BRACE BRACKET FOR FORM WALL

TECHNICAL FIELD

This disclosure relates generally to a brace or bracket for use in forming cementitious walls or panels utilized in tilt-up construction, and more particularly to a brace or bracket for supporting a form wall positioned on a casting platform.

BACKGROUND

Many building structures, including commercial, industrial, apartment, and office building structures are built using tilt-up concrete wall construction techniques. In general, in tilt-up wall construction a concrete slab building floor is poured at the construction site and allowed to cure. The upper surface of the concrete slab floor is then used as a casting platform whereon sidewall panels of the building are cast horizontally. In other examples, the casting platform may include a non-concrete surface such as, by way of example, wood, metal, or foam board. Form walls that define the perimeter and other boundaries of a sidewall panel are positioned on the casting platform and held in place by various means including form braces or brackets positioned about the form walls. A removable coating or grease is spread on the casting platform inside the form walls to disallow concrete poured into the sidewall panel form to adhere to the top surface of the casting platform. Concrete is poured into the horizontal sidewall panel form over the concrete casting platform flooring. After the concrete cures, the brackets are detached from the casting platform and the form walls. The form walls are then removed from the cured sidewall panel. The sidewall panel is tilted upward to be generally perpendicular to the concrete slab floor and affixed to other sidewall panels, which were also manufactured and tilted upward in an analogous manner, to form the vertical side walls of the building structure.

It is common that concrete form walls are constructed using standard wood stock 2×4's, 2×6's, or 2×8's positioned on top of the casting platform to define a perimeter area into which concrete is poured into and on top of the casting platform. In the past, to set up the form walls on top of the casting platform, it was common to use metal L-shaped brackets or right-angle triangle bracket pieces of 2×4's, 2×6's, or 2×8's in a manner such that a lower surface of the bracket was removably attached and abutted to the casting platform and a vertical surface of the bracket was removably attached and abutted against an outer surface of the form wall. The metal or wooden brackets both supported the form walls in a generally horizontal position and kept the form walls stationary against the force of the wet cement pour until cured.

As tilt-up concrete wall construction was used to build taller and taller building structures, the thickness of the concrete tilt-up wall panels increased. To physically support the increased weight of taller tilt-up concrete panels, the thickness of the concrete panels began to exceed the width of standard 2×12 boards. Additionally, existing form bracket supports made of plastic, wood and other materials became too small, weak, and ineffective for maintaining stationary support of form walls having a height greater than about 14 inches when the concrete form is filled with a wet concrete pour, or other cementitious materials.

SUMMARY

In some aspects, the subject matter described herein relates to a brace bracket for securing a form wall to a casting platform including: a first planar portion including: a lower surface configured to engage a casting platform; and a front edge and a back edge opposite the front edge, wherein the front edge is linear; a second planar portion coupled to the first planar portion for a first distance D1 on the front edge of the first planar portion, the second planar portion being disposed perpendicular to the first planar portion and having a height distance Z1, the second planar portion including a front surface configured to engage the form wall, and a first inner edge; a third planar portion coupled to the first planar portion for a second distance D2 on the front edge of the first planar portion, the third planar portion being disposed perpendicular to the first planar portion and having the height distance Z1, the third planar portion having a front surface configured to engage the form wall, and the third planar portion having a second inner edge spaced a third distance D3 from the first inner edge of the second planar portion; and a first and a second facing sidewall, each facing sidewall having a facing surface disposed perpendicular to the first planar portion, the facing surfaces of the first and second facing sidewalls face each other and are spaced apart by the third distance D3, a front edge of the first facing sidewall disposed on the first inner edge of the second planar portion, and a front edge of the second facing sidewall disposed on the second inner edge of the third planar portion, wherein the first and second facing surfaces and a strip area of the first planar portion located between the facing surfaces define a channel extending from the first inner edge and the second inner edge towards the back edge of the first planar portion, and wherein the channel is configured to accept a plank having a thickness Xp that is less than the third distance D3.

In some aspects, the subject matter described herein relates to a brace bracket, wherein the first planar portion includes at least one aperture for receiving a fastener configured for holding the brace bracket to the casting platform.

In some aspects, the subject matter described herein relates to a brace bracket, wherein one of the first facing sidewall or the second facing sidewall include at least one through hole for receiving a fastener for holding the brace bracket to the plank.

In some aspects, the subject matter described herein relates to a brace bracket, wherein the first planar portion further includes a curved or angled edge along a side edge or a back edge of the first planar portion.

In some aspects, the subject matter described herein relates to a brace bracket, wherein a combination of the brace bracket and the plank are configured to support a form wall at an angle of between about 5 and 175 degrees from horizontal.

In some aspects, the subject matter described herein relates to a brace bracket, wherein the first and second facing walls are each vertically higher proximate to the second planar portion and the third planar portions than distally from the second planar portion and the third planar portion.

In some aspects, the subject matter described herein relates to a brace bracket, wherein at least one of the first facing sidewall and the second facing sidewall include an edge segment.

In some aspects, the subject matter described herein relates to a brace bracket for securing a form wall to a casting platform, the brace bracket including: a first planar portion including: a lower surface configured to engage a casting platform; a front edge and a back edge opposite the front edge, wherein the front edge is linear; and an extended portion; a second planar portion coupled to the first planar portion for a first distance D1 on the front edge of the first planar portion, the second planar portion being disposed perpendicular to the first planar portion and having a vertical height Z1; and a first facing sidewall disposed perpendicular to the first planar portion and the second planar portion, wherein the extended portion extends a distance D3 from the first facing sidewall and is configured to accept a plank, wherein the first facing sidewall includes at least one through hole for receiving a fastener configured for holding the plank stationary.

In some aspects, the subject matter described herein relates to a brace bracket, wherein the first facing sidewall includes at least one through hole for receiving a fastener for holding the brace bracket to the plank.

