The present invention relates to construction formwork systems, and more particularly to a FLYMODECK Formwork System for slab casting, specifically engineered to support and shape thick Cheese/Waffle slab geometries. The invention notably provides a structurally integrated, reusable deck assembly capable of resisting complex load distributions and facilitating rapid casting cycles without ground-based
shoring.

Waffle / Cheese Slabs, also known as ribbed or coffered slabs, are widely employed in medium- and long-span structural applications due to their improved stiffness-to- weight ratio and structural efficiency. Such slabs consist of intersecting orthogonal ribs formed using reusable mould units that generate a grid-like structural configuration capable of reducing dead load while maintaining flexural rigidity.
Conventionally, waffle / cheese slabs are constructed using ground-supported falsework arrangements comprising vertical props, horizontal ledgers, bracing systems, and deck panels. While such systems provide adequate load-carrying capability, they typically involve dense shoring configurations extending from ground level to slab level. These arrangements may cause congestion at construction sites, increase workmen and material handling requirements, prolong construction cycles, and restrict simultaneous execution of lower-floor activities.
To address such concerns, FLYMODECK Formwork System have been developed to enable slab form panels to be repositioned without complete dismantling. Certain prior art references disclose modular slab form assemblies and striking mechanisms, including US Paten

Patent No. 7,222,469, and EP Patent No. 3652392B1. These references generally disclose reusable modular deck panels, beam-supported form tables, and hydraulic lowering arrangements primarily intended for flat slabs or conventional beam-slab
construction.
Further, EP 2589719B1 discloses a lightweight slab or structural element configured to accommodate service equipment passing through the slab body. The disclosure is directed toward permanent structural slab arrangements rather than temporary formwork systems used during slab concreting operations.
WO 2016/004887 A1 discloses a lightweight steel residential framework system relating to prefabricated structural framework construction. The disclosure primarily concerns permanent building structural assemblies and does not address reusable deck formwork configurations.
CN 113605771 B discloses a prestressed assembly-type frame structure system relating to load-bearing structural framing and prefabricated assembly techniques. The reference focuses on structural frame behavior and prestressing systems rather than modular slab formwork assemblies.
Although the above references disclose modular structural systems, slab assemblies, and reusable formwork tables, such disclosures do not adequately address the structural behavior and construction requirements associated with waffle slab systems.
3. OBJECTIVES OF THE INVENTION
The objectives of the invention is to provide a FLYMODECK Formwork Systemsystem
that:
■ Provides a structurally engineered deck capable of carrying complex Cheese/Waffle slab loads without ground-based propping.

Incorporates a hierarchical load-bearing network of primary and secondary members that uniformly transfer load to column supports; Enables dimensional accuracy control of rib geometry for thick slab casting. ■ Minimizes deflection and vibration under heavy construction loads. ■ Facilitates rapid reuse with minimal assembly/disassembly. ■ Improves overall construction efficiency while reducing labour and cycle time.
10-AR5-2026/53511/202641046172/Form 2(Title Page)
4* SUMMARY OF THE INVENTION
The present invention provides a FLYMODECK Formwork System particularly suited for Cheese/Waffle slab construction. The system comprises a plurality of column­mounted bracket assemblies and a structurally integrated modular deck assembly
that combines:
(i) Primary plate girder beams designed for high bending resistance and uniform bending moment distribution; (ii) A secondary beam network composed of IS and Rectangular Hollow Sections (RHS) members arranged relative to waffle / cheese rib geometry for efficient load
transfer;
(iii) Modular waffle / cheese mould units configured to enforce precise rib spacing, depth, and cavity geometry; and (iv) Deck sheathing panels that contribute to global stiffness and enable continuous
form surface.
The deck structure is engineered as a single, rigid entity capable of resisting composite slab loads through a non-obvious structural synergy between its constituent members. Loads from wet concrete, reinforcement, and live construction loads are transferred through the waffle mould grid and sheathing into the secondary

beams, and from the secondary beams into the primary7 plate girders,, which then transmit forces to the column-hung bracket supports.
By using this structurally integrated deck, the system achieves:
■ High load-bearing capacity relative to weight. ■ Controlled deflection behaviour under high slab loads. ■ Dimensional repeatability across multiple cycles. ■ Inherent stiffness that prevents localised buckling or deformation.
The modular nature allows the deck to be disassembled into kit-of-parts only when necessary, ensuring maximum reuse efficiency.
While the system may further include mechanisms for controlled lowering and repositioning after slab strength attainment, the novelty and inventive step primarily reside in the deck's structural arrangement, where the hierarchical load path and modular unit integration significantly outperform known formwork
configurations.

