The present invention relates to concrete form braces. More particularly, the invention relates to an adjustable concrete form brace with reinforcement bar hangers.
Historically, concrete has been used to form the base or foundation of a building. During construction, channels defining the borders of the base or foundation are prepared. Concrete forms are then set up in the channels where the concrete forms are located adjacent to and connected to each other and arranged to match the dimensions of the required foundation or footing. The forms, which are typically made from steel panels or wooden boards or planks, are put into position on their edges across from each other and parallel to each other near the side walls of the channels.
In order to strengthen the foundation, steel reinforcement is used. Generally, this reinforcement is put into place using reinforcing bars. For best effect, the reinforcing bars are positioned within the concrete forms such that poured concrete will cover all surfaces of the reinforcing bars, top and bottom. For example, a horizontally oriented reinforcing bar is conventionally held in place by using separate reinforcing bar mounting stands. Some of the generally available reinforcing bar stands can be connected to the form after the form has been constructed, while others are positioned in the form and the reinforcing bar is placed on the device. Similarly, vertically oriented reinforcing bars are conventionally secured in the forms by devices that are connected to the form after it is constructed. Placing the reinforcing bar securing devices in the desired location within the form requires a substantial amount of labor and some degree of skill.
In one example as disclosed in U.S. Pat. No. 5,688,428, issued Nov. 18, 1997 to Maguire and entitled “Holder for Vertical Steel Rebar,” a member having first and second vertically extending leg portions, and a base member connecting one end of each leg member, a wood beam for the concrete structure being positioned in the channel formed between the first and second leg portions are included. A plurality of cup shaped members is formed along the outside surface of the first leg portion, in one embodiment, and along the outside surface of both leg portions in a second embodiment, vertical steel rebars are positioned in a selected one of the cup shaped members. Holes may be formed in the base member to receive fasteners to secure the member to the underlying wood frame member.
In another example, as disclosed in U.S. Pat. No. 6,247,273, issued Jun. 19, 2001 to Nickel and entitled “Adjustable Form Brace,” an adjustable bracing system is configured for supporting poured concrete wall systems and includes a vertical brace for engaging the wall. A slider slides vertically along a channel of the vertical brace. An adjustable length leg member connects at an upper end to the slider and extends outwardly away from the brace and connects at a lower end to a foot member. The leg is rotatably mounted at one end to a threaded member, wherein rotation of the leg in a first direction extends the threaded member and the length of the leg member, and rotation in a second opposite direction retracts the threaded member and shortens the length of the leg member.
In yet another example, as disclosed in U.S. Pat. No. 7,467,772, issued Dec. 23, 2008 to Huber and Hartman (the inventor of the present invention) and entitled “Devices for Securing Reinforcing Bars within Concrete Forms for Concrete,” devices for supporting horizontally oriented reinforcing bars in a form for concrete and devices for supporting vertically oriented reinforcing bars are disclosed. The devices for supporting horizontally oriented reinforcing bars engage the side walls of a form, span the space between the walls, and remain securely in position. The device includes guide members for guiding reinforcing bar sections into a desired position, and members that secure the reinforcing bar in position. The devices for supporting vertically oriented reinforcing bars are used with a generally L-shaped section of reinforcing bar and secured to two parallel sections of horizontal reinforcing bar. U.S. Pat. No. 7,467,772 is hereby incorporated herein by reference.
Many other types of concrete form braces have been used and designed. Unfortunately, known devices do not have the ability to adjust to various widths of forms defining footing or foundation borders. There is also a need for an adjustable vertical brace for holding hooked reinforcement bars in position. This has led to a situation wherein a myriad of parts must be kept on hand in order to adapt to various construction situations. Using conventionally available bracing devices, requires manufacturing about 60 different parts ranging in inches from 6×12 to 6×48, 8×12 to 8×48, 10×16 to 10×48, 12×20 to 12×48, etc. in order to service customer demand. Current devices and methods exhibit several drawbacks including higher cost, rust issues, and many require stakes, tie wire, and additional lumber for bracing. Further, due to the myriad of parts needed and complicated installation techniques, commercially available devices are labor intensive.
In a striking improvement over conventionally available concrete form braces, the present invention for the first time provides an adjustable concrete form brace that will adjust to any size in depth and width. In addition, the improved form brace disclosed herein, in one embodiment, can service customer demand for width adjustment by requiring a substantially reduced number of parts. No other commercially available concrete form bracket can adjust to depth and width. It is believed that the adjustable concrete form brace disclosed herein will reduce labor by up to 50%. In addition, the disclosed concrete form brace can be made of durable injection mold plastic that has a limited range of flexibility, will not rust or break and will be able to withstand heavy form pressure as well as the weight of concrete. Further the adjustable concrete form brace disclosed herein is the only product needed to set form spacing to exact specifications, stop spreading, and securely hold rebar at the appropriate height and width. Further still, the adjustable concrete form brace disclosed herein allows for a smoother top finish since after installation there are no hardware/obstacles to impede troweling.
This summary is provided to introduce, in a simplified form, a selection of concepts that are further described below in the Detailed Description. This summary is not intended to identify key features of the claimed subject matter, nor is it intended to be used as an aid in determining the scope of the claimed subject matter.
Disclosed herein is an adjustable concrete form brace that includes a horizontal adaptable extension member. A first lower brace element and a second lower brace element opposing the first lower brace element each have a horizontal insertion channel adapted to receive the horizontal extension member. A first upper brace element and second upper brace element are attached to the first lower brace element and the second lower brace element respectively. Each of the lower brace members include a saddle, and each saddle is adapted to retain one or more reinforcement bars. The first upper brace element and second upper brace element each include a form retaining element.
