Stay-in-place formwork with engaging and abutting connections

An apparatus for a formwork assembly comprises a plurality of elongated panels connectable to one another in edge-adjacent relationship. The plurality of panels comprise first and second edge-adjacent panels connectable to one another at a connection between a male connector component of the first panel and a female connector component of the second panel. The female connector component comprises a female engagement portion which defines a principal receptacle and the male connector component comprises a male engagement portion which is received in the principal receptacle to form the connection. The female connector component comprises a first abutment portion and the male connector component comprising a second abutment portion which abuts against the first abutment portion to form the connection. The first and second abutment portions are located outside of the principal receptacle.

TECHNICAL FIELD

The technology disclosed herein relates to formwork for fabricating structural parts of buildings, tanks and/or other structures out of concrete or other similar curable construction materials. Particular embodiments of the invention provide connector components for modular formworks and methods for providing connections between modular formwork units.

BACKGROUND

Any discussion of the prior art throughout the specification should in no way be considered as an admission that such prior art is widely known or forms part of general common knowledge in the field.

It is known to fabricate structural parts for buildings, tanks or the like from concrete using modular stay-in-place formworks. Such structural parts may include walls, ceilings or the like. Examples of such modular stay in place formworks include those described US patent publication No. 2005/0016103 (Piccone) and PCT publication No. WO96/07799 (Sterling). A representative drawing depicting a partial formwork28according to one prior art system is shown in top plan view inFIG. 1. Formwork28includes a plurality of wall panels30(e.g.30A,30B,30D), each of which has an inwardly facing surface31A and an outwardly facing surface31B. Each of panels30includes a terminal male T-connector component34at one of its transverse, vertically-extending edges (vertical being the direction into and out of theFIG. 1page) and a terminal female C-connector component32at its opposing vertical edge. Male T-connector components34slide vertically into the receptacles of female C-connector components32to join edge-adjacent panels30and to thereby provide a pair of substantially parallel wall segments (generally indicated at27,29). Depending on the needs for particular wall segments27,29, different panels30may have different transverse dimensions. For example, comparing panels30A and30B, it can be seen that panel30A has approximately ¼ of the transverse length of panel30B.

Formwork28includes support panels36A which extend between, and connect to each of, wall segments27,29at transversely spaced apart locations. Support panels36A include male T-connector components42slidably received in the receptacles of female C-connector components38which extend inwardly from inwardly facing surfaces31A or from female C-connector components32. Formwork28comprises tensioning panels40which extend between panels30and support panels36A at various locations within formwork28. Tensioning panels40include male T-connector components46received in the receptacles of female C-connector components38.

In use, formwork28is assembled by slidable connection of the various male T-connector components34,42,46in the receptacles of the various female C-connectors32,38. Liquid concrete is then poured into formwork28between wall segments27,29. The concrete flows through apertures (not shown) in support panels36and tensioning panels40to fill the inward portion of formwork28(i.e. between wall segments27,29). When the concrete solidifies, the concrete (together with formwork28) may provide a structural component (e.g. a wall) for a building or other structure.

A known problem with prior art systems is referred to colloquially as “unzipping”. Unzipping refers to the separation of connector components from one another due to the weight and/or outward pressure generated by liquid concrete when it is poured into formwork28. By way of example, unzipping may occur at connector components32,34between panels30.FIG. 2schematically depicts the unzipping of a prior art connection50between male T-connector component34and corresponding female C-connector component32at the edges of a pair of edge-adjacent panels30. The concrete (not explicitly shown) on the inside51of connection50exerts outward forces on panels50(as shown at arrows52,54). These outward forces tend to cause deformation of the connector components32,34. In theFIG. 2example illustration, connector components32,34exhibit deformation in the region of reference numerals56,58,60,62,64,68. This deformation of connector components32,34may be referred to as unzipping.

Unzipping of connector components can lead to a number of problems. In addition to the unattractive appearance of unzipped connector components, unzipping can lead to separation of male connector components34from female connector components32. To counteract this problem, prior art systems typically incorporate support panels36A and tensioning panels40, as described above. However, support panels36A and tensioning panels40may not completely eliminate the unzipping problem. Notwithstanding the presence of support panels36A and tensioning panels40, in cases where male connector components34do not separate completely from female connector components32, unzipping of connector components32,34may still lead to the formation of small spaces (e.g. spaces70,71) or the like between connector components32,34. Such spaces can be difficult to clean and can represent regions for the proliferation of bacteria or other contaminants and can thereby prevent or discourage the use of formwork28for particular applications, such as those associated with food storage or handling or other applications requiring sanitary conditions or the like. Such spaces can also permit the leakage of liquids and/or gasses between inside51and outside53of panels30. Such leakage can prevent or discourage the use of formwork28for applications where it is required that formwork28be impermeable to gases or liquids (e.g. to provide the walls of tanks used to store water or other liquids). Such leakage can also lead to unsanitary conditions on the inside of formwork28and/or cause or lead to corrosion of reinforcement bars (rebar) used in the concrete structure.

In some applications (e.g. in the walls of tanks used to store water or other fluids), there is a desire to maintain a fluid-tight seal at connections between connector components (e.g. connector components32,34). Most prior art systems do not provide fluid-tight seals between connector components. Those prior art systems that do provide fluid tight seals can be difficult to work with because of difficulties associated with making and breaking the fluid-tight connections between connector components (which can be desirable during assembly of a formwork or fabrication of a corresponding structure).

Also, some prior art formwork systems can be difficult to assemble. For example, some prior art formwork systems involve making connections by initially orienting the panels at relatively large angles (e.g. orthogonal angles) relative to one another. Again, this can be difficult or impossible in some constrained spaces.

There remains a general need for effective apparatus and methods for modular formwork systems.

SUMMARY

One aspect of the invention provides a formwork assembly comprising a plurality of elongated panels connectable to one another in edge-adjacent relationship. The plurality of panels comprises first and second edge-adjacent panels connectable to one another at a connection between a male connector component of the first panel and a female connector component of the second panel. The female connector component comprises a female engagement portion which defines a principal receptacle and the male connector component comprises a male engagement portion which is received in the principal receptacle to form the connection. The female connector component comprises a first abutment portion and the male connector component comprises a second abutment portion which abuts against the first abutment portion to form the connection. The first and second abutment portions comprise corresponding first and second abutment surfaces which are bevelled with respect to outer surfaces of the first and second edge-adjacent panels.