In some aspects, the subject matter described herein relates to a brace bracket, wherein the first planar portion further includes a raised outer edge, wherein the raised outer edge is angled or curved upward from the lower surface.

In some aspects, the subject matter described herein relates to a brace bracket, wherein a combination of the brace bracket and the plank are configured to support a concrete form wall at an angle of between about 5 and 175 degrees from horizontal.

In some aspects, the subject matter described herein relates to a brace bracket, wherein the first facing wall is vertically higher proximate to the second planar portion than distally from the second planar portion.

In some aspects, the subject matter described herein relates to a brace bracket, wherein the first facing sidewall include an edge segment opposite the second planar portion.

In some aspects, the subject matter described herein relates to a method for securing a form wall to a casting platform including the steps of: providing a brace bracket including: a first planar portion including: a lower surface configured to engage a casting platform; and a front edge and a back edge opposite the front edge, wherein the front edge is linear; a second planar portion coupled to the first planar portion for a first distance D1 on the front edge of the first planar portion, the second planar portion being disposed perpendicular to the first planar portion and having a height distance Z1, the second planar portion including a front surface configured to engage the form wall, and a first inner edge; a third planar portion coupled to the first planar portion for a second distance D2 on the front edge of the first planar portion, the third planar portion being disposed perpendicular to the first planar portion and having the height distance Z1, the third planar portion having a front surface configured to engage the form wall, and the third planar portion having a second inner edge spaced a third distance D3 from the first inner edge of the second planar portion; and a first and a second facing sidewall, each facing sidewall having a facing surface disposed perpendicular to the first planar portion, the facing surfaces of the first and second facing sidewalls face each other and are spaced apart by the third distance D3, a front edge of the first facing sidewall disposed on the first inner edge of the second planar portion, and a front edge of the second facing sidewall disposed on the second inner edge of the third planar portion, connecting the brace bracket to the casting platform; securing a plank to one of the first facing sidewall and the second facing sidewall; and connecting the plank to the form wall, wherein the brace bracket is connected between the form wall and the casting platform via the plank.

In some aspects, the subject matter described herein relates to a method, further includes the step of applying an adhesive between the lower surface and the casting platform.

In some aspects, the subject matter described herein relates to a method, further includes the step of holding the brace bracket to the casting platform via insertion of a mechanical fastener through an aperture of the first planar portion.

In some aspects, the subject matter described herein relates to a method, further includes the step of holding the plank to one of the first facing sidewall and the second facing sidewall via insertion of a fastener through a through hole within one of the first facing sidewall and the second facing sidewall.

In some aspects, the subject matter described herein relates to a method, wherein the form wall is secured to the plank at an angle of between 5 and 175 degrees from a top surface of the casting platform.

In some aspects, the subject matter described herein relates to a method, wherein the form wall is secured to the plank at an angle of about 45 degrees and abuts an edge segment of the brace bracket.

BRIEF DESCRIPTION OF THE DRAWINGS

A more complete understanding of the various objects and advantages of the invention will become apparent and more readily appreciated from the following description of various embodiments and methods of the invention, taken in conjunction with the accompanying Drawings in which:

FIG. 1 is a perspective view of an embodiment of a brace bracket being used in tilt-up construction.

FIG. 2 is a perspective view of an embodiment of the brace bracket.

FIG. 3 is a perspective view of an embodiment of the brace bracket.

FIG. 4 is a top perspective view of an embodiment of the brace bracket.

FIG. 5 is a side perspective view of an embodiment of the brace bracket.

FIG. 6 illustrates an example brace bracket being used on a casting platform adjacent to a form wall in accordance with an embodiment of the invention.

FIG. 7 illustrates an example brace bracket with plank variations being used on a casting platform adjacent to a form wall in accordance with embodiments and methods of the invention.

FIG. 8 illustrates an example brace bracket with plank variations being used on a casting platform adjacent to a form wall in accordance with embodiments and methods of the invention.

FIG. 9 illustrates an example brace bracket with plank variations being used on a casting platform adjacent to a form wall in accordance with embodiments and methods of the invention.

FIG. 10 is a perspective view of an embodiment of the brace bracket.

DETAILED DESCRIPTION

Referring now to the drawings, wherein like reference numbers are used herein to designate like and similar elements throughout, the various views and embodiments of the brace bracket for a form wall are illustrated and described, and other embodiments are described. The figures are not necessarily drawn to scale, and in some instances the drawings have been exaggerated and/or simplified in places for illustrative purposes only. One of ordinary skill in the art will appreciate the many possible applications and variations of the invention based on the following embodiment examples.

It is advantageous to read and understand the set forth definitions of certain words and phrases that may be used throughout this patent document. The terms “include” and “comprise,” as well as their derivatives, mean inclusion without limitation. The term “or” is inclusive, meaning and/or. The phrase “associated with,” as well as derivatives thereof means to include be included within, interconnect with, contain, be contained within, connect to or with, couple to or with, be communicable with, cooperate with, interleave, juxtapose, be proximate to, be bound to or with, have, have a property of, have a relationship to or with, or the like.

As used herein, the terms “configured to” may be interchangeably used with the terms “suitable for,” “having the capacity to,” “designed to,” “adapted to,” “made to,” or “capable of,” depending on circumstances.

As used herein, the terms “have,” “may have,” “include,” “may include,” “can have,” or “can include” a feature (e.g., a number, function, operation, or component such as a part) and their derivations indicate the existence of the feature and do not exclude the existence of other features.

As use herein, the terms “A or B,” “at least one of A and/or B,” or “one or more of A and/or B” may include all possible combinations of A and B. For example, “A or B,” “at least one of A and B,” “at least one of A or B,” may indicate all of (1) including at least one A, (2) including at least B, or (3) including at least one A and at least one B.

