Modular, multiperforated permanent formwork construction system for reinforced concrete

A modular permanent formwork system suitable for use with concrete, comprising:

• a plurality of extrudate components with at least some of the extrudate components being of different configuration, and wherein at least some of the extrudate components define a plurality of interconnected cavities, the plurality of extrudate components including an extrudate component that is a flat multiperforated profile and comprises:
• i. a longitudinal surface having a plurality of perforations;
• and
• ii. at each opposite end of the longitudinal surface there is provided an edge that is perpendicular to the longitudinal surface, and along each opposite edge respective female and male interlocking elements are provided;
• and;
• iii. a plurality of longitudinal rails of a first shape to receive at least one flat connector, the plurality of longitudinal rails disposed at intervals along the width of the longitudinal surface;
• wherein the plurality of perforations provided in the longitudinal surface are dimensioned for communication with at least one of the interconnected cavities such that if concrete were poured into the resulting permanent formwork it would be able to pass from the at least one of said interconnected cavities and through at least one of the plurality of perforations to an outer surface of the resulting permanent formwork as to form a concrete covering on that outer surface.

A modular, multiperforated permanent formwork or centering construction system for reinforced concrete, comprising:

• a front wall and a rear wall having a plurality of perforations through which the concrete springs as to provide a new surface to which a surface finish can be provided;
• various extruded thermoplastic structural extrudate profiles, with each profile being a single longitudinal member going from the floor to the ceiling;
• and the various extrudate profiles comprising an elongated hollow rectangular configuration, reinforcement ribs for the rectangular shape and core sections transversally cut in the ribs in order to introduce reinforcing rods into the structure and to evenly allow the progressive filling of concrete from profile to profile, and where lateral faces of the profile comprise male-female longitudinal coupling rails;
• said extrudate profiles comprising:
• a flat extrudate profile comprising a multiperforated longitudinal surface;
• at each end of the multiperforated longitudinal surface there is provided a perpendicular longitudinal extension, with each extension comprising one of a male configured coupling rail and a female configured coupling rail;
• and along the width of the multiperforated longitudinal surface there is a plurality of longitudinal T-shaped rails for engaging a connector profile;
• a flat modular connector profile comprising a longitudinal surface with cut core sections distributed longitudinally, and at opposite ends of the longitudinal surface there is a U-shaped longitudinal rail with inwardly extending edges;
• a longitudinal hollow rectangular section flat modular connector profile comprising a multiperforated front wall, a multiperforated rear wall and longitudinal ribs with cut core sections, which longitudinal ribs are perpendicularly attached to the multiperforated walls for forming the rectangular shape, and male and female configured coupling rails are provided at the edges or ends of the rectangular shape;
• a corner hollow modular connector profile comprising two interconnected elongated perpendicular longitudinal sides, with cut cores longitudinally distributed on each side, the longitudinal sides are attached to a semicircular longitudinal multiperforated surface, a perpendicular longitudinal side has two integrated female-configuration coupling rails, the remaining side has two male-configuration coupling rails;
• a modular elongated hollow rectangular configuration panel, comprising:
• a longitudinal multiperforated front wall, a longitudinal multiperforated rear wall, a plurality of longitudinal ribs with core cut sections distributed longitudinally, forming between these, interconnected hollow rectangular cavities, at the ends of the multiperforated modular panel on the coupling edges there are two female-configuration longitudinal coupling rails, and the remaining end having two integrated male-configuration longitudinal coupling rails;
• and wherein the male and female coupling rails on said respective structural extrudate profiles provide a coupling means that comprises a shape and geometry defined as a female locking member and a male locking member, the male locking member fits and slides on a groove of the female locking member in the coupling such that different ones of the various extruded profiles can be coupled to another type of extruded profile.

A method for producing a modular, multiperforated permanent formwork or centering construction for reinforced concrete, which formwork includes various extruded thermoplastic extrudates with a defined configuration, structural reinforcement rods, and poured concrete, the method comprising:

• a. assembling the different types of longitudinal thermoplastic extrudates, having coupling male projection rails and female groove rails, in a foundation with vertical reinforcing rods extending within at least some of the extrudates;
• b. fitting and sliding the male rail of one extrudate on the groove of the female rail of another extrudate;
• c. transversely crossing reinforcing rods into cut section areas of aligned extrudates;
• d. forming, by assembling said elements, a wall structure with sectioned hollow cavities;
• e. pouring and filling the hollow cavities with concrete, in the wall structure;
• f. flattening or texturing concrete present on at least one of a front wall surface and a rear wall surface of the associated extrudates, wherein, upon pouring, the concrete sprouts through perforations, and extends along an outer region of at least one of the front and rear wall surfaces.