DESCRIPTION

Particular embodiments of the invention provide formwork assemblies comprising a plurality of elongated panels connectable to one another in edge-adjacent relationship. The plurality of panels comprises first and second edge-adjacent panels connectable to one another at a connection between a male connector component of the first panel and a female connector component of the second panel. The female connector component comprises a female engagement portion which defines a principal receptacle and the male connector component comprises a male engagement portion which is received in the principal receptacle to form the connection. The female connector component comprises a first abutment portion and the male connector component comprises a second abutment portion which abuts against the first abutment portion to form the connection. The first and second abutment portions comprise corresponding first and second abutment surfaces which are bevelled with respect to outer surfaces of the first and second edge-adjacent panels.

FIG. 3Ais a partial cross-sectional view of a modular stay-in-place formwork128according to a particular embodiment of the invention which may be used to fabricate a portion of a wall of a building or other structure. Formwork128of theFIG. 3Aembodiment includes panels130,133and support members136which are connected to one another to provide wall segments127,129which, in the illustrated embodiment, extend in the vertical direction (into and out of the page in theFIG. 3Aview) and in the transverse direction17. The components of formwork128(i.e. panels130,133and support members136) are preferably fabricated from a lightweight and resiliently deformable material (e.g. a suitable plastic) using an extrusion process. By way of non-limiting example, suitable plastics include: poly-vinyl chloride (PVC), acrylonitrile butadiene styrene (ABS) or the like. In other embodiments, the components of formwork128may be fabricated from other suitable materials, such as steel or other suitable alloys, for example. Although extrusion is the currently preferred technique for fabricating the components of formwork128, other suitable fabrication techniques, such as injection molding, stamping, sheet metal fabrication techniques or the like may additionally or alternatively be used.

Formwork128comprises a plurality of panels130,133which are elongated in the vertical direction (i.e. the direction into and out of the page ofFIG. 3Aand shown by double-headed arrows19inFIGS. 3B and 3C) and which extend in transverse directions17. Panels130,133respectively comprise outward facing (exterior) surfaces131A,135A and inward facing (interior) surfaces131B,135B. In the illustrated embodiment, exterior surfaces131A,135A are substantially flat, although in other embodiments, exterior surfaces131A,135A may be provided with desired shapes (e.g. corrugation or the like). Interior surfaces131B,135B comprise a number of features described in more detail below.

In the illustrated embodiment, panels130,133have a substantially uniform cross-section along their entire vertical length, although this is not necessary. In the illustrated embodiment, the transverse dimensions (direction17) of panels130,133are the same for each of panels130,133. This is not necessary. In general, it can be desirable to fabricate panels130,133having a number of different transverse dimensions which may suit particular applications. By way of non-limiting example, panels130,133may be provided with 2, 3, 4 and 6 inch transverse dimensions or such other transverse dimensions as may be appropriate or desirable for particular applications. In some embodiments, panels130,133are prefabricated to have a variety of different vertical dimensions with may be suitable for a variety of different applications. In other embodiments, the vertical dimensions of panels130,133may be made arbitrarily and then panels130,133may be cut to length for different applications. Preferably, panels130,133are relatively thin in the inward-outward direction (shown by double-headed arrow15ofFIG. 3A) in comparison to the inward-outward dimension of the resultant walls fabricated using formwork128. In some embodiments, the ratio of the inward-outward dimension of a structure formed by formwork128to the inward-outward dimension of a panel130,133is in a range of 10-600. In some embodiments, the ratio of the inward-outward dimension of a structure formed by formwork128to the inward-outward dimension of a panel130,133is in a range of 20-300.

In theFIG. 3Aembodiment, panels130,133are different from one another in the manner that edge-adjacent panels130,133connect to one another to provide wall segments127,129. In other embodiments, both wall segments127,129may be comprise the same types of panels. For example, wall segment129may be provided by panels133in the place of panels130.

Panels133incorporate first, generally female, connector components132at one of their transverse edges and second, generally male, connector components134at their opposing transverse edges. As shown inFIG. 3Aand explained further below, connector components132,134are complementary to one another such that connector components132,134of edge-adjacent panels133may be joined together to form connections150between edge-adjacent panels133. Panels133may be connected in edge-adjacent relationship to provide wall segment127.

Panels130of the illustrated embodiment incorporate generally C-shaped, female connector components137at both of their transverse edges. Connector components137are connected to complementary T-shaped, male connector components139at the inner or outer edges of support members136so as to form connections140which connect panels130in edge-adjacent relationship and to thereby provide wall segment129. Connector components137of panels130and connector components139of support members136may be connected to one another by slidably inserting male connector components139into female connector components137. In other embodiments, connector components137,139may be different than those shown in the illustrated embodiment and may connect to one using techniques other than relative sliding, such as, by way of non-limiting example, deformable “snap-together” connections, pivotal connections, push on connections and/or the like. In some embodiments, panels130may be provided with male connector component and support members136may comprise female connector components.

FIG. 3Dshows a support member136according to a particular embodiment. Support members136comprise a number of apertures141,143which permit a flow of liquid concrete therethrough. As mentioned above, support member136comprises a pair of connector components139at each of its inner and outer edges. In the illustrated embodiment, connector components139each comprise male, T-shaped connector components. Like panels130,133, support members136may be fabricated to have a number of vertical lengths or may be cut to desired lengths. Further, support members136may be made to have different width dimensions (see arrow15ofFIG. 3A) so as to provide formwork128with different width dimensions, suitable for different applications.

Panels133comprise a connector component142which is complementary to the pair of connector components139of support members136. In the illustrated embodiment, connector components142of panels133comprise “double-J” shaped, female connector components that slidably receive T-shaped connector components139of support members136to provide connections145between support members136and panels133. In other embodiments, connector components139,142may be different than those shown in the illustrated embodiment and may connect to one using techniques other than relative sliding, such as, by way of non-limiting example, deformable “snap-together” connections, pivotal connections, push on connections and/or the like. In some embodiments, panels133may be provided with male connector component and support members136may comprise female connector components.

Connector components142may be located relatively close to one of the transverse edges of panels133. In the illustrated embodiment, connector components142are located relatively close to the transverse edges of panels133which include connector components132. In the particular case of the illustrated embodiment, connector components142are immediately adjacent connector components132and connector components142,132share a connector wall portion167with one another. The proximity of connector components142to one of the transverse edges of panels133means that connections145between panels133and support members136are also located relatively close to one of the transverse edges of panels133, such that support members136reinforce connections150between edge-adjacent panels133.

Support members136may also optionally be connected to panels130,133at locations away from their transverse edges, as is shown in theFIG. 3Aembodiment. In theFIG. 3Aembodiment, panels133comprise interior connector components144which are complementary to a pair of connector components139on the edges of support panels136and panels130comprise interior connector components146which are complementary to a pair of connector components139on the edges of support panels136. In the illustrated embodiment, interior connector components144,146comprise “double-J” shaped, female connector components that slidably receive T-shaped connector components139of support members136. In other embodiments, connector components139,144,146may be different than those shown in the illustrated embodiment and may connect to one using techniques other than relative sliding, such as, by way of non-limiting example, deformable “snap-together” connections, pivotal connections, push on connections and/or the like. In some embodiments, panels133,130may be provided with male connector component and support members136may comprise female connector components.