While the novel features of the invention are set forth with particularity in the appended claims, the invention, both as to organization and content, will be better understood and appreciated, along with other objects and features thereof, from the following detailed description taken in conjunction with the drawings, in which:
In the drawings, identical reference numbers call out similar elements or components. The sizes and relative positions of elements in the drawings are not necessarily drawn to scale. For example, the shapes of various elements and angles are not drawn to scale, and some of these elements are arbitrarily enlarged and positioned to improve drawing legibility. Further, the particular shapes of the elements as drawn, are not necessarily intended to convey any information regarding the actual shape of the particular elements, and have been solely selected for ease of recognition in the drawings.
The following disclosure describes an adjustable concrete form brace. Several features of methods and systems in accordance with example embodiments are set forth and described in the figures. It will be appreciated that methods and systems in accordance with other example embodiments can include additional procedures or features different than those shown in the figures. Example embodiments are described herein with respect to an adjustable concrete form brace for use in pouring concrete footings. However, it will be understood that these examples are for the purpose of illustrating the principles, and that the invention is not so limited.
Generally, as used herein, the following terms have the following meanings, unless the use in context dictates otherwise:
The use of the word “a” or “an” when used in conjunction with the term “comprising” in the claims or the specification means one or more than one, unless the context dictates otherwise. The term “about” means the stated value plus or minus the margin of error of measurement or plus or minus 10% if no method of measurement is indicated. The use of the term “or” in the claims is used to mean “and/or” unless explicitly indicated to refer to alternatives only or if the alternatives are mutually exclusive. The terms “comprise”, “have”, “include” and “contain” (and their variants) are open-ended linking verbs and allow the addition of other elements when used in a claim.
Reference throughout this specification to “one example” or “an example embodiment,” “one embodiment,” “an embodiment” or combinations and/or variations of these terms means that a particular feature, structure or characteristic described in connection with the embodiment is included in at least one embodiment of the present disclosure. Thus, the appearances of the phrases “in one embodiment” or “in an embodiment” in various places throughout this specification are not necessarily all referring to the same embodiment. Furthermore, the particular features, structures, or characteristics may be combined in any suitable manner in one or more embodiments.
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Each of the lower brace members 10, 12 may advantageously include saddles 20, 22, 24, 26 in which reinforcement bars 73 may be constrained or retained. The saddles 20, 22, 24, 26 may be extruded as part of the process of manufacturing the various parts, or may be attached separately using conventional techniques. The saddles 20, 22, 24, 26 may advantageously be made to accommodate at least two reinforcement bars laying lengthwise inside of the saddles. This allows reinforcement bars to overlap at the ends as required by most building codes.
The second lower brace element 12 is constructed substantially similarly to the first lower brace element 10 with a few differences. In a departure from the construction of the first lower brace element 10, the second lower brace element includes a horizontal lower brace element 68. Depending on the locking scheme used, one of the brace elements may not require detents. For example, an affixed extension member 70 may be constructed to protrude lengthwise in line with the horizontal lower brace element 68 to provide added length. The extension member 70 advantageously includes locking snap tabs 72 adapted to mate with the detents 54. In operation, the extension member 70 allows the combination of the first and second brace members to be adjusted in width as needed. Extension member 70 may include screw holes 55 which are used as needed when installing. Other members may also include screw holes although not all are shown here in order to simplify the drawings to promote understanding of the general concepts of the disclosed example.
The first and second upper brace elements 7, 9, each comprise a horizontal upper element 14, 16 respectively having apertures 15 for concrete flow through purposes. The horizontal elements 14, 16 are each attached to an upper vertical element 56, 58 respectively. The upper vertical elements 56, 58 may advantageously be attached perpendicularly to the upper horizontal elements. Inserted into each upper horizontal element 14, 16 is a form retaining element 30. The form retaining element 30 includes a downward protruding elongated attachment member 32 having a lip 34. A web 62 is attached between each upper horizontal element 14, 16 and each upper vertical element 56, 58. The web 62 is bounded and further supported by an arcuate support 60 attached between the upper horizontal and vertical elements for added strength. As indicated by downward arrows 66 (showing direction only and not part of the device), the upper brace elements have an outside perimeter sufficiently small to be inserted into a channel inside of the vertical lower brace element 11. A similar channel is in the vertical lower brace element 11 for lower brace 12. When lowered, the attachment members 32 will engage forms 40, where the forms 40 are typically boards or steel plates delineating the borders of a foundation or footings.
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Having described the configuration of the example embodiments, it will now be useful to the understanding of the invention to describe how the various components are manufactured. The devices can be constructed from any material having properties that make the material satisfactory for use with concrete and provide sufficient strength to support the form side walls against deformation under hydrostatic pressure. For example, the brace components may preferably be fabricated using techniques such as casting or injection molding, and fabricated from a variety of materials, such as metal, plastic or the like.
The invention has been described herein in considerable detail in order to comply with the Patent Statutes and to provide those skilled in the art with the information needed to apply the novel principles of the present invention, and to construct and use such exemplary and specialized components as are required. However, it is to be understood that the invention may be carried out by different equipment, and devices, and that various modifications, both as to the equipment details and operating procedures, may be accomplished without departing from the true spirit and scope of the present invention.
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