COLUMN FORMING SYSTEM

Abstract

A column forming system for creating chamfer corners and allowing efficient movement from one column location to the next. The column forming system comprises a plurality of formwork panels, a hinge corner bracket moveable between an open and a closed position, and a plurality of corner brackets. The connection of the components allows for the manipulation of the formwork panels relative to one another. A closed position of the hinge corner bracket results in the column forming system defining a column interior.

Description

TECHNICAL FIELD

The present disclosure relates generally to a column forming system, and, more particularly, to an improved column forming system for the creation of chamfered corners.

BACKGROUND

In the construction industry, column forming systems are known to provide the capability to pour-in-place concrete columns on-site. Column forming systems typically include three or more formwork panels, corner brackets, and an attachment system for attaching the formwork panels to the corner brackets to form the column shape. Current column forming systems include rigid corner brackets such that, when the concrete has cured, two or more of the corner brackets must be disconnected from the formwork panels to allow for the column forming system to be removed and taken to the next column location. Removing the corner brackets, and then having to reconnect them in the new column location, can be time consuming. In addition, column forming systems typically create ninety-degree corner angles which have sharp edges once the concrete cures. Thus, it is desirous to create chamfer corners to remove the sharp edges as a safety precaution, allow for easier removal of the formwork panels from the cured concrete columns, create aesthetic appeal, and make it easier to fill the interior of the column forming system, i.e. sharp corners tend to be tougher to completely fill with concrete than chamfer corners. Typically, to create chamfer corners, an additional device is inserted between the corner bracket and the interior of the column forming system or an additional attachment to the corner bracket is used. These deficiencies prompt the need for a column forming system having a corner bracket that creates chamfer corners and allows the column forming system to be easily moved from one column location to the next.

SUMMARY

In accordance with the present invention, a column forming system is provided which overcomes the deficiencies described above, and has other advantages.

In one embodiment, a column forming system is provided. The column forming system comprises a first formwork panel having a first edge and a second edge, a second formwork panel having a first edge and a second edge, a third formwork panel having a first edge and a second edge, a hinge corner bracket, a first corner bracket, and a second corner bracket. The hinge corner bracket has a first rail and a second rail and is moveable between an open position and a closed position. The first rail is attached to the second edge of the first formwork panel and the second rail is attached to the first edge of the second formwork panel. In the closed position, the hinge corner bracket forms a hinge chamfered panel extending between the first formwork panel and the second formwork panel.

The first corner bracket has a first rail, a second rail, and a first chamfered panel extending between the first rail and the second rail. The first rail is attached to the second edge of the second formwork panel and the second rail is attached to the first edge of the third formwork panel such that the first chamfered panel extends between the second formwork panel and the third formwork panel. The second corner bracket has a first rail, a second rail, and a second chamfered panel extending between the first rail and the second rail. The first rail is attached to the second edge of the third formwork panel. The open position of the hinge corner bracket is configured to allow manipulation of the first formwork panel, the second formwork panel, and the third formwork panel relative to one another. When the hinge corner bracket is in the closed position, the column forming system defines a column interior.

Another disclosed embodiment provides a method of forming a concrete column. The method comprises the steps of: attaching a first rail of a hinge corner bracket to a second edge of a first formwork panel, the hinge corner bracket moveable between an open position and a closed position; attaching a second rail of the hinge corner bracket to a first edge of a second formwork panel such that when the hinge corner bracket is in the closed position a hinge chamfered panel extends between the first formwork panel and the second formwork panel; and performing the following attachment steps: (i) attaching a first rail of a first corner bracket to a second edge of the second formwork panel; (ii) attaching a second rail of the first corner bracket to a first edge of a third formwork panel such that a first chamfered panel extends between the second formwork panel and the third formwork panel; (iii) attaching a first rail of a second corner bracket to a second edge of the third formwork panel; (iv) attaching a second rail of the second corner bracket to a first edge of a fourth formwork panel such that a second chamfered panel extends between the third formwork panel and the fourth formwork panel; (v) attaching a first rail of a third corner bracket to a second edge of the fourth formwork panel; (vi) attaching a second rail of the third corner bracket to a first edge of the first formwork panel such that a third chamfered panel extends between the fourth formwork panel and the first formwork panel; moving the hinge corner bracket into the closed position, wherein one of attachment steps (i)-(vi) occurs after the hinge corner bracket is moved to the closed position so as to create a column forming system which defines a column interior; introducing a cementitious material into the column interior; allowing the cementitious material to cure into a cementitious column; detaching one of either the first rail or the second rail of one of the first corner bracket, second corner bracket or third corner bracket; moving the hinge corner bracket into the open position allowing manipulation of the first formwork panel, the second formwork panel, the third formwork panel, and the fourth formwork panel relative to one another; and manipulating the first formwork panel, the second formwork panel, the third formwork panel, and the fourth formwork panel relative to one another such that the column forming system can be removed to expose the cementitious column and moved to a new location.

