Method of forming a rebate in a surface of a slip form cast core using a rebate form with ferrule support

1. A method of forming a rebate in a surface of a slip cast core with at least one cast-in ferrule opening into the rebate for receiving a reinforcing or fastening element, said method using a formwork system,

the formwork system comprising:

a ferrule having an interior passage;

a rebate form, and

at least one ferrule support carried by the rebate form,

wherein the ferrule support comprises a finger, the finger projects from an inner face of the rebate form and the finger is received within the interior passage of the ferrule to engage an internal surface of the interior passage of the ferrule to provide support for the ferrule along the interior passage of the ferrule during casting of the ferrule into the core; and

wherein the finger is axially withdrawable from the interior passage of the ferrule after casting by a withdrawal of the rebate form from the core in an outward movement perpendicular to the face of the core thereby exposing an outer end of the ferrule which opens onto the rebate to receive a reinforcing or fastening element;

said method comprising:

attaching the rebate form to a slip form or reinforcement, with the ferrule support carried by the rebate form;

pushing the at least one ferrule onto the finger of the ferrule support so that the finger is received within the interior passage of the ferrule to engage the internal surface of the interior passage of the ferrule;

casting the ferrule into the core with the finger providing support for the ferrule along the interior passage of the ferrule during said casting; and

after said casting, withdrawing the rebate form from the core in an outward movement perpendicular to the surface of the core, thereby exposing the outer end of the ferrule which opens onto the rebate to receive the reinforcing or fastening element, wherein said withdrawing axially removes the finger from the interior passage of the ferrule without destroying the ferrule support.

2. A formwork system for forming a rebate in a face of a core produced by slip form casting, said system comprising:

a ferrule having an interior passage;

a rebate form, and

at least one ferrule support carried by the rebate form;

wherein the ferrule support comprises a finger, the finger projects from an inner face of the rebate form and the finger is receivable within the interior passage of the ferrule to engage an internal surface of the interior passage of the ferrule to provide support for the ferrule along the interior passage of the ferrule during casting of the ferrule into the core; and

wherein the finger is axially withdrawable from the interior passage of the ferrule after casting, thereby exposing an outer end of the ferrule which opens onto the rebate to receive a reinforcing or fastening element;

wherein the finger of the ferrule support is push fit within the interior passage of the ferrule to retain the ferrule during casting and to retain the outer end of the ferrule substantially flush with the inner face of the rebate form.

3. A system according to claim 2 , wherein the rebate form has means for mounting the at least one ferrule support at selected positions along a length of the rebate form.

4. A system according to claim 2 , wherein

the rebate form has a series of spaced passages opening to the inner face of the rebate form, and

the series of spaced passages have either the ferrule support, or a closure plug selectively and releasably applied thereto.

5. A system according to claim 4 , wherein the system comprises multiple said rebate forms each of which is of modular construction enabling a rebate of required length to be produced by assembling two or more said rebate forms in end-to-end relation.

6. A system according to claim 5 , wherein each said rebate form has interlocking end fittings configured for interlocking engagement with the end fittings of adjacent said rebate forms.

7. A formwork system for forming a rebate in a face of a core produced by slip form casting, said system comprising:

a ferrule having an interior passage;

a rebate form, and

at least one ferrule support carried by the rebate form;

wherein

the ferrule support comprises a finger, the finger projects from an inner face of the rebate form and the finger is receivable within the interior passage of the ferrule to engage an internal surface of the interior passage of the ferrule to provide support for the ferrule along the interior passage of the ferrule during casting of the ferrule into the core;

the finger is axially withdrawable from the interior passage of the ferrule after casting, thereby exposing an outer end of the ferrule which opens onto the rebate form to receive a reinforcing or fastening element;

the rebate form has a series of spaced passages opening to the inner face of the rebate form;

the series of spaced passages have either the ferrule support, or a closure plug selectively and releasably applied thereto;

the system comprises multiple said rebate forms each of which is of modular construction enabling a rebate of required length to be produced by assembling two or more said rebate forms in end-to-end relation; and

each said rebate form has interlocking end fittings configured for interlocking engagement with the end fittings of adjacent said rebate forms.

8. A formwork system for forming a rebate in a face of a core produced by slip form casting, said system comprising:

a ferrule having an interior passage;

a rebate form, and

at least one ferrule support carried by the rebate form,

wherein the ferrule support comprises a finger, the finger projects from an inner face of the rebate form and the finger is received within the interior passage of the ferrule to engage an internal surface of the interior passage of the ferrule to provide support for the ferrule along the interior passage of the ferrule during casting of the ferrule into the core; and

wherein the finger is axially withdrawable from the interior passage of the ferrule after casting by a withdrawal of the rebate form from the core in an outward movement perpendicular to the face of the core, thereby exposing an outer end of the ferrule which opens onto the rebate to receive a reinforcing or fastening element.

9. A system according to claim 8 , wherein the rebate form includes means for mounting the at least one ferrule support at selected positions along a length of the rebate form.

10. A system according to claim 8 , wherein the rebate form has a series of spaced passages opening to the inner face of the rebate form, the spaced passages configured to selectively and releasably engage the ferrule support,

the system further comprising a closure plug to be applied to each passage not engaging the ferrule support.

11. A system according to claim 10 , wherein the system comprises multiple said rebate forms each of which is of modular construction enabling a rebate of required length to be produced by assembling two or more said rebate forms in end-to-end relation.

12. A formwork system for forming a rebate in a face of a core produced by slip form casting, said system comprising:

a rebate form having at least one passage which has an opening on an inner surface of the rebate form; and

at least one ferrule support having a boss, a finger, and a head between the boss and the finger,

wherein

the boss is receivable in and releasably engageable with the passage to removably attach the ferrule support to the rebate form;

the finger is receivable within an interior passage of a ferrule to provide support for the ferrule during casting of the ferrule into the core, and is axially withdrawable from the interior passage of the ferrule after casting;

the head has an outer diameter greater than those of the boss and the finger; and

when the boss is engaged with the passage, the head closes the opening of the passage against entry of concrete during casting.

13. A system according to claim 12 , wherein

the passage has, in order from the opening, an annular recess and a section engageable with the boss; and

when the boss is engaged with said section of the passage, the head is seated within the annular recess.

14. A system according to claim 13 , wherein

when the boss is engaged with said section of the passage, the head is seated within the annular recess and flush with the inner surface of the rebate form.

15. A system according to claim 13 , wherein

the boss and said section of the passage have matching threads or bayonet members for releasable engagement with each other.

16. A system according to claim 12 , wherein the passage has, in order from the opening,

a first section of a larger diameter and engageable with the boss; and

a second section of a smaller diameter for receiving a fastener inserted into the passage for fastening the rebate form to a front face of a slip form.

17. A system according to claim 12 , wherein the finger has, in order from the head,

a first section of a larger diameter and adapted to be push-fit within an outer end of the interior passage of the ferrule so as to engage and seal the outer end of the interior passage of the ferrule; and

a second section of a smaller diameter and adapted to engage an internal surface of the interior passage of the ferrule without providing significant resistance to insertion or removal of the finger into and out of the ferrule.

18. A system according to claim 12 , further comprising

a closure plug having a head and a boss;

wherein

the boss of the plug is receivable in and releasably engageable with the passage to removably closing the passage when the ferrule support is not attached to said passage;

the head of the plug has an outer diameter greater than that of the boss of the plug; and

when the boss of the plug is engaged with the passage, the head of the plug closes the opening of the passage against entry of concrete during casting.

19. A system according to claim 18 , wherein

the head of the plug has a slot for engagement with a tool.