Patent Publication Number: US-2018038125-A1

Title: Modular shuttering block

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
     This application is a national phase entry under 35 U.S.C. §371 of International Patent Application PCT/FR2016/050454, filed Feb. 29, 2016, designating the United States of America and published as International Patent Publication WO 2016/135431 A1 on Sep. 1, 2016, which claims the benefit under Article 8 of the Patent Cooperation Treaty to French Patent Application Serial No. 1551693, filed Feb. 27, 2015. 
    
    
     TECHNICAL FIELD 
     This application relates to the field of prefabricated construction elements, notably for producing structures such as swimming pools or swimming pool elements. 
     More particularly, the disclosure relates to a modular shuttering block and notably finds its application in the production of angled steps for swimming pools. 
     BACKGROUND 
     Usually such steps consist either of a one-piece construction added and fastened to a wall or in the angle formed by two walls of the basin, or of a masonry structure, produced like a wall construction, by stacking bricks, or pouring concrete into a formwork. 
     One-piece steps are very expensive, since they require some large dimension molds, and they are also very bulky with regard to both their storage and their transport. In addition the number of models provided is limited, so that they do not allow original creations. 
     Masonry steps allow more originality, within the limits, however, of the structures used and the capabilities of the installer. They also have drawbacks, notably a lengthy implementation, more particularly when they are made of poured concrete, notably for installing the formwork. Conventional formwork means made of wood must be removed after construction. 
     Another formwork technique also conventionally used in the field of swimming pool construction, and notably the construction of swimming pool steps, consists in using shuttering blocks that remain in the construction after the concrete has been poured inside them and solidified there. The shuttering blocks currently used are rectangular or cubic in shape and require cutting and adjustment work in the particular case of angled steps. This cutting and adjustment work can be difficult, lengthy and therefore expensive. Furthermore, the exact dimensions of a set of angled steps may vary according to the adjustments made to compensate for the inaccuracy of the cuts. It is therefore also necessary to adapt the exact dimensions of the flexible watertight envelope (“liner”) to each construction, which is also expensive and causes longer delivery times. In addition, the inaccuracy of the cuts and/or measurements may cause defects during the installation of the “liner,” notably possibly causing problems of watertightness when placing the swimming pool in operation. 
     BRIEF SUMMARY 
     One object of this disclosure is to simplify and enhance the reliability of the construction of angled steps notably for a swimming pool basin. 
     The disclosure relates to a modular shuttering block defining a through-housing connecting a first face of the modular block and a second face opposite the first, for the reception of a filling material; the modular block being provided with assembly means for assembly with at least one other block. According to the disclosure, the modular block is in the shape of a right prism with isosceles triangular bases formed by the first and second faces. 
     The modular shuttering block according to the disclosure, therefore, has a shape particularly suited to the construction of a set of angled steps, in particular of a swimming pool, thus avoiding all cutting and adjustment work. 
     According to advantageous features of the disclosure, taken singly or in combination:
         the through-housing is defined by at least three walls forming the rectangular lateral faces of the right prism, two of these walls having the same dimensions;   the through-housing comprises a plurality of ribs delimiting at least one through-compartment.       

     These advantageous features both ensure a good rigidity and improve the mechanical strength of the modular block during the filling by the shuttering material. 
     According to other advantageous features of the disclosure, the two walls having the same dimensions are orthogonal. 
     Thus, the modular block is particularly suited to the construction of right angled steps, which are the most common, the right angle at the top of the triangular bases of the right prism making it possible to optimize the number of modular blocks to be assembled for forming the future steps. 
     According to other advantageous features of the disclosure, taken singly or in combination:
         the assembly means are formed on each of the two lateral walls of the same dimension;   the assembly means include at least one male member and one female member configured for engaging with the male and female members of another block;   the male member is formed by a tenon of a trapezoidal section extending from the first face to the second face and the female member is formed by a groove of complementary shape, making assembly possible by sliding with another block;   the tenon has different widths at the first and second face, so as to lock the sliding of the tenon in the groove of the complementary shape of another block during assembly;   the groove has different widths at the first and second face, so as to lock the sliding of a tenon of complementary shape of another block in the groove during assembly;   the groove comprises a stop in its narrowest end capable of locking a tenon of another block in a defined assembly position;   the tenon comprises a notch in its narrowest end capable of engaging with the stop of the groove of another block, for locking the tenon in a defined assembly position.       

     These advantageous features simplify assembly by interlocking the modular blocks and ensure the alignment of all the modular blocks in the planes of the first and second faces during assembly. 
     According to other advantageous features of the disclosure:
         the walls, the ribs and the assembly means are formed of plastic material;   the assembly means are integrated into the lateral walls of the same dimension.       