Additionally, to help with clarity, the phrase “at least one of,” when used with a list of items, means that different combinations of one or more of the listed items may be used, and only one item in the list may be needed. For example, “at least one of: A, B, and C” includes any of the following combinations: A, B, C, A and B, A and C, B and C, and A and B and C.

As used herein, the terms “first,” or “1st,” and “second,” or “2nd,” may modify various components regardless of importance or order, and do not limit the components. These terms are only used to distinguish one component from another. For example, a 1st user device and a 2nd user device may indicate different devices from each other regardless of the order or importance of the devices. For example, a first component may be denoted a second component, and vice versa without departing from the scope of the present disclosure.

The terms as used herein are provided merely to describe embodiments thereof, but not to limit the scope of other embodiments of the present disclosure. It is to be understood that singular forms “a,” “an,” and, “the” include plural references unless the context clearly dictates otherwise. All terms, including technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which the embodiments of the present disclosure belong. It will be further understood that terms, such as those defined in commonly used dictionaries, should be interpreted as having a meaning that is consistent with their meaning in the context of the relevant art and will not be interpreted in an idealized or overly formal sense unless expressly so defined herein. In some cases, the terms defined herein may be interpreted to exclude embodiments of the present disclosure.

As used herein, the term “user” may denote a human.

Definitions for other certain words and phrases may also be provided throughout this patent document. Those of ordinary skill in the art should understand that in many if not most instances, such definitions apply to prior as well as future uses of such defined words and phrases in this patent document.

Embodiments relate to a bracket, brace, or concrete form bracket (herein collectively referred to as a “brace bracket”) used to hold and support cementitious form material used in tilt-up, precast, cast in place, and other related types of concrete casting used in concrete construction or concrete object creation. Example bracket embodiments are configured to hold regular and heightened form walls generally perpendicular to a casting surface, plane, or bed (herein collectively “casting surface”). A casting surface is generally defined as an upper or top surface of a casting platform. A casting platform is not limited to a raised platform having a casting surface. A casting platform can be substantially any structure created or used for the purpose of providing an area where on a casting surface is located or created within form walls. Other example bracket embodiments may be configured to be combined with a plank having straight or angled ends and/or of regular or heightened form wall heights to hold concrete form walls at angles ranging from about 5 degrees to about 175 degrees from horizontal with respect to a casting platform surface. Embodiments can effectively, yet simply, support concrete forms for forming walls used in the process of making tilt-up concrete walls, segments, sections, non-tilt up concrete slabs, constructs, and the like used when constructing tilt-up building structures or used in other construction efforts such as, but not limited to making concrete floors or floor coverings, slab sections, concrete formed parts, concrete composite materials, concrete layered materials, concrete furniture parts, concrete dock or water barrier portions, concrete transportation structures and related construction, concrete polymer construction, concrete tiles, 3D printed concrete-composite items and construction, and derivations thereof. When brace brackets 108 are used in tilt-up construction the tilt-up structure formation thicknesses may range from about 5 inches to about 36 inches and may or may not have mitered or feathered edges at a desired angle of between about 5 degrees to about 175 degrees.

FIG. 1 illustrates an example of a brace bracket 108 (a or b) being used in tilt-up construction according to example embodiments of the invention. Here a casting platform 100 has been poured and cured at a construction site and comprises a top surface 101. The casting platform 100 may be part of a concrete slab or floor of the building under construction. The casting platform 100 may be a poured slab that is not part of the building's floor or foundation, but instead created separately from the building construction for use as the casting platform 100. The casting platform 100 may be a temporary construct, which may be demolished or removed from the construction the site. As tilt-up construction advances and the structures and buildings being built become taller and have more floors, it is perceivable that the casting platform 100 could be a building floor other than a building's ground or bottom floor of the structure under construction. The casting platform 100 may also comprise cured concrete that has been reinforced with rebar, tension cables, inground concrete beams or pillars or other known concrete slab reinforcement techniques. In an embodiment, the top surface 101 is generally level and generally smooth, which enables a sidewall 102 to be poured in a horizonal orientation on top of the top surface 101.

Prior to pouring concrete to make the sidewall 102, grease or another suitable release agent (not specifically shown) may be applied to the top surface 101 of the casting platform 100 inside the concrete form 104. The grease or other release agent is used to prevent the sidewall 102 from sticking or attaching to the top surface 101 of the casting platform 100 as the sidewall 102 cures. The concrete form 104 is generally made of a plurality of form walls 106 (a or b). The plurality of form walls 106 may be positioned on the casting platform 100 to define, among other things, the perimeter and perimeter shape of the sidewall 102. The plurality of form walls 106 may comprise planks that are made of wood, dimensional lumber, metal, composite materials, plastics, polymers, or the like. The planks have a thickness, width, and length. For example, the plurality of form walls 106 may made with conventional standard wooden board lumber stock having nominal dimensions T×W, wherein T is the nominal thickness and W is the nominal width of the board or plank. The length L of the raw material planks may be any standard or useful miscellaneous length. A wooden board or plank labeled 2×6 (for T×W) as its nominal dimension size, is not actually, two inches by six inches (2″×6″), but instead abides by an industry standard wherein the actual board or plank's dimensional measurements are about 1½ inches by×5½ inches (1½″×5½″). Common nominal dimensions of lumber boards used for the plurality of form walls 106 are boards having nominal sizes of 2×4, 2×6, 2×10, and 2×12 wherein the width (W) dimension is generally used as the perpendicular height of the plurality of form walls 106. Additionally, planks used in accordance with various embodiments can be constructed of a wide variety of materials, including without limitation, wood, particle board, plastics, polymers, metal, composite materials, recycled materials, coated materials, pressure cured materials, and materials comprising a coating that releases easily from cured concrete.