In the illustrated embodiment, panels133,130respectively comprise one interior connector component144,146which is generally centrally located along the transverse dimension of panels133,130. In other embodiments, panels133,130may be provided with different numbers (e.g. zero or a plurality) of interior connector components144,146which may depend on the transverse (direction17) width of panels133,130and/or the strength requirements of a particular application. It will be understood that the mere provision of connector components144,146on panels133,130does not mean that support members136must be connected to these panels.

FIGS. 4A-4Dshow schematic views of a method for making a connection150between female connector component132and male connector component134of edge adjacent panels133of formwork128. In the illustrated embodiment, connection150may be formed between edge-adjacent panels133A,133B by positioning panels133A,133B so that their complementary connector components132,134are aligned with one another at an oblique angle (FIG. 4A), moving panels133A,133B relative to one another in direction19such that complementary connector components132,134slideably engage one another in a relatively loose-fit connection180(FIG. 4B), continuing to move panels133A,133B relative to one another at the oblique angle with connector components132,134in loose-fit connection180until panels133A,133B are aligned in direction19(FIG. 4C) and then pivoting panels133A,133B relative to one another about an axis generally parallel with direction19to move panels133A,133B into a generally flattened orientation (FIG. 4D). It will be appreciated that while described as a vertical direction, direction19may generally be any direction depending on the desired orientation of panels133A,133B during assembly. Panels133A,133B may be engaged in loose-fit connection180(FIG. 4B) by insertion of male connector component134into female connector component132at an end117of panel133A, for example.

FIGS. 4E and 4Frespectively show enlarged partial plan views of connector components132,134when edge-adjacent panels133A,133B in the loose-fit connection180(FIG. 4C) and when edge-adjacent panels133A,133B have been flattened to provide connection150(FIG. 4D). Each of connector components132,134comprises an engagement portion and an abutment portion. More particularly, female connector component132comprises an engagement portion182and an abutment portion184and male connector component134comprises an engagement portion186and an abutment portion188. When connector components132,134are in loose-fit connection180ofFIG. 4E, engagement portions182,186of connector components132,134are engaged with one another, but there is no substantial contact or friction between abutment portions184,188. When connector components132,134are moved into connection150, engagement portions182,186remain engaged with one another, but abutment portions184,188are also brought into contact with one another to complete connection150.

Connector components132,134may be shaped such that loose-fit connection180(FIGS. 4B,4C,4E) may effected by engaging engagement portions182,186of the respective connector components132,134to one another (by inserting male engagement portion186into female engagement portion182) without abutting abutment portions184,188against one another. Connector components132,134may be shaped such that loose-fit connection180may be effected without substantial deformation of, or friction between, connector components132,134. More particularly, when in loose-fit connection180, male engagement portion186of connector component134may be located in female engagement portion182of connector component132without substantial contact or friction between engagement portions182,186(seeFIG. 4E) and abutment portions184,188of connector components132,134are not in contact with one another. This lack of friction and deformation when connector components132,134are in loose-fit connection180may facilitate easy relative sliding motion between connector components132,134, even where panels133A,133B are relatively long in direction19(e.g. the length of one or more stories of a building).

In some embodiments, as shown inFIG. 4Efor example, the relative interior angle θ between the transverse extensions (e.g. exterior surfaces135A) of panels133A,133B when connector components132,134are in loose-fit connection180and at the aforementioned oblique angle is in a range of 120°-179°. In other embodiments, this angular orientation θ between panels133A,133B is in a range of 165°-179°. In still other embodiments, this angular orientation θ between panels133A,133B when connector components132,134are in loose-fit connection180is in a range of 175°-179°. Allowing for sliding movement between the panels at a range of oblique orientation angles θ allows for more flexibility in assembling a formwork. This flexibility may be because some play or movement is permitted between panels133A,133B both in direction19and pivotally (e.g. about an axis parallel to direction19), which allows for adjustments to be made when installing support members136or reinforcing bars (rebar). Also, allowing for sliding movement between the panels at a range of oblique orientation angles θ allows edge adjacent panels133A,133B to be assembled in more confined environments by adjusting the oblique orientation angle θ as desired to fit within the confined environment.

As discussed above, once panels133A,133B have been moved in direction19into a desired alignment (FIG. 4C) they may be flattened (FIG. 4D) to complete connection150. Flattening panels133A,133B to move between loose-fit connection180(FIGS. 4C,4E) and connection150(FIGS. 4D,4F) may involve pivoting panels133A,133B relative to one another about an axis generally parallel with direction19(into and out of the page in the view ofFIGS. 4E and 4F) to increase the interior angle θ between the transverse extensions of panels133A,133B and to bring abutment portions184,188of connector components132,134into contact with one another. For example, flattening panels133A,133B may involve increasing the interior angle θ between exterior surfaces135A of panels133A,133B prior to introduction of concrete and/or prior to connection of support members136to panels133A,133B. Forming connection150(FIG. 4F) involves increasing the interior angle θ between edge-adjacent panels133A,133B until abutment portions184,188of connector components132,134are pressed into contact with one another. As explained in more detail below, abutment portions184,188may respectively comprise abutment surfaces172,157which may be bevelled at angles that are complementary to one another when connection150is formed.

A detailed description of the formation of connection150is now provided, with reference toFIGS. 4E and 4F. In the illustrated embodiment, engagement portion182of female connector component132comprises back wall167and a pair of retaining arms164A,164B (collectively, retaining arms164) which define a principal receptacle172having a mouth165and engagement portion186of male connector components134comprises a splayed protrusion152. In the illustrated embodiment, abutment portion184of female connector component132comprises bevelled abutment surface172and abutment portion188of male connector component134comprises bevelled abutment surface157.

As shown inFIG. 4E, loose-fit connection180may be formed by engaging engagement portion186,182of connector components132,134—e.g. by inserting male engagement portion186of connector component134into female engagement portion182of connector component134to thereby engage engagement portions182,186. More particularly, in the illustrated embodiment, loose-fit connection180is formed by slidably inserting splayed protrusion152of male engagement portion186of connector component134into principal receptacle or recess162of female engagement portion182of connector component132. As discussed above, the insertion of splayed protrusion152into principal receptacle162to provide loose-fit connection180may be made without substantial deformation of connector components132,134and/or without substantial friction therebetween. Furthermore, when loose-fit connection180is made, panels133A,133B (and connector components132,134) may be arranged such that panels133A,133B may be moved relative to one another without substantial friction between, or deformation of, connector components132,134.

