portions which may be located into the openings on the upper surface of the module in order to positively locate the bar rail support relative to the module and to retain the bar rail support in a particular orientation relative to the module.

[0113] Generally, a pair of openings 28 is provided substantially parallel to but spaced from each of the side edges of the module 10 and/or submodule 16, 17.

[0114] The location of modules 10 in the preferred layout forms a number of channels between the adjacent modules and which are suitable for being filled with aggregate material such as concrete or similar in order to form bearing beams. In another form, the present invention resides in a plurality of modules laid out in a regular array in this way.

[0115] The module 10 of the preferred embodiment will typically be formed in a single piece and be of unitary construction. Typically, the module 10 will be manufactured of a plastic material but other materials may be used if appropriate or if they have material characteristics that are required or desired in the module. Portions of the module 10 may be formed from one or more different materials.

[0116] In the present specification and claims (if any), the word 'comprising' and its derivatives including 'comprises' and 'comprise' include each of the stated integers but does not exclude the inclusion of one or more further integers.

[01171 Reference throughout this specification to 'one embodiment' or 'an embodiment' means that a particular feature, structure, or characteristic described in connection with the embodiment is included in at least one embodiment of the present invention. Thus, the appearance of the phrases 'in one embodiment' or 'in an embodiment' in various places throughout this specification are not necessarily all referring to the same embodiment. Furthermore, the particular features, structures, or characteristics may be combined in any suitable manner in one or more combinations.

[0118] In compliance with the statute, the invention has been described in language more or less specific to structural or methodical features. It is to be understood that the invention is not limited to specific features shown or described since the means herein described comprises preferred forms of putting the invention into effect. The invention is, therefore, claimed in any of its forms or modifications within the proper scope of the appended claims (if any)

I

/ appropriately interpreted by those skilled in the art.

Claims

1. A void forming module including: at least one hollow body with at least one upper surface and a lower abutment perimeter, and at least one shaped support extending from the at least one upper surface and terminating at a level coplanar with the lower abutment perimeter.

2. A void forming module as claimed in claim 1, wherein the hollow body tapers inwardly from the lower abutment perimeter as it extends upwardly towards the at least one upper surface.

3. A void forming module as claimed in claim 1 or claim 2, further including at least one side wall, and the lower abutment perimeter is formed from a bottom edge of the at least one sidewall.

4. A void forming module as claimed in claim 3, wherein the at least one shaped support is provided within or partially within a hollow volume formed by the at least one upper surface and the at least one sidewall.

5. A void forming module as claimed in claim 3 or claim 4, further including at least one laterally extending flange extending from the at least one sidewall.

6. A void forming module as claimed in claim 5, further including at least one bar support.

7. A void forming module as claimed in claim 6, wherein the at least one laterally extending flange includes at least a part of the at least one bar support to allow placement of a reinforcing bar thereon to position the reinforcing bar relative to the void forming module.

8. A void forming module as claimed in claim 7, wherein each bar support is configured as a cradle with at least one support surface spaced above the lower abutment perimeter.

9. A void forming module as claimed in claim 7 or claim 8, wherein each bar support includes a pair of support surfaces oriented at an obtuse angle relative to one another to form an angled depressed junction or cradle or valley to support a bar thereon.

10. A void forming module as claimed in any one of claims 7 to 9, wherein each bar support includes a location formation.

11. A void forming module as claimed in claim 10, wherein the location formation is a locating flange, the locating flange being provided on an elevated central portion of the bar support extending substantially perpendicularly to a sidewall of the module.

12. A void forming module as claimed in any one of claims 6 to 11, further including at least one attachment assembly to attach a module to or relative to at least one other module which has the same configuration.

13. A void forming module as claimed in claim 12, wherein the at least one attachment assembly is or is a part of the at least one bar support provided at or relative to the perimeter of the module.

14. A void forming module as claimed in any one of the preceding claims, further including one or more partial supports.

15. A void forming module as claimed in any one of the preceding claims, further including one or more openings in the upper surface of the module for locating bar rails relative to the module.

16. A void forming module as claimed in any one of the preceding claims, wherein the void forming module is divided into a number of submodules.

17. A void forming module as claimed in claim 16, wherein one or more submodules are separable from one another.

18. A void forming module as claimed in claim 16 or claim 17, wherein the void forming module includes a line of weakness for allowing separation of the submodules.

19. A void forming module as claimed in any one of claims 16 to 18, wherein the void forming module is configured to have three submodules.

20. A void forming module as claimed in any one of claims 16 to 19, wherein the submodules are arranged linearly.

21. A void forming module as claimed in any one of claims 16 to 20, wherein each submodule includes at least one upper surface and 4 sidewalls which depend from the upper wall, and at least one laterally extending flange provided about a lower side of each of the 4 sidewalls forming a part of the lower abutment perimeter for the submodule and the module as a whole.

22. A void forming module as claimed in claim 16 to 21, wherein the submodules are joined to one another by the at least one laterally extending flange extending therebetween.

23. A void forming module as claimed in any one of claims 16 to 22, wherein the void forming module further includes a ridge between adjacent submodules.

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