FIG. 1 depicts brace brackets 108 (a or b) being used in accordance with various embodiments. Each of the brace brackets 108 are positioned on a top surface or casting surface of the casting platform 100 such that a lower or bottom surface of the brace bracket 108 abuts against the top surface or casting surface of the casting platform 100. A vertical front surface of brace brackets 108a abut or are attached to an outer vertical surface of the form wall 106a. FIG. 1 further depicts another embodiment wherein the example brace bracket 108b has a vertical surface positioned adjacent to or spaced from an outer non-horizontal surface of the form wall 106b. A plank having an angled front face edge is held in a channel of the brace bracket 108b by at least one mechanical fastener 602 such that the angled front face edge of the plank abuts or is attached to an outer surface of the form wall 106b and holds the form wall 106b at an angle of between 5 degrees and 175 degrees from horizontal such that a mitered sidewall edge 114 of the sidewall 102 can be formed.

Reinforcement rebar or tension cables may be positioned inside and across a width or length of the concrete form 104. Concrete is poured into the concrete form 104 and allowed to cure on top of the casting platform 100. After curing, the sidewall 102 can be tilted up from the casting platform 100 into a generally perpendicular or vertical orientation with respect to the casting platform 100. After being tilted-up, the sidewalls 102 can be attached or affixed together to form a vertical side wall structure of the structure or building being constructed.

Additionally, embodiments of brace bracket 108 can be used in various types of concrete casting. For example, the brace bracket 108 be used in precast concrete casting where concrete casting is typically done indoors in a climate controlled or at least in an area protected from outdoor elements. In precast concrete casting, or in other concrete form casting on a casting platform 100, the casting platform 100 or the casting platform's top or casting surface may comprise one or more materials selected from concrete, concrete derivatives, plywood, epoxy, ceramic, metal, fiberglass, silicon, rubber, plastic, specialized polymers or non-stick coatings, foam, gravel, sand, crushed or shredded materials, hollow tubing, or derivatives or combinations thereof.

Additionally, other embodiments of the brace bracket 108 may be used in cast in place practices wherein, for example, the casting platform 100 may include one or more layers (not specifically shown) comprising at least one material selected from gravel, sand, crushed concrete, plastic sheeting, mesh or screen sheeting, one-way vapor barrier sheeting, and insulation material, wherein the top surface of the top layer can be the casting surface on which a concrete form 104 is held in place and supported about at least a portion of the concrete form's periphery by the brace brackets 108. If in some methods of using a brace bracket 108, the poured then cured sidewall 102 within the concrete form 104 is not separated from the casting surface of the casting platform 100 such that the sidewall 102 remains on the casting platform as a concrete floor portion or a protective slab over the casting platform. During construction of such an insulated floor, brace brackets 108 can be adhered with glue, adhesive tape or other known adhesives to the top surface or casting surface of the casting platform 100 in accordance with embodiments wherein mechanical fasteners, such as nails or screws are not used to hold a brace bracket 108 to the top surface of the casting platform 100 so that damage to the top surface or casting platform 100 is avoided. As already stated, the brace brackets 108 are positioned to support the concrete form 104, which provides boundaries of the insulated concrete slab (i.e., sidewall 102). It is pointed out that that in this example method, the top or casting surface of the casting platform 100 does not necessarily have to be generally flat, smooth, or level.

Referring now to FIGS. 1, 2, 3, 4, and 5, which are various perspective views of embodiments of the brace bracket 108. In the example embodiments, the brace bracket 108 is provided for use in securing one of a plurality of form walls 106 in an upstanding position (vertical or non-vertical position) in relation to a top surface 101 of a casting platform 100. The brace bracket 108, includes a first planar portion 200 having a lower surface 202. When the brace bracket 108 is being used, the lower surface 202, is generally intended to face the top surface 101 of the casting platform 100. The first planar portion 200 is configured to engage the top surface 101 during various methods of use. In various embodiments, the lower surface 202 (not specifically shown) may be a generally smooth and flat. In other embodiments, the lower surface 202 may take the form of different types of surfaces. For example, the lower surface 202 many have a non-smooth surface, a surface with indentions in the form of grooves, geometric shapes or irregular shapes, or a textured surface. The various lower surface 202 surface-types may be included in embodiments to increase or decrease an amount of contact or grip the lower surface 202 has with the top surface 101, or with an adhesive (not specifically shown) placed between the lower surface 202 and the top surface 101. The adhesive may be used to enhance a detachable contact, grip, or engagement the brace bracket 108 and top surface 101.

The first planar portion 200 of the brace bracket 108 includes a front edge 204. In various embodiments the front edge 204 extends a width X1 of the first planar portion 200 at the front edge 204. In various embodiments, the front edge 204 can have a width X1 ranging from between about 2 inches and about 20 inches. If an embodiment has a generally rectangular planar portion as shown, the width X1 may also be the general width of the first planar portion 200. Alternatively, if the first planar portion shape is other than a generally rectangular shape, the width X1 can be the width of the first planar portion 200 at the front edge 204 of the first planar portion 200. The first planar portion 200 of the brace bracket 108 includes a back edge 206 at an opposing side from the front edge 204 of the first planar portion 200. The back edge 206 may be generally linear or parallel with the front edge 204, but in various embodiments may have a non-linear edge that defines the back edge 206 of the first planar portion 200.

The brace bracket 108 may further comprise a second planar portion 208 and a third planar portion 210. The second planar portion 208 is coupled to the first planar portion 200 along a first length or distance D1 of the front edge 204 of the first planar portion 200. The second planar portion 208 is disposed generally perpendicular or orthogonal to the first planar portion 200 and extends a vertical height distance Z1 from the first planar portion 200. The second planar portion 208 has a front surface 212 that is configured to engage one of a plurality of form walls 106 of a concrete form 104. In various embodiments, the front surface 212 of the second planar portion 208 is generally planar and may have a smooth flat surface. In other embodiments, the front surface 212 may be generally planar with a non-smooth surface, with a surface having indentations in the form of grooves, geometric shapes, or irregular shapes, be generally planar with a surface having protrusions in the form of geometric shapes, non-geometric shapes, or be generally planar with a textured surface. The various generally planar front surfaces of the front surface 212 of the second planar surface may aid to increase or decrease an amount of contact or grip the front surface 212 has when engaged with the form wall 106a of the concrete form 104, or with an adhesive that may be applied between the front surface 212 of the second planar portion and the form wall 106a in order to enhance a detachable contact, grip, or engagement of the brace bracket 108 with the form wall 106a.