As shown inFIG. 4E, retaining arms164of female engagement portion182of connector component132respectively comprise upper arms165A,165B (collectively, upper arms165) which project away from back wall167of connector component132and angled forearms166A,166B (collectively, forearms166) which project from the ends of upper arms165back toward back wall167to provide convex elbows169A,169B (collectively, elbows169) and concave hooks168A,168B (collectively, hooks168). As explained in more detail below, hooks168may engage fingers156of male engagement portion186of connector component134.

In the illustrated embodiment, bevelled abutment surface172of abutment portion184of connector component132is also provided by forearm166B. Forearms166may comprise convex or rounded phalanges161A,161B (collectively, phalanges161). Phalanges161may allow splayed protrusion152to pivot upon them while connections150,180are being formed. Back wall167may provide support for engagement portion182of female connector component132and, in the illustrated embodiment, may also provide a connector wall portion of connector component142, discussed above. When panels133A,133B are in the connected configuration150ofFIG. 4F, elbow169B may be generally aligned with knee153of connector component134and abutment surface172of abutment portion184of female connector component132may abut against abutment surface157of abutment portion188of male connector component134to provide exterior surfaces135A of panels133A,133B with a substantially flat surface. In the illustrated embodiment, interior bevel angle β between abutment surface172and exterior surface135A of panel133A is approximately 45°, although this is not necessary and interior bevel angle β may have any suitable angle that is more or less than 45°.

As mentioned briefly above, engagement portion186of male connector component134of the illustrated embodiment comprises splayed protrusion152having fingers156A,156B (collectively, fingers156). Fingers156may be sized and/or shaped so as to not deform, or create substantial friction with, engagement portion182of female connector component134when connector components132,134are in loose-fit connection180(FIG. 4E). In the illustrated embodiment, fingers156are shaped to provide concave hooks159A,159B (collectively, hooks159), which have concavities that are oriented generally away from the concavities of hooks168of connector component132when connection150(FIG. 4F) is formed. Male connector component134also comprises an abutment portion188, which in the illustrated embodiment, comprises a bevelled abutment surface157. When panels133A,133B are in the connected configuration150ofFIG. 4F, abutment surface157of abutment portion188of male connector component134may abut against abutment surface172of abutment portion184of female connector component132to provide exterior surfaces135A of panels133A,133B with a substantially flat surface. In the illustrated embodiment, interior bevel angle α between abutment surface157and exterior surface135A of panel133B is approximately 45°, although this is not necessary and interior bevel angle α may have any suitable angle that is more or less than 45°.

When connector components132,134are flattened to bring abutment surfaces157,172of abutment portions188,184into contact with one another and to thereby provide connection150(FIG. 4E), connector components132,134are shaped to provide several interleaving parts. The interleaving parts of components132,134may provide connection150with a resistance to unzipping and may prevent or minimize leakage of fluids (e.g. liquids and, in some instances, gases) through connection150.

In theFIG. 4Fembodiment, the interleaving parts comprise hooks168A,159A, hooks168B,159B and abutment surfaces172,157. In particular, the interaction between hooks168A,159A acts to prevent relative movement in directions13,14and16; the interaction between hooks168B,159B acts to prevent relative movement in directions14,16, and18; the interaction between abutment surfaces172,157acts to prevent relative movement in directions14and18(seeFIG. 4F). These interleaving components help to prevent unzipping of connection150under the pressure provided by the weight of liquid concrete and helps to provide a seal that minimizes leakage of fluids through connection150.

In particular, when a curable material, such as liquid concrete, is introduced into a formwork comprising panels133A,133B, it exerts a pressure on panels133A,133B which is generally oriented in direction14. This pressure asserts corresponding force on the abutment engagement between bevelled abutment surfaces172,157of abutment portions184,188of connector components132,134and thereby helps to prevent leakage of fluids through connection150. Furthermore, because of the angle of abutment surfaces172,157, the pressure of liquid construction material (e.g. concrete) oriented in direction14causes hooks168A,159A and hooks168B,159B to pull toward one another, thereby further engaging hooks168A,159A and hooks168B,159B. Accordingly, the pressure associated with introducing the curable construction material into the formwork actually reinforces connection150by causing hooks168A,159A and hooks168B,159B to be further engaged in this manner.

FIGS. 5A and 5Brespectively show enlarged partial plan views of a loose-fit connection280and a completed connection250between a pair of edge-adjacent panels233A,233B and their respective connector components232,134according to another embodiment. Connector component134of panel233B may be substantially identical to connector component134of panel133described above and may comprise engagement portion186and abutment portion188that are substantially identical to the corresponding portions of connector component134of panel133described above. Connector component232of panel233A may be similar to connector component132of panel133described above and similar reference numbers are used to refer to features of connector components232,132except that the reference numbers of connector component232are preceded by the numeral “2” whereas the reference numbers of connector component132are preceded by the numeral “1”. Connector components232of panel233A comprises engagement portion282and abutment portion284.

Connector component232differs from connector component132in that engagement portion282of connector component232comprises a projection273. In the illustrated embodiment, projection273projects from upper arm265A toward upper arm265B—i.e. into principal recess262. Projection273is shaped to provide resistance to flattening panels233A,233B (e.g. to moving panels233A,233B from loose-fit connection280(FIG. 5A) to completed connection250(FIG. 5B)) by resisting movement of finger156A toward the concavity274of hook268A. When additional force (or torque) is applied to pivot panels233A,233B relative to one another and to increase the interior angle θ between panels233A,233B, finger156A pushes against protrusion273, causing resilient deformation of one or both of connector components134,232(e.g. finger156A and/or restraining arm264A) until finger156A slides past protrusion273and into concavity274of hook268A.

The resilient deformation of one or both of connector components134,232caused by the relative pivotal motion of panels233A,233B and the movement of finger156A against protrusion273create restorative deformation forces (i.e. forces that tend to restore connector components134,232to their original, non-deformed configuration). As finger156A moves past protrusion273with the continued relative pivotal movement of panels233A,233B, these restorative deformation forces tend to force finger156A into concavity274of hook268A. The action of these restorative deformation forces provides a so-called “snap-together” fitting between connector components134,232. When finger256A projects into concavity274of hook268A to provide connection250(FIG. 5B), finger156A is locked in place and is prevented from movement back toward principal recess262by protrusion273. Accordingly, when connection250is made the angle θ between the transverse dimensions of panels233A,233B is held at or near to whatever maximum angle is permitted by the shape of connector components232,134.

In other embodiments (not shown), a surface of protrusion273and/or a surface of finger156A may be provided with one or more surface features which may tend to prevent the withdrawal of finger156A from concavity274of hook268A—i.e. to lock finger156A in concavity274of hook268A. Such surface features may comprise complementary barbs, complementary ridges and/or the like.