     The disclosure also relates to an assembly formed of a plurality of modular shuttering blocks, the modular blocks being juxtaposed in rows. 
     This assembly may further include a plurality of rows of modular blocks superimposed on one another. 
     According to one advantageous feature, the assembly comprising a plurality of superimposed modular shuttering blocks may also comprise a rail slid into an opening formed by the alignment of the through-compartments of the modular blocks. The dimension of the rail is adjusted to the dimension of the compartments, so that the rail may ensure the vertical alignment of stacked modular blocks, and more particularly of stacked rows of modular blocks. 
     The disclosure finally relates to a set of swimming pool steps including such an assembly. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The disclosure will be better understood upon reading the following description and examining the accompanying figures. These figures are given by way of illustration but are in no way restrictive to the disclosure. 
         FIGS. 1 and 2   a  represent perspective views of the modular shuttering block according to one implementation of the disclosure; 
         FIG. 2 b    represents a plan view of a triangular face of the modular shuttering block according to one implementation of the disclosure; 
         FIG. 3  represents a plan view of a lateral face of the modular shuttering block according to one implementation of the disclosure; 
         FIG. 4  represents a top plan view of an assembly of a plurality of modular shuttering blocks according to one implementation of the disclosure; 
         FIG. 5  represents a perspective view of an assembly of a plurality of modular shuttering blocks for the construction of a set of swimming pool angled steps, according to one implementation of the disclosure; and 
         FIG. 6  represents a sectional view along a plane bisecting the angle of a swimming pool of an assembly of a plurality of modular shuttering blocks for the construction of a set of swimming pool angled steps, formed of three steps (M 1 , M 2 , M 3 ); 
     
    
    