The second planar portion 208 of the brace bracket 108 further includes a first inner edge 214 extending generally vertically from the first planar portion 200 from a location proximate to the front edge 204 of the first planar portion, and a distance of at least D1 from a first outer edge outer edge 216 of the first planar portion 200. The first inner edge 214 of the second planar portion 208 may extend generally vertically for the height distance Z1 to a top edge 218 of the second planar portion 208.

The third planar portion 210 is coupled to the first planar portion 200 along a second portion or distance D2 of the front edge 204 of the first planar portion 200. The third planar portion 210 is disposed generally perpendicular or orthogonal to the first planar portion 200 and extends the height distance Z1 above the first planar portion 200. The third planar portion 210 has a front surface 220 that is configured to engage the plurality of form walls 106 of the concrete form 104. In various embodiments, the front surface 220 of the third planar portion 210 is generally planar and may have a smooth flat surface. In other embodiments, the front surface 220 of the third portion 210 may be generally planar with a non-smooth surface, be generally planar with a surface having indentations in the form of grooves, geometric shapes, or irregular shapes, be generally planar with a surface having protrusions in the form of geometric shapes or non-geometric shapes or be generally planar with a textured surface. The various generally planar front surface configurations of the front surface 220 of the third planar portion 210 may aid to increase or decrease an amount of contact or grip the front surface 220 has when engaged with one of the plurality of form walls 106 of the concrete form 104, or with an adhesive that may be applied between the front surface 220 of the third planar portion and form wall 106a in order to enhance a detachable contact, grip, or engagement of the brace bracket 108 with the form wall 106a.

The third planar portion 210 of the brace bracket 108 further includes a second inner edge 222 extending generally vertically from the first planar portion 200, from a location proximate to the front edge 204 of the first planar portion 200 and a distance D3 from the first inner edge 214 of the second planar portion 208, wherein the distance D3 is measured from the first inner edge 214 along the front edge 204 of the first planar portion 200 in a direction away from the first outer edge 216 of the first planar portion 200. The second inner edge 222 of the third planar portion 210 extends generally vertically for the height distance Z1 to a top edge 224 of the third planar portion 210.

In various embodiments, the sum of the distances D1+D2+D3 may be less than or equal to the width X1 ([D1+D2+D3]≤X1) of the first planar portion 200 at, at least, the front edge 204 of the first planar portion 200. In various embodiments, the distance D3 has a general range of between about 1 inch and 2.5 inches. In other various embodiments, the distance D3 may range from about 1 inch to 6.5 inches in order to accommodate different thicknesses (T) of a board or plank 700.

Still referring to FIGS. 1, 2, 3, 4, and 5, embodiments of the brace bracket 108 further include a first sidewall 226 and a second facing sidewall 228. Each of the first facing sidewall 226 and the second facing sidewall 228 are disposed on and generally perpendicular to the first planar portion 200. Additionally, each of the first facing sidewall 226 and the second facing sidewall 228 have a front edge 234, 236 disposed such that the front edges 234, 236 of the first and second sidewalls 226, 228 coincide with the first and second inner edges 214, 222 of the second and third planar portions 208, 210, respectively. The first and second facing sidewalls 226, 228 are generally parallel to each other such that a distance between a first facing surface 230 of the first sidewall 226 and a second facing surface 232 of the second facing sidewall 228 is generally equal to the distance D3 over at least a portion of both first and second facing surfaces 230, 232. In other words, the first and second facing sidewalls 226, 228 are generally parallel and spaced apart by the distance D3. A combination of at least a portion of each of the first and second facing sidewalls 226, 228 and at least a portion of a top strip area 238 of the first planar portion 200 that is between the first and second facing surfaces 230, 232 define an open channel 240. The open channel 240 of an embodiment is open to open air above the first and second facing sidewalls 226, 228, and above the top strip area 238. The open channel 240 extends from the front surfaces 212, 220 of the second and third planar portions 208, 210, respectively, toward the back edge 206 of the first planar portion 200. In various embodiments, the open channel 240 extends from the front surfaces 212, 220 of the second and third planar portions 208, 210 to the back edge 206 of the first planar portion 200. In other embodiments, the open channel 240 does not extend to the back edge 206 (not specifically shown). In yet other embodiments, one or both of the first and second facing sidewalls 226, 228 are not a continuous wall (not specifically shown) from the front edge 204 toward the back edge 206 of the first planar portion 200. The front, back, and upper open area of the open channel 240 are open and clear of channel blocking elements over the length of the open channel 240 and beyond the front, back, and upper open areas of the open channel 240 such that the open channel 240 is configured to accept insertion of a plank (700a, b, or c) or derivations thereof as discussed below in FIG. 7, 8, or 9.

In various embodiments, the first and second facing sidewalls 226, 228 have a height generally equal to the height distance Z1 for at least a first portion of each of the first and second facing sidewalls 226, 228 beginning at the front edges 234, 236 of the first and second facing sidewalls 226, 228. In various embodiments, the first and second facing sidewalls 226, 228 each have a distal portion having a height Z3. The distal portion being a portion of each of the first and second facing sidewalls 226, 228 that include at least a first and second distal end 242, 246, respectively, of each of the facing sidewalls 226, 228. The height Z3 is less than or equal to the height distance Z1 (Z3≤Z1). In yet other embodiments, a middle portion positioned between the first portion and the distal portion of each of the of the first and second facing sidewalls 226, 228 has a height Z2, wherein the height Z2 may be between the height distances Z1 and Z3 (Z3<Z2<Z1). In other embodiments, the height distance Z3 may range from or between about 0 inches to about the height distance Z1 along the length of one or both of the first and second facing sidewalls 226, 228. Furthermore, the height distance Z1 may range from about 2 inches to about 24 inches.