In other respects, panels233A,233B, their connector components232,134and their connections280,250are substantially similar to panels133A,133B, connector components132,134and connections180,150described herein and any reference to panels133A,133B, connector components132,134and connections180,150should be understood to be applicable (where appropriate) to panels233A,233B, connector components232,134and connections280,250.

As discussed above, moving edge-adjacent panels133A,133B between loose-fit connection180(FIG. 4E) and completed connection150(FIG. 4F) may involve pivoting panels133A,133B relative to one another about an axis generally parallel with direction19(into and out of the page in the view ofFIGS. 4E and 4F) to increase the interior angle θ between the transverse extensions of panels133A,133B. A maximum angle θ=θmaxbetween the transverse extension of panels133A,133B (e.g. between exterior surfaces135A of panels133A,133B) may be defined where θmaxis equal to the maximum angle between the transverse extensions of panels133A,133B (e.g. the exterior surfaces135A of panels133A,133B) without deformation of panels133A,133B. In the case of the illustrated embodiment ofFIGS. 4E and 4F, θmaxis equal to a sum of an interior bevel angle β at which abutment surface172is bevelled with respect to exterior surface135A of panel133A and an interior bevel angle α at which abutment surface157is bevelled with respect to outer surface135A of panel133B (seeFIG. 4F). Referring toFIGS. 4E and 4F, the maximum angle θ=θmaxmay occur when there is complementary contact between abutment portions184,188of connector components132,134or, more particularly in the case of the illustrated embodiment, the abutment of bevelled abutment surfaces172,157.

In some embodiments, like the illustrated embodiment ofFIGS. 4E and 4F, where it is desired that panels133A,133B join together to provide a flat surface (e.g. a flat wall where outer surfaces135A of panels133A,133B are generally parallel with one another), the sum of interior bevel angle β of abutment surface172and interior bevel angle α of abutment surface157is approximately 180°, so that θmax≈180°. In the particular case of the embodiment ofFIGS. 4E and 4F, abutment surface172is bevelled at an interior bevel angle β of approximately 45° and abutment surface157is bevelled at an interior bevel angle α of approximately 135°, so that θmax≈180°. In other embodiments, it may be desirable that the value of θmaxbe something other than 180°. For example, in some cases where it is desired that panels133A,133B join together to provide a convex surface (e.g. a curved wall where outer surfaces135A of panels133A,133B form a convex surface across connection150), the value of θmaxbe less than 180° (e.g. in a range between 160° and 179°). Conversely, in some cases where it is desired that panels133A,133B join together to provide a concave surface (e.g. a curved wall where outer surfaces135A of panels133A,133B form a concave surface across connection150), the value of θmaxbe greater than 180° (e.g. in a range between 181° and 200°).

In some embodiments, it may be desirable to provide θmaxwith a value that is less than the desired ultimate angle θdesiredbetween outer surfaces135A of panels133A,133B. This may be accomplished, for example, by providing interior bevel angle β and/or interior bevel angle α of the abutment surfaces at other angles such that the sum of interior bevel angle β and interior bevel angle α (i.e. θmax) is less than the desired ultimate angle θdesired. Such an embodiment is shown inFIGS. 6A and 6B, which respectively depict enlarged partial plan views of a loose-fit connection380and a completed connection350between a pair of edge-adjacent panels333A,333B and their respective connector components332,334according to another embodiment. Panels333A,333B may be similar to the above-described panels133A,133B and similar reference numbers are used to refer to features of panels333A,333B and133A,133B except that the reference numbers of panels333A,333B are preceded by the numeral “3” whereas the reference numbers of panels133A,133B are preceded by the numeral “1”.

Panels333A,333B differ from panels133A,133B only in that θmax, which is provided by the sum of interior bevel angle β and interior bevel angle α of abutment surfaces372,357, is less than the desired ultimate angle θdesired. In the case of theFIGS. 6A and 6Bembodiment, the desired ultimate angle θdesired=180°, but this is not necessary and the desired ultimate angle θdesiredmay be greater than 180° (e.g. for concave walls) or less than 180° (e.g. for convex walls). In the particular case of the embodiment ofFIGS. 6A and 6Binterior bevel angle β of abutment surface372is still approximately 45° while interior bevel angle α of abutment surface357has been reduced to approximately 133°. Accordingly, θmax≈178°. In some embodiments, θmax(the sum of bevel angles α, β) may be designed to be in a range of 95-99.5% of the value of the desired ultimate angle θdesired. In still other embodiments, θmaxmay be in a range of 97-99.5% of the value of the desired ultimate angle θdesired. Since θmaxrepresents the sum of the bevel angles α and β, it will be appreciated that selection of a value for θmaxmay be accomplished by varying either or both of bevel angles α and β.

Obtaining the desired ultimate angle θdesiredmay involve forcing abutment surfaces157,172into one another with such force that the force causes deformation of panels333A,333B (or more particularly, connector components332,334) so that the interior angle between panels333A,333B increases from θmaxto θdesired. Such force may be applied when support members136are connected to panels333A,333B, for example. For example, when θmaxis less than θdesiredand support members136are connected to panels333A,333B, outwardly directed force may be applied to panels333A,333B, such that one or both of panels333A,333B may tend to deform under the forces caused this pressure in the direction of arrow15. This deformation may cause exterior surfaces335A of panels333A,333B to become relatively more parallel with one another—i.e. so that the angle between the exterior surfaces335A of panels333A,333B changes from θmax(prior to connection of support members136) to a value closer to the desired ultimate angle θdesired(after the connection of support members136). Accordingly, selecting a value of θmax<θdesiredmay effectively result in an angle between the exterior surfaces335A of panels333A,333B that is closer to θdesired(after the connection of support members136). In the case of the illustrated embodiment ofFIGS. 6A and 6B, selecting a value of θmax<180° (prior to the connection of support members136) may effectively create an angle between the exterior surfaces335A of panels333A,333B that is closer to θdesired=180° (after the connection of support members136).