BRIEF DESCRIPTION OF DRAWINGS:
■ Figure 1: 3D view of FLYMODECK Formwork System for Cheese / Waffle slab Figure 2: Plan View of FLYMODECK Formwork ■ Figure 3: Sectional View of FLYMODECK Formwork ■ Figure 4: FLYMODECK Formwork Arrangement Layout ■ Figure 5: FLYMODECK Formwork Section ■ Figure 6: FLYMODECK Formwork Arrangement Details

DETAILED DESCRIPTION OF THE INVENTION:
The present invention relates to a FLYMODECK Formwork System for Cheese / Waffle slab formwork, emphasizing structural continuity, load distribution, dimensional precision, and reuse efficiency across multiple casting cycles.
General Arrangement of the System;
The system comprises an integrated modular deck table supported on column­mounted brackets. The deck table is engineered to behave as a composite structural entity under high slab loads, with load paths designed to avoid concentrations of local stress and prevent undue deflection.
Column-Mounted Bracket Assembly
Each bracket assembly provides vertical support points for the modular-deck and transmits loads directly into permanent structural columns. The bracket supports are spaced according to structural grid requirements and are configured to interface securely with the deck's primary girders.
Mechanical Screw Jack Modular Deck Structure
The modular deck is a structurally coupled assembly comprising:
1. Primary Plate Girder Beams
Heavy plate girder beams serve as the primary load carriers. Their depth, flange geometry, and web configuration are selected based on predicted slab loads, span length, and dynamic load factors.

These girders are arranged to span between bracket supports and act as the backbone of the deck structure, resisting bending moments and shear forces without excessive deflection.
2. Secondary Beam Network
IS section members and RHS sections (e.g., 90 x 90 x 3) form a planar network that distributes load from waffle moulds to the primary girders. This
network:
■ Aligns with typical rib directions in Cheese/Waffle slabs. ■ Supports waffle mould units with minimal distortion. ■ Balances load distribution across the deck surface.
3. Modular Waffle / Cheese Mould Units
Modular moulds made of FRP / plastic / steel are arranged to match slab rib spacing and depths. These moulds are anchored to the secondary network to maintain robust positional stability during concrete placement.
The geometry of the waffle / cheese moulds contributes to the load path by converting slab loads into distributed forces that can be efficiently carried by the secondary and primary members.
4. Deck Sheathing
Where required, 18 mm film-faced plywood is used to form continuous soffit surfaces. This sheathing adds to global stiffness and prevents localised concrete leakage or deformation at ribs.

Integrated Structural Behaviour The combination of primary, secondary, mould, and sheathing elements creates a deck with composite structural properties: ■ high moment capacity ■ efficient load transfer paths ■ controlled deflection behaviour, and ■ dimensional consistency across repeated cycles.
This composite action represents a non-obvious synergy that significantly improves load performance and reuse capability compared to conventional segmented or simply supported deck systems.
Operation During Concreting
During slab construction, the modular deck is positioned on column-hung bracket supports and adjusted to the required soffit level. Concrete is then poured over the waffle mould grid and sheathing.
The deck, by virtue of its integrated structure, resists slab loads without ground-based props and maintains stiffness such that rib geometry is preserved, and casting tolerances are maintained.
After the slab attains early-age strength, controlled support mechanisms may be used to disengage the deck with minimal disturbance to the slab soffit.

The invention provides:
■ A non-obvious FLYMODECK Formwork System capable of supporting thick Cheese/Waffle slabs without ground shoring.
■ A hierarchical load distribution network that prevents localised deformation. ■ A structurally integrated assembly that reduces deflection and improves
dimensional accuracy.
■ High reuse efficiency with minimal assembly/disassembly. ■ Improved cycle times and reduced labour intensity. ■ Suitability for large floor plates and repetitive slab layouts.
These effects are not achievable by merely combining known modular tables or support systems but arise from the integrated structural synergy of the deck assembly.
8. INDUSTRIAL APPLICABILITY
The invention is industrially applicable to high-rise buildings, podium slabs, transfer decks, and infrastructure projects requiring repetitive slab construction.

A column-hung modular deck formwork system for cheese or waffle slab construction comprises a plurality of column-mounted bracket assemblies configured to be fixed to structural columns; and a modular deck structure supported by the column-mounted bracket assemblies; wherein the modular deck structure comprises a plurality of primary plate girder beams arranged to span between the column-mounted bracket assemblies, a secondary beam network supported on the primary plate girder beams and configured to distribute slab loads, a plurality of modular waffle mould units positioned in relation to the secondary beam network, and deck sheathing
*
panels supported over the secondary beam network; wherein the modular deck structure defines an integrated hierarchical load path extending from the deck sheathing panels through the secondary beam network and the primary plate girder beams to the column-mounted bracket assemblies such that the system is configured to support wet concrete loads without the use of ground-supported falsework. 2. The system as claimed in claim 1, wherein the primary plate girders are sized
$
to resist predicted bending moments and shear forces induced by thick slab
loads.
3. The system as claimed in claim 1, wherein the secondary beam network aligns with waffle rib directions to ensure uniform load distribution. 4. The system as claimed in claim 1, wherein the modular waffle mould units maintain dimensional stability and rib geometry during concrete placement. 5. The system as claimed in claim 1, wherein the deck sheathing contributes to global stiffness and structural continuity.