Various embodiments of the brace bracket 108 may also include a raised outer edge 252 that extends along, at least, a portion of, the outer or flange edge(s) of the first planar portion 200. The raised outer edge 252 may be angled or curved upward from the lower surface 202 of the first planar portion 200 such that the raised outer edge 252 provides a perimeter portion of the lower surface 202 that does not engage with the top surface of the casting platform 100. After the brace bracket 108 is removably attached, via adhesive and/or fasteners to the casting platform 100, the raised outer edge 252 in combination with the top surface of the casting platform 100 establish a gap or slot therebetween. The gap or slot can be utilized and configured to enable a tool, such as a wedge, crowbar, or scraper tool, to be forcibly pressed, slid, or hammered into the gap or slot, in order to detach the brace bracket 108 from the top surface of the casting platform 100. Embodiments of the brace bracket 108 are designed and made of plastic, polymers, composite materials, or reinforced materials so the brace bracket 108 may flex and resist breakage during removal or detachment from the concrete form 104 and the casting platform 100. As such, some embodiments are intended to be reusable.

In various embodiments, the raised outer edge 252 may be extend along, at least a portion of, the outer flange edges of the second and third planar portions 208, 210 to help enable removal of the brace bracket 108 from the plurality of form walls 106. Additionally, embodiments of the brace bracket 108 may be rotated 90 degrees about the front edge 204 axis and be used in an alternative manner such that the second and third planar portion's respective front surfaces 212, 220 can be engaged with the top surface of the casting platform 100 and the lower surface 202 of the first planar portion 200 can engaged with one of the plurality of form walls 106 in a manner substantially similar to an unrotated brace bracket 108 and to perform a substantially similar function.

In yet other embodiments, the distance Y1, measured from the front edge 204 to the back edge 206 of the first planar surface is greater than the height distance Z1, measured from the front edge 204 to the top edges 218, 224 of the second or third planar portions 208, 210 (Y1>Z1). It will be understood by those of ordinary skill in the art that, with the exception of the front edge 204 of the first planar portion 200 and the inner edges of the second and third planar portions 208, 210 being linear or generally straight edges, the remaining outer edges of the first, second and third planar portions do not have to be straight or linear as shown in FIGS. 1-9, but may also include or be non-linear, curved, multi-faceted, or curvilinear edges segments about their respective planar portions. An example range of the distance Y1 may be between about 5.5 to about 16 inches, but larger and smaller.

In various embodiments, a thickness of the first and/or second facing sidewalls 226, 228 may vary at determined locations, provided that the first and second facing surfaces 230, 232 of the respective first and second facing sidewalls 226, 228 are each planar, generally parallel to each other, and generally perpendicular to the first planar portion 200. A function or purpose of varying the thickness of the first and/or second facing sidewalls 226, 228 may be to add structural strength or support to the facing sidewalls, or for decorative, cosmetic, or marketing purposes. Additionally, the top of the first planar portion 200, the backside surfaces of the second and third planar portions 208, 210 may each have raised or varying thicknesses to accommodate structural strength requirements, manufacturing processes, or decorative, cosmetic, or marketing purposes associated with the brace bracket 108.

As shown in FIGS. 1-5, each one of the first, second, and third planar portions 200, 208, 210 may have at least one aperture 248 that is reinforced by an increased material thickness of the relevant planar portion surrounding the aperture 248. The apertures 248 are each configured to receive a mechanical faster 602 (See, FIGS. 1 and 6) that is used to attach or secure the brace bracket 108 to the casting platform 100 or one of the plurality of form walls 106. Each mechanical fastener 602 can be a removable mechanical fastener such as, but not limited to being, one or more nails, screws, nail-screws, metal rods, bolts, screws with anchors, and the like that are known. Additionally, as briefly mentioned above, an adhesive in the form of double sided adhesive tape, adhesive pads, liquid/gel/or paste adhesives, or removable glues may be used between the lower surface 202 of the first planar portion 200 and/or the front surface(s) 212, 220 of the second and/or third planar portion(s) to adhere or attach respective bracket surface(s) of the brace bracket 108 to the casting platform 100 and/or one of the plurality of form walls 106.

One or both of the first and second facing sidewalls 226, 228 may include at least one through hole 250 for receiving a mechanical fastener 602.

FIG. 6 illustrates an example embodiment and method of using the brace bracket 108 in a manner to make a concrete form 104 on a casting platform 100. The brace bracket 108 is positioned on a casting platform 100 adjacent to one of a plurality of form walls 106. Here one of the plurality of form walls 106 is supported by the brace bracket 108. The brace bracket 108 is positioned with the bottom or lower surface 202 of the first planar portion on or over the top surface of the casting platform 100 and with the brace bracket's second and third front surfaces 212, 220, of the second and third planar portions 208, 210, against one of the plurality of form walls 106 to be supported. The brace bracket's second and third front planar surfaces 212, 220 are then abutted against and attached to the outside surface of one of the plurality of form walls 106 by inserting mechanical fasteners 602 through the aperture(s) 248 in the second and/or third planar portion(s) 208, 210. The mechanical fastener(s) 602 are each then fastened to or into one of the plurality of form walls 106 to secure the brace bracket 108 to the one of the plurality of form walls 106. Generally, a next step is to engage and attach the bottom or lower surface 202 of the brace bracket's first planar portion 200 to the casting platform 100. Attachment of the brace bracket's first planar portion 200 to the casting platform 100 may be accomplished by inserting a mechanical fastener 602 through at least one of the apertures 248 that extend through the first planar portion 200. The mechanical fasteners 602 are then fastened to or into the casting platform in a manner known in the art to secure the brace bracket 108 in a stationary position on the casting platform 100. In some embodiments of the method, only one mechanical fastener is required for each of a horizonal and vertical first, second, or third planar portion to attach the brace bracket 108 securely in place and support one of the plurality of form walls 106. In other embodiments, an adhesive (not shown), is applied between the first planar portion's lower surface 202 and the casting platform 100 and/or between the front surfaces 212, 220 of the second and third planar portions 208, 210 and one of the plurality of form walls 106 to attach and secure the brace bracket 108 to the casting platform 100 and/or the front surfaces 212, 220, respectively.