The forces which cause deformation of panels333A,333B so that the interior angle between panels333A,333B increases from θmaxto θdesiredmay additionally or alternatively come from the introduction of liquid concrete to the corresponding formwork. For example, where panels333A,333B and their respective connection350(FIG. 6B) are part of a formwork and liquid concrete (or other curable construction material) is introduced into an interior of the formwork, the weight of the liquid concrete applies pressure to panels333A,333B. More particularly, forces associated with this pressure will act generally perpendicularly to interior surfaces335B of panels333A,333B as shown by arrows14(in the case of panel333A) and15(in the case of panel333B). One or both of the portions of panels333A,333B illustrated inFIGS. 6A and 6Bmay tend to deform under the forces caused this pressure in the direction of arrow15. This deformation under the weight of liquid concrete may cause exterior surfaces335A of panels333A,333B to become relatively more parallel with one another—i.e. so that the angle between the exterior surfaces335A of panels333A,333B changes from θmax(prior to the introduction of concrete) to a value closer to the desired ultimate angle θdesired(after the introduction of concrete). Accordingly, selecting a value of θmax<θdesired(prior to the introduction of concrete) may effectively result in an angle between the exterior surfaces335A of panels333A,333B that is closer to θdesired(after the introduction of concrete). In the case of the illustrated embodiment ofFIGS. 6A and 6B, selecting a value of θmax<180° (prior to the introduction of concrete) may effectively create an angle between the exterior surfaces335A of panels333A,333B that is closer to θdesired=180° (after the introduction of concrete).

Providing a value of θmax<θdesiredmay also increase the sealing force between connector components332,334of panels333A,333B. More particularly, forces caused by the connection of support members136to panels333A,333B and/or the pressure associated with the weight of liquid concrete may be directed generally perpendicularly to interior surface335B of panel333B. Forces oriented in this direction include transversely directed components which tend to pull the hooks368of connector component332toward, and into more forceful engagement with, the hooks359of connector component334, thereby increasing the sealing force between connector components332,334of panels333A,333B. Further forces oriented in this direction include outward components which create torques which tend to push abutment surfaces357,372toward, and into more forceful engagement with one another.

In other respects, panels333A,333B, their connector components332,334and their connections380,350are substantially similar to panels133A,133B, connector components132,134and connections180,150described herein and any reference to panels133A,133B, connector components132,134and connections180,150should be understood to be applicable (where appropriate) to panels333A,333B, connector components332,334and connections380,350.

Referring back toFIGS. 4E and 4F, the surface area of contact between abutment surfaces157,172when connector components132,134form connection150may comprise a relatively large contact surface area. Such a large contact surface area may advantageously improve the seal provided by connection150against fluids (e.g. liquids or, in some cases, gases). Such a large contact surface area may also improve the robustness of connection150to thermal expansion—e.g. because abutment surfaces157,172may be permitted to move relative to one another (as may occur with thermal expansion or corresponding contraction), while still maintaining connection150with a sufficient seal against the passage of fluids. In some embodiments, a ratio of the contact surface area of abutment surfaces157,172to the area associated with back wall167is greater than 25%. In some embodiments, this ratio is greater than 33%. It will be appreciated that the cross-section of panels133A,133B may be uniform along their longitudinal dimensions (e.g. into and out of the page in the illustrated views ofFIGS. 4E and 4F). Consequently in such embodiments, these surface area ratios may be equivalently expressed as ratios of the width of the abutment surfaces157,172(in a direction along their contact) to the depth of back wall167(or effectively to the depth of connector component132).

In some embodiments, a sealing material (not shown) may be provided on some surfaces of connector components132,134. Such sealing material may be relatively soft (e.g. elastomeric) when compared to the material from which the remainder of panels133are formed. Such sealing materials may be provided using a co-extrusion process or coated onto connector components132,134after fabrication of panels133, for example. Such sealing materials may help to make connections150between edge adjacent panel133A,133B impermeable to liquids or gasses. Such sealing materials may be provided on any one or more contact surfaces of connector components132,134, including, by way of non-limiting example, such sealing materials may be provided on: one or both of fingers156; one or both of restraining arms164; one or both of phalanxes161; elbow169B; knee153; and one or both of abutment surfaces172,157.

FIG. 7Ashows a connection450between connector components432,434of edge-adjacent panels433A,433B according to an example embodiment where elastomeric sealing material417is provided on abutment surface472in a vicinity of knee469B. Sealing material417may be co-extruded with panel433A as discussed above. When abutment surfaces457,472abut one another as described above to provide connection450, sealing material417may be compressed to help maintain a seal between abutment surfaces457,472that reduces the permeability of connection450to fluids. In other respects, panels433A,433B and connection450may be similar to panels133A,133B and connection150described herein.

Bevelled abutment surfaces152,157of connector components132,134are generally planar surfaces. In some embodiments, the bevelled abutment surfaces of connector components may be provided with one or more complementary profile features (e.g. one or more complementary convexities and concavities) which may help to provide connections between the corresponding connector components and corresponding edge-adjacent panels.FIG. 7Bshows a connection550between connector components532,534of edge-adjacent panels533A,533B according to an example embodiment where abutment surface572comprises a concavity517and abutment surface557comprises a complementary convexity519which projects into concavity517when forming connection550. The projection of convexity519into concavity517may help to register connector components532,534and panels533A,533B relative to one another during the formation of connection550and may also help to prevent connection550from unzipping. Sealing material (not shown) may be co-extruded or otherwise applied to the surface(s) of one or both of concavity517and convexity519to help seal connection550. In other respects, panels533A,533B and connection550may be similar to panels133A,133B and connection150described herein.

In some embodiments, multiple complementary profile features may be provided on the bevelled abutment surfaces of connector components.FIG. 7Cshows a connection550′ between connector components532′,534′ of edge-adjacent panels533A′,533B′ according to an example embodiment where abutment surface572′ comprises a plurality of alternating concavities and convexities (e.g. in a toothed pattern517′) and abutment surface557comprises a complementary plurality of alternating concavities and convexities (e.g. in a complementary toothed patter519′). When forming connection550′, toothed patterns517′,519′ engage one another and may help to register connector components532′,534′ and panels533A′,533B′ relative to one another and may also help to prevent connection550′ from unzipping. Sealing material (not shown) may be co-extruded or otherwise applied to the surface(s) of one or both of toothed patterns517′,519′ to help seal connection550′. In other respects, panels533A′,533B′ and connection550′ may be similar to panels133A,133B and connection150described herein.

FIG. 7Dshows a connection550″ between connector components532″,534″ of edge-adjacent panels533A″,533B″ according to an example embodiment where abutment surface572″ comprises a plurality of alternating concavities and convexities (e.g. in a toothed pattern517″) and abutment surface557is coated with a layer of sealing material521(e.g. elastomeric material). Sealing material521may be co-extruded with panel533B″ as discussed above. When forming connection550″, toothed pattern517″ may be squeezed into sealing material521may help to form a seal between abutment surfaces557″,572″ that reduces the permeability of connection550″ to fluids. In other respects, panels533A″,533B″ and connection550″ may be similar to panels133A,133B and connection150described herein.