     DETAILED DESCRIPTION 
       FIGS. 1 through 3  represent a modular shuttering block  1  according to the disclosure and forming a lost formwork element for constructing a structure such as swimming pools and steps, notably swimming pool angled steps. 
     “Modular block,” is understood to mean an element capable of being assembled with other identical elements, with the aid of assembly means described in more detail later. 
     The modular shuttering block  1  is in the shape of a right prism, the faces A, B of which form isosceles triangular bases. 
     The modular block  1  comprises a through-housing advantageously defined by at least three walls  3 ,  4 ,  5  forming the rectangular lateral faces (C, D, E) of the right prism, which connects the first face A and the second face B and serves for receiving the filling material, in particular, the concrete to be poured. The through-housing therefore has no closed wall at the faces A, B making it possible for the filling material to flow through the modular block  1 . 
     Preferably, the through-housing comprises a plurality of ribs  6  delimiting compartments of sufficient size to allow an effective flow of the filling material in the structure. The term “rib” is understood to mean a wall internal to the through-housing at least one end of which may rest on one of the three walls  3 ,  4 ,  5  of the through-housing. 
     As illustrated in  FIGS. 1 through 2   b , but by way of example only, the ribs  6  delimit nine compartments of different sizes inside the through-housing. 
     These ribs  6  and the walls  3 ,  4 ,  5  help to rigidify the structure of the modular block  1  and reinforce its mechanical resistance to the internal pressures exerted by the filling material. 
     According to one variant not represented, a portion of one or both sides A, B may be closed by a wall, thereby shutting off a portion of the compartments of the through-housing: this variant makes it possible to limit the number of through-compartments and therefore the quantity of filling material introduced into the block for the formwork. 
     The height h of the modular block  1  forms a dimension of the lateral wall  5 . 
     Since the triangular bases of the prism are isosceles, the two lateral walls  3 ,  4 , termed “main lateral walls,” are of identical dimensions. The two main lateral walls  3 ,  4  are arranged to form a determined angle between same. This angle may be chosen to correspond to (or be a divisor of) an angle of a swimming pool basin in which a set of steps has to be formed. Advantageously, and as represented in the figures, the two main lateral walls  3 ,  4  form an angle of 90 degrees between same, thereby limiting the number of modular blocks to be assembled for forming the steps of a right angled set of steps, which are the most common angled steps. 
     The two main lateral walls  3 ,  4  comprise assembly means  2  for rigidly interconnecting multiple modular shuttering blocks. These means include male members  7  and female members  8  making it possible to set up an assembly by sliding between two modular blocks. Thus as represented in the figures, the male members  7  may be formed of tenons and the female members  8  of grooves, the complementary shapes of which engage to allow a dovetail assembly. 
     In the particularly advantageous implementation represented in  FIG. 3 , the tenon has different widths  1 ,  1 ′ in the first face A and the second face B of the modular block. In the same manner, the groove has different widths in the first and second face A, B of the modular block. This particular configuration makes it possible to lock the sliding of a tenon of a first modular block in a groove of complementary shape of a second modular block during the assembly of two modular blocks. 
     The assembly of two modular blocks is performed via their respective lateral faces C, D; the blocks being head to tail, one having its face A facing downward and the other having its face A facing upward, the lateral face D of the first block is assembled with the face C of the second block, by sliding the tenons in the grooves provided for this purpose. 
     Advantageously, and as illustrated in  FIGS. 1 through 3 , each main lateral wall  3 ,  4  has a shape defining a plurality of tenons and grooves, in particular, two tenons and two grooves, extending all along these walls. In other words, the assembly means  2  are integrated into the main lateral walls  3 ,  4 . This preferred feature simplifies the manufacture of the assembly means and promotes cohesion of the assembled modular blocks. 
     In addition, a stop  9  may be present at the narrowest end of one groove at least, for locking the tenon of another block in a defined assembly position. Advantageously, each groove comprises a stop at the narrowest end making it possible to adjust the position and lock the interlocking of the tenons of another block in their final assembly position. 
     Preferably, each tenon comprises a notch  10  in its narrowest end capable of engaging with the stop  9  of the groove of another block, for locking it in a defined assembly position. Thus, each groove being provided with a stop and each tenon with a notch, the interlocking of a first modular block onto a second modular block will be easily adjusted and locked in its final assembly position. 
       FIG. 4  depicts an assembly formed of a first row of modular shuttering blocks. This view reveals an alternation of the exposed faces A, B between adjacent modular blocks, resulting from the method of assembly described above. 
     A plurality of rows or modular shuttering blocks may be stacked with a correct alignment, by positioning the rows or blocks on one another and fitting a rail in an opening formed by the alignment of a through-compartment of each block. A dimension of the rail is adjusted to a dimension of the compartment of each block, so that the rail makes it possible to ensure the vertical alignment of stacked modular blocks. 
     The assembly of a plurality of modular shuttering blocks, juxtaposed in rows, then stacked, allows the construction of different masonry elements. 
     According to one advantageous example of implementation, such an assembly of modular shuttering blocks may be used for the manufacture of a set of swimming pool angled steps, as illustrated in  FIG. 5 . 
     The manufacture of a swimming pool requires pouring a concrete structure, notably for the construction of the base slab and the walls thereof. The implementation according to the disclosure makes it possible to pour the concrete in one go, for the base slab, the walls and swimming pool steps. 
     The modular blocks are assembled in rows through the blocks being interlocked with one another via the assembly means, as previously described, and without cutting. 
     Each row may rest, at its ends, on the perpendicular walls of the swimming pool basin. Optionally, support rails  12  may be fastened onto the walls of the basin or onto the floor for supporting the first rows; these first rows may also be supported by at least one central support rail and/or at least one stud fastened onto the floor. These rails and/or studs are positioned for making the level of the final bottom of the swimming pool flush and making it possible to adjust the level of the steps, before the concrete is poured. 
     The lateral wall  5  of the modular blocks  1  will form the exposed face of the riser. And the height h of the modular block will form the step height. By way of example, this height may be between 5 cm and 50 cm, preferably its dimension will be 30 cm. Advantageously, when the two main lateral walls  3 ,  4  are orthogonal, the step depth is defined by the half-width of the lateral wall  5  of the modular blocks. By way of example, it may be between 15 cm and 40 cm, preferably its dimension will be 30 cm. 
     The first row to be positioned for preparing the steps is the row R 1  of the step M 3  that can be seen in  FIG. 6  representing the sectional view of the right-angled steps of  FIG. 5  along a bisector plane. This is wedged against the walls of the swimming pool  14  and optionally on the rails  12  or support studs. The row R 2  of the step M 3 , then the row R 3  of this same step are then stacked on the row R 1  for forming step M 3 . For ensuring the alignment of this stack, a rail  11  is introduced vertically into an opening formed by the alignment of the through-compartments of the modular blocks. By way of example, and as represented in  FIG. 2 b   , the rail  11  is introduced into the compartment  13 . The width of the rail  11  is adjusted to the dimension of the compartments, so that the rail ensures the vertical alignment of stacked modular blocks and more particularly of stacked rows of modular blocks. The length of the rail  11  is adjusted to the number of stacked rows: it must be sufficiently long to traverse the stack of modular blocks, thus ensuring its function of aligning the superimposed rows. 
     After assembly of the step M 3 , i.e., the superimposition of the three rows R 1 , R 2 , R 3  and the positioning of the alignment rail, the assembly may be held in position by fastening elements such as screws, against the walls of the swimming pool. 
     The assembly of the steps M 2  and M 1  is then performed in a similar manner to that which has just been described for the step M 3 . 
     The assembly of modular blocks as described above and illustrated in  FIG. 5  is ready for the subsequent shuttering operation. The filling material, such as concrete, is poured to produce the base slab of the swimming pool and make the final floor flush with the step M 1 . The material may be poured into the assembly of modular blocks; it flows through the through-compartments down to the floor, and until the steps M 1 , M 2 , M 3  are filled and made flush. 
     After drying, a set of swimming pool angled steps is obtained, not requiring any cutting, poured simultaneously with the base slab and the walls of the swimming pool, thus forming a one-piece structure with the entire basin. 
     Its dimensions are accurate and reproducible. In addition, the one-piece character provides the structure with great solidity. 
     In the example according to  FIG. 5 , the set of angled steps comprises three steps, the dimensions of which are defined by the size of the modular blocks. 
     The standardization of the dimensions of a set of angled steps advantageously allows the standardization of flexible watertight envelopes (“liners”), leading to lower costs and shorter delivery times. 
     The modular block and the assembly by juxtaposition and/or stacking according to the disclosure are not restricted to this single use. They may, for example, also be used for the construction of straight steps or shuttering walls. For this purpose, provision may be made for a second category of modular blocks of different shape and complementary to that exposed, so as to be able to define lost formworks of any shape and dimension without needing cutting or by limiting the cutting of any modular shuttering block.