FIG. 7 depicts another embodiment of an example brace bracket 108 and method of making or using an example brace bracket 108. As the demand for taller tilt-up structures and buildings increases, there is a need for thicker, stronger, and in some instances miter-edged 114 sidewalls 102 to be used in building structures. Taller building structure sidewalls must be able to support increased weight and loads. To manage the increased weight and loads, thicker weight bearing concrete sidewalls are framed, reinforced, and poured. Thicker concrete sidewalls can require the plurality of form walls 106 that are higher than, for example, the width of standard 2×16 wooden planks. FIG. 7 depicts an example brace bracket 108 on a casting platform 100 and positioned adjacent to a vertical form wall 106a having a height Z4, which may be equal to or greater than the height distance Z1 of the brace bracket 108 to accommodate a higher concrete form wall 106a. In other embodiments, Z4 may be less than or equal to Z1. The open channel 240 is configured to accept and/or incorporate a support element or plank 700a. The plank 700a has a height Z5 that is similar or slightly less than the height Z4 of the concrete form wall 106a and has a thickness Xp that is slightly less than the width or third distance D3 between the first and second facing walls 226, 228. The support plank 700a may be shaped or cut to have a squared-off front end surface 702, such that a front end surface 702 of the plank 700a is generally parallel with the front surfaces 212, 220 of the bracket's second and third planar portions 208, 210 and engaged or abutted against the side surface of the adjacent vertical form wall 106a. In some embodiments the front end surface of the support plank 700a is positioned to abut the form wall 106a to support and hold the form wall 106a in position. In some embodiments or methods, the front end surface 702a of the plank 700a may be removably attached to the form wall 106a by using a screw, nail, or other known attachment fastener.

The horizontal length Yp of the plank 700a inserted into the open channel 240 can extend from the form wall 106a toward the back edge 206 of the brace bracket 108. Generally, the plank 700a has a horizontal length Yp such that the back end of the plank 700a extends to or beyond the back edge 206 of the first planar portion 200. In other embodiments, the plank 700a may extend beyond a first one of the apertures or through holes 250 in the first and/or second facing sidewalls nearest to the front end of the brace bracket 108, so the plank 700a can be secured in place within the open channel 240. The plank 700a can be secured in place within the open channel 240 by inserting mechanical fasteners 602 through, at least, one of the through holes 250 and into or through the plank 700a in a known manner. A fastener-secured plank 700a in the open channel 240 provides support strength for holding the form wall 106a that has a height Z4, which is higher than the height distance Z1 of the brace bracket 108. Embodiments may include or incorporate a plank 700a having a Z5 height from about 5.5 inches to about 36 inches to accommodate similar form wall heights. It is understood that in embodiments, the form wall height Z4 will be the thickness of the sidewall 102. The height Z4 is greater or equal to the height Z5 (Z4≥Z5).

The plank 700 (700a, 700b, or 700c of FIGS. 7, 8 and 9) may be comprised of wood, metal, composite material, plastic, polymer, or other suitable material that may be provided with or as an accessory to go with the brace bracket 108. The plank 700a may be provided in various Yp lengths and Z5 heights. The plank 700b may be provided in various lengths sizes and front angles to accommodate various common mitered edges of concrete sidewalls. Additionally, in some circumstances the planks 700 (700a, 700b, or 700c) may be cut from wood or other materials at the construction site.

FIG. 8 depicts another embodiment of an example brace bracket 108 and method of making or using brace bracket 108. Here an example brace bracket 108 is positioned on a casting platform 100 adjacent to a non-vertical form wall 106b. The brace bracket 108 is configured to incorporate a support element or plank 700b in the open channel 240. The plank 700b has a vertical height Z5 similar to or slightly less than the vertical height Z4 of the tilted-at-an-angle form wall 106b. The plank 700b, like the planks 700, has a thickness 703 that is slightly less than the width or third distance D3 between the first and second facing walls 226, 228. The support plank 700b may be shaped or cut to have an angled-off front end surface 702, such that the angled-off front end surface 702 of the plank 700b is generally parallel with the side surface of the adjacent non-vertical (angled) form wall 106b. The support plank 700b may extend beyond the front faces of the bracket's second and third planar portions 208, 210 in order to engage and support the plank 700b. The plank 700b can be secured in place within the open channel 240 using mechanical fasteners 602 inserted through the through holes 250 and them into or through the plank 700b. A mechanical fastener secured plank in the open channel 240 supplies additional support strength for holding a form wall 106b at an angle 800 that is between about 5 degrees and 175 degrees from horizontal in order to hold a form wall 106b in a position for creating a mitered edge 114 of a same or similar angular range. Additionally, embodiments can hold a form wall 106b at substantially any desired angle from 0 degrees to 180 degrees from horizontal of the casting platform 100 in order to hold form wall 106b or other forming object in place for a custom concrete formation. In some embodiments, the front end surface 702 of the plank 700b is positioned to abut against the angled form wall 106b to support and hold it in place. Yet in other embodiments, the front end surface 702 of plank 700b is removably attached to the form wall 106b by using a mechanical fastener, such as a nail, screw, metal rod, bent sheet-metal bracket, adhesive material, or other known reasonable means to removably attach the plank 700b to the form wall 106b.