FIG. 8Ais a partial cross-sectional view of a portion of a modular stay-in-place formwork628according to an example embodiment. Formwork628is similar to formwork128discussed above and comprises panels133,130and support members136which are substantially similar to panels133,130and support members136of formwork128. Formwork628differs from formwork128in that formwork628comprises tensioning braces640which extend between panels133and support members136to reinforce connections150. Tensioning braces640, which may be apertured to permit concrete flow therethrough, comprise connector components642at their respective ends to connection to complementary connector components644,646on panels133and support members136respectively. In the illustrated embodiment, connector components642of tensioning braces640comprise female, C-shaped connector components which slidably receive male, T-shaped connector components644,646of panels133and support members136.

In other embodiments, connector components642,644,646may be different than those shown in the illustrated embodiment and may connect to one using techniques other than relative sliding, such as, by way of non-limiting example, deformable “snap-together” connections, pivotal connections, push on connections and/or the like. In some embodiments, tensioning braces640may be provided with male connector component and panels133and support members136may comprise female connector components. While not shown in the illustrated embodiment, tensioning braces640may additionally or alternatively be connected between connector components648of support members136and connector components650of panels130.

In other respects, formwork628is substantially similar to formwork128described herein.

FIG. 8Bis a partial cross-sectional view of a portion of a modular stay-in-place formwork628′ according to an example embodiment. Formwork628′ is similar to formwork128discussed above and comprises panels133and support members136which are substantially similar to panels133and support members136of formwork128. Formwork628′ differs from formwork128in that formwork628′ comprises wall segments627′,629′ which are both provided by panels133—i.e. formwork628′ comprises panels133on both sides of each support member136. The connections150between, and operation of, panels133on ether side of support members136are substantially similar to that described above. In other respects, formwork628′ is substantially similar to formwork128described herein.

FIG. 9Ais a partial cross-sectional view of a portion of a modular stay-in-place formwork728according to an example embodiment. Formwork728is similar to formwork128discussed above and similar reference numbers are used to refer to similar features, except that features of formwork728are referred to using reference numbers preceded by the numeral “7” whereas features of formwork128are referred to using reference numbers preceded by the numeral “1”. Formwork728of the illustrated embodiment includes panels730,733and support members736which are connected to one another to provide wall segments727,729which, in the illustrated embodiment, extend in the vertical direction (into and out of the page in theFIG. 9Aview) and in the transverse direction17.

Panels730,733of formwork728comprise female connector components732and male connector components734which are respectively substantially similar to female connector components132and male connector components134described herein. More particularly, female and male connector components732,734comprise engagement portions and abutment portions (not specifically enumerated inFIG. 9A) which are substantially similar to engagement portions182,186and abutment portions184,188of connector components132,134described herein and which function in a similar manner to provide connections750between edge-adjacent panels.

Panels730,733differ from panels130,133in that panels730respectively comprise outward facing (exterior) surfaces731A,735A and inward facing (interior) surfaces731B,735B that are spaced apart from one another and inward facing (interior) surfaces731B,735B of panels730,733are shaped to provide inwardly protruding convexities703between the transverse edges of panels730,733. In the illustrated embodiment, convexities703are arcuately shaped, but this is not necessary and convexities703may be linearly convex.

Extending between exterior surfaces731A,735A and interior surfaces731B,735B of panels730,733comprise a plurality of brace elements832A,832B,834A,834B,836A,836B,838A,838B,840A,840B. Brace elements832A,832B,834A,834B,836A,836B,838A,838B,840A,840B of the illustrated embodiment are oriented at non-orthogonal angles to both exterior surfaces731A,735A and interior surfaces731B,735B of panels730,733. In the illustrated embodiment, all of brace elements832A,832B,834A,834B,836A,836B,838A,838B,840A,840B in any one panel730,733are non-parallel with one another. In the illustrated embodiment, brace elements832A,832B,834A,834B,836A,836B,838A,838B,840A,840B are oriented to be symmetrical about a notional transverse mid-plane842—i.e. more particularly:the transversely outermost pair of brace elements832A,832B have orientations that are mirror images of one another relative to mid-plane842and are oriented with the same interior angle relative to exterior surfaces731A,735A;the second transversely outermost pair of brace elements834A,834B have orientations that are mirror images of one another relative to mid-plane842and are oriented with the same interior angle relative to exterior surfaces731A,735A;the third transversely outermost pair of brace elements836A,836B have orientations that are mirror images of one another relative to mid-plane842and are oriented with the same interior angle relative to exterior surfaces731A,735A;the fourth transversely outermost pair of brace elements838A,838B have orientations that are mirror images of one another relative to mid-plane842and are oriented with the same interior angle relative to exterior surfaces731A,735A;the transversely innermost pair of brace elements840A,840B have orientations that are mirror images of one another relative to mid-plane842and are oriented with the same interior angle relative to exterior surfaces731A,735A.

This shape of exterior and interior surfaces731A,731B and735A,735B and the orientations of brace elements832A,832B,834A,834B,836A,836B,838A,838B,840A,840B can reduce deformation (e.g. pillowing and bellying) in panels730,733. It will be appreciated that panels730,733of the illustrated embodiment comprise five pairs of brace elements832A,832B,834A,834B,836A,836B,838A,838B,840A,840B that are symmetrical with respect to notional mid-plane842, but that in other embodiments, panels may comprise other numbers of pairs of symmetrical brace elements.

Panels730,733also differ from panels130,133in that panels730,733comprise connector component reinforcement structures721which reinforce connector components732and742and provide panels730,733with additional stiffness and resistance to deformation in the region of connector components732and742. In the illustrated embodiment, connector component reinforcement structures721are rectangular shaped comprising inward/outward members and transverse members (not specifically enumerated), although this is not necessary. In other embodiments, connector component reinforcement structures721could be provided with other shapes, while performing the same or similar function. For example, connector component reinforcement structures721could be made to have one or more non-orthogonal and non-parallel brace elements (e.g. similar to brace elements832A,832B,834A,834B,836A,836B,838A,838B,840A,840B described above) or connector component reinforcement structures721could be made to have one or more orthogonal and parallel brace elements.

In other respects, formwork728is substantially similar to formwork128described herein.

FIG. 9Bis a partial cross-sectional view of a portion of a modular stay-in-place formwork728′ according to an example embodiment. Formwork728′ is similar in many respects to formwork728discussed above and similar reference numbers are used to refer to similar features, except that features of formwork728′ are referred to using reference numbers followed by the prime symbol (′). Panels733′ of formwork728′ comprise female connector components732′ and male connector components734′ which are respectively substantially similar to female connector components732and male connector components734of panels733described herein. Panels733′ are also similar to panels733in that they comprise outward facing (exterior) surfaces735A′ and inward facing (interior) surfaces735B′ that are spaced apart from one another and interior surfaces735B′ of panels733′ are shaped to provide inwardly protruding convexities703′ between the transverse edges of panels733′. Panels733′ are also similar to panels733in that they comprise brace elements (not specifically enumerated inFIG. 9B) which extend between exterior surfaces735A′ and interior surfaces735B′ of panels733′ and which are substantially similar to brace elements832A,832B,834A,834B,836A,836B,838A,838B,840A,840B of panels733described herein.

Formwork728′ differs from formwork728in that formwork728′ comprises support members136(substantially identical to those of formwork128) and edge-adjacent pairs of panels733′ are each provided with a J-shaped connector component742A′,742B′ at their transverse edges for engaging a portion of the connector component139of support member136. More particularly, when panels733′ are connected in edge-adjacent relationship, a pair of J-shaped connector components742A′742B′ (one from each edge-adjacent panel733′) together provide a “double-J” shaped female connector component for receiving the complementary connector component139of support member136. This configuration of connector components may help to reinforce the connections between edge-adjacent panels733′.

In other respects, formwork728is substantially similar to formwork128described herein.

Processes, methods, lists and the like are presented in a given order. Alternative examples may be performed in a different order, and some elements may be deleted, moved, added, subdivided, combined, and/or modified to provide additional, alternative or sub-combinations. Each of these elements may be implemented in a variety of different ways. Also, while elements are at times shown as being performed in series, they may instead be performed in parallel, or may be performed at different times. Some elements may be of a conditional nature, which is not shown for simplicity

Those skilled in the art will appreciate that directional conventions such as “vertical”, “transverse”, “horizontal”, “upward”, “downward”, “forward”, “backward”, “inward”, “outward”, “vertical”, “transverse” and the like, used in this description and any accompanying claims (where present) depend on the specific orientation of the apparatus described. Accordingly, these directional terms are not strictly defined and should not be interpreted narrowly.

Unless the context clearly requires otherwise, throughout the description and any claims (where present), the words “comprise,” “comprising,” and the like are to be construed in an inclusive sense, that is, in the sense of “including, but not limited to.” As used herein, the terms “connected,” “coupled,” or any variant thereof, means any connection or coupling, either direct or indirect, between two or more elements; the coupling or connection between the elements can be physical, logical, or a combination thereof. Additionally, the words “herein,” “above,” “below,” and words of similar import, shall refer to this document as a whole and not to any particular portions. Where the context permits, words using the singular or plural number may also include the plural or singular number respectively. The word “or,” in reference to a list of two or more items, covers all of the following interpretations of the word: any of the items in the list, all of the items in the list, and any combination of the items in the list.

While a number of exemplary aspects and embodiments have been discussed above, those of skill in the art will recognize certain modifications, permutations, additions and sub-combinations thereof. For example:In theFIG. 3embodiment, formwork128comprises a pair of wall segments127,129which extend in the vertical direction19and the transverse direction17. Formworks used for tilt-up walls and/or for lining structures need only comprise a single wall segment. In addition, structures fabricated using formworks according to various embodiments of the invention are not limited to walls. In such embodiments, groups of edge-adjacent panels133connected in edge-to-edge relationship at connections150may be more generally referred to as formwork segments instead of wall segments. In the illustrated embodiment, wall segments127,129are spaced apart from one another in the inward-outward direction by an amount that is relatively constant, such that wall segments127,129are generally parallel. This is not necessary. In some embodiments, wall segments127,129need not be parallel to one another and different portions of formworks according to the invention may have different inward-outward dimensions.In some embodiments, it may be desirable to provide walls which incorporate insulation. Insulation may be provided in the form of rigid foam insulation. Non-limiting examples of suitable materials for rigid foam insulation include: expanded poly-styrene, poly-urethane, poly-isocyanurate or any other suitable moisture resistant material. By way of non-limiting example, insulation layers may be provided in any of the forms described herein. Such insulation layers may extend in the longitudinal direction and in a transverse direction (i.e. between the interior and exterior surfaces of a formwork). Such insulation layers may be located centrally within the wall or at one side of the wall. Such insulation may be provided in segments whose transverse widths match those of the panels (e.g. panels133) described herein and may fit between corresponding pairs of support members (e.g. support members136) described herein. In some embodiments, sound-proofing materials may be layered into the forms described herein in a manner similar to that of insulation.As is well known in the art, reinforcement bars (sometimes referred to as rebar) may be used to strengthen concrete structures. Rebar may be assembled into the formworks described above. By way of non-limiting example, rebar may be assembled into formwork128described above by extending rebar transversely (e.g. horizontally) through apertures141,143in support members136(FIG. 3D) and vertically oriented rebar may be tied or otherwise fastened to the horizontal rebar.In the embodiments described herein, the structural material used to fabricate the wall segments is concrete. This is not necessary. In some applications, it may be desirable to use other structural materials which may be initially be introduced placed into formworks and may subsequently solidify or cure.In the embodiments described herein, the outward facing surfaces (e.g. surfaces135A) of some panels (e.g. panels133) are substantially flat. In other embodiments, panels may be provided with inward/outward corrugations. Such corrugations may extend longitudinally and/or transversely. Such corrugations may help to further prevent or minimize pillowing of panels under the weight of liquid concrete.In the embodiments described herein, various features of the panels described herein (e.g. connector components132,134of panels133) are substantially co-extensive with the panels in longitudinal dimension19. This is not necessary. In some embodiments, such features may be located at various locations on the longitudinal dimension19of the panels and may be absent at other locations on the longitudinal dimension19of the panels.In some embodiments, the formworks described herein may be used to fabricate walls, ceilings or floors of buildings or similar structures. In general, the formworks described above are not limited to building structures and may be used to construct any suitable structures formed from concrete or similar materials. Non-limiting examples of such structures include transportation structures (e.g. bridge supports and freeway supports), beams, foundations, sidewalks, pipes, tanks, beams and the like.Structures (e.g. walls) fabricated according to the invention may have curvature. Where it is desired to provide a structure with a certain radius of curvature, panels on the inside of the curve may be provided with a shorter length than corresponding panels on the outside of the curve. This length difference will accommodate for the differences in the radii of curvature between the inside and outside of the curve. It will be appreciated that this length difference will depend on the thickness of the structure.Portions of connector components may be coated with or may otherwise incorporate antibacterial, antiviral and/or antifungal agents. By way of non-limiting example, Microban™ manufactured by Microban International, Ltd. of New York, N.Y. may be coated onto and/or incorporated into connector components during manufacture thereof. Portions of connector component may also be coated with elastomeric sealing materials. Such sealing materials may be co-extruded with their corresponding components.Many embodiments and variations are described above. Those skilled in the art will appreciate that various aspects of any of the above-described embodiments may be incorporated into any of the other ones of the above-described embodiments by suitable modification.