FIG. 9 depicts another embodiment of a brace bracket 108 and method of making or using brace bracket 108 in, for example, tilt-up construction to set up a form wall 106c or make a mitered angle on a sidewall 102. Creating a mitered edge 114 in a sidewall 102 continues to become more common in tilt-up construction. In an embodiment of the brace bracket 108, an edge segment 900 is included as part of each of the first and second facing sidewalls 226, 228 near their distal ends. The edge segments can be used to help set up the angled form wall 106c more easily. The bracket(s) 108 with the edge segments 900 are placed on the casting platform 100 and positioned adjacent to and with the desired angled form wall 106c leaning against the edge segments 900 of the second and third planar portions. In some embodiments, the edge segments 900 is mitered at an angle of about 45 degrees from horizontal. The bracket is positioned with the second and third front surfaces 212, 220 of the second and third planar portions 208, 210, respectively, facing directly away from the form wall 106c. The bracket's first and second facing sidewalls 226, 228, each with the edge segment 900 aides in holding the form wall 106c while an angled-off front end surface 702 of the plank 700c is positioned within the open channel 240 to abut and be attached to the angled form wall 106c in a known matter, while the plank 700c is anchored to the brace bracket 108 via the through holes 250 using mechanical fasteners 602. The support plank 700c may extend beyond the back edge 206 of the brace bracket 108 in order to engage and support the form wall 106c. The plank 700c may also extend beyond the front surfaces 212, 220 of the second and third planar portions 208, 210, respectively. Additional embodiments may have edge segments 900 or derivations thereof configured at angles between about 1 and 89 degrees from horizontal to aid in performing a same function in substantially the same way to provide the same or comparable results, or to provide another related or unrelated function. Furthermore, some embodiments may not include edge segments 900 or derivations thereof.

Referring to FIG. 10, a further embodiment of the brace bracket 108 is illustrated having a first planar portion 200, a second planar portion 208 connected to and perpendicular to the first planar portion 200, and a first facing sidewall 226 connected to and perpendicular to the both the first planar portion 200 and the second planar portion 208.

The first planar portion 200 may comprise a front edge 204, a back edge 206 opposite the front edge, and a lower surface 202 being generally smooth and flat. The first planar portion 200 comprises an extended portion 260 which extends a third distance D3 away from the first facing sidewall 226. The extended portion 260 is configured to accept a plank (not shown) that may abut the extended portion 260 and the first facing sidewall 226. Each one of the first planar portion 200 and the second planar portion 208 may include at least one aperture 248 that is reinforced by an increased material thickness of the relevant planar portion surrounding the aperture 248. The apertures 248 are each configured to receive a mechanical faster 602 (See, FIGS. 1 and 6) that is used to attach or secure the brace bracket 108 to the casting platform 100 or the plurality of form walls 106.

The embodiment of the brace bracket 108 illustrated in FIG. 10 may also include a raised outer edge 252 that extends along, at least, a portion of, the outer or flange edge(s) of the first planar portion 200. The raised outer edge 252 may be angled or curved upward from the lower surface 202 of the first planar portion 200 such that the raised outer edge 252 provides a perimeter portion of the lower surface 202 that does not engage with the top surface of the casting platform 100. The second planar portion 208 may extend upwardly and away from the front edge 204 of the first planar portion 200 to a top edge 218. The second planar portion 208 connected to and extending along the front edge 204 a first distance D1. In various embodiments, the first facing sidewall 226 has a height generally equal to the height distance Z1 for at least a first portion of the first facing sidewalls 226 beginning at a front edge 234 of the first facing sidewall 226. In various embodiments, the first facing sidewall 226 has a first distal end 242 having a height Z3. The height Z3 is less than or equal to the height distance Z1 (Z3≤Z1). In yet other embodiments, a middle portion 237 is at least partially positioned between the front edge 234 and the first distal end 242 has a height Z2, wherein the height Z2 may be between the height distances Z1 and Z3 (Z3<Z2<Z1). In other embodiments, the height Z3 may range from or between about 0 inches to about the height distance Z1 along the length of the first facing sidewall 226. Furthermore, the height distance Z1 may range from about 2 inches to about 24 inches.

The first facing sidewall 226 may include at least one through hole 250 for receiving a mechanical fastener 602 (not shown) for fasting a plank (not shown) to the brace bracket 108. The first facing sidewall 226 may further include an edge segment 900 extending between the first distal end 242 and the middle portion 237 of the first facing sidewall 226. In some embodiments, the edge segments 900 is mitered at an angle of about 45 degrees from horizontal. Additional embodiments may have an edge segment 900 configured at angles between about 1 and 89 degrees from horizontal.

It will be appreciated by those skilled in the art having the benefit of this disclosure that the brace bracket for a concrete form wall provides a bracket, brace, or form bracket used to hold and support form walls of concrete forms used in tilt-up construction. Bracket embodiments are configured to hold form walls perpendicular to or, with the inclusion of a plank having an angled front edge, at angles ranging from about 5 degrees to 175 degrees from horizontal with respect to a casting platform. The drawings and detailed description herein are to be regarded in an illustrative rather than in a restrictive manner and are not intended to be limiting to the forms and examples disclosed. On the contrary, included in with the various forms and examples disclosed are any further modifications, changes, rearrangements, substitutions, alternatives, design choices, and embodiments apparent to those of ordinary skill in the art, without departing from the essence and breadth hereof, as defined by the following claims. Thus, it is intended that the following claims be interpreted to embrace all such further modifications, changes, rearrangements, substitutions, alternatives, design choices, and embodiments.

BRACE BRACKET FOR FORM WALL

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