BRIEF DESCRIPTION OF THE DRAWINGS

The drawings included with this application illustrate certain aspects of the embodiments described herein. However, the drawings should not be viewed as exclusive embodiments.

FIG. 1 is a perspective view of a column forming system with a hinge corner bracket in the closed position creating a closed system of the column forming system in accordance with one embodiment of the present disclosure.

FIG. 2 is a perspective view of a column forming system with a hinge corner bracket in the open position allowing for manipulation of the formwork panels relative to one another in accordance with one embodiment of the present disclosure.

FIG. 3 is a top view of a column forming system with a hinge corner bracket in the closed position creating a closed system of the column forming system in accordance with one embodiment of the present disclosure.

FIG. 4 is a top view of a column forming system with a hinge corner bracket in the open position allowing for manipulation of the formwork panels relative to one another in accordance with one embodiment of the present disclosure.

FIG. 5A is a top view of a hinge corner bracket prior to assembly in accordance with one embodiment of the present disclosure.

FIG. 5B is a top view of the hinge corner bracket of FIG. 5A assembled in accordance with one embodiment of the present disclosure.

FIG. 6 is a top view of a corner bracket in accordance with one embodiment of the present disclosure.

FIG. 7A is an enlarged perspective view of a hinge corner bracket in the closed position receiving two formwork panels in accordance with one embodiment of the present disclosure.

FIG. 7B is an enlarged perspective view of a hinge corner bracket in the open position receiving two formwork panels in accordance with one embodiment of the present disclosure.

FIG. 8 is an enlarged perspective view of a hinge corner bracket prior to assembly in accordance with one embodiment of the present disclosure.

DETAILED DESCRIPTION

The present disclosure may be understood more readily by reference to these detailed descriptions. For simplicity and clarity of illustration, where appropriate, reference numerals may be repeated among the different figures to indicate corresponding or analogous elements. In addition, numerous specific details are set forth in order to provide a thorough understanding of the various embodiments described herein. However, it will be understood by those of ordinary skill in the art that the embodiments described herein can be practiced without these specific details. In other instances, methods, procedures, and components have not been described in detail so as not to obscure the related relevant feature being described. Also, the description is not to be considered as limiting the scope of the embodiments described herein. The drawings are not necessarily to scale and the proportions of certain parts have been exaggerated to better illustrate details and features of the present disclosure.

Referring now to FIGS. 1-8 generally, the column forming system of the present disclosure is illustrated and generally designated by the numeral 10. As shown by the drawings, the general form of column forming system 10 includes a first formwork panel 20a having a first edge 22a and second edge 24a, a second formwork panel 20b having a first edge 22b and a second edge 24b, a third formwork panel 20c having a first edge 22c and a second edge 24c, a fourth formwork panel 20d having a first edge 22d and a second edge 24d, a hinge corner bracket 30, a first corner bracket 40a, a second corner bracket 40b, and a third corner bracket 40c. Such configuration provides for a square column. However, one skilled in the art understands that the number of formwork panels and corner brackets can be adjusted based on the job application. For example, in some embodiments, column forming system 10 may include three formwork panels 20a, 20b, and 20c, hinge corner bracket 30, and two corner brackets 40a, 40b. Such configuration provides a triangular column. In some embodiments, the components of column forming system 10 are comprised of aluminum and/or steel.

Hinge corner bracket 30 includes a first rail 32 and a second rail 34 and is moveable between an open position and a closed position. In the open position, as shown by FIGS. 2, 4, and 7B, hinge corner bracket 30 allows manipulation of formwork panels 20a, 20b, 20c, and 20d relative to one another such that column forming system 10 can move from one column form location to the next. In the closed position, as shown by FIGS. 1, 3, and 7A, hinge corner bracket 30 forms a hinge chamfered panel 36 between two of formwork panels 20a, 20b, 20c, and 20d. The closed position defines a column interior 12 configured to receive a cementitious material for forming a column.

In some embodiments, as shown more specifically in FIGS. 5A, 5B, and 8, hinge chamfered panel 36 includes a first portion 37a and a second portion 37b. First portion 37a includes a portion of hinge chamfered panel 36, first rail 32, and a pivotal connection portion 37c. Second portion 37b includes a portion of hinge chamfered panel 36, second rail 34, and a pivotal connection portion 37d. When hinge corner bracket 30 is assembled, pivotal connection portions 37c, 37d interlock and align such that a rod 37e can be slid down through pivotal connection portions 37c, 37d to connection first portion 37a to second portion 37b. In some embodiments, first portion 37a is integrally formed with first rail 32. Second portion 37b is integrally formed with second rail 34. Integral formation of first portion 37a and second portion 37b allows manipulation of first portion 37a and second portion 37b relative to one another when hinge corner bracket 30 is moved between the open position and the closed position.

As shown more specifically by FIGS. 5B and 6, the top view of each of hinge corner bracket 30, when in the closed position, first corner bracket 40a, second corner bracket 40b, and third corner bracket 40c have a wing shape 50. Wing shape 50 is defined by a plane 52 that runs parallel to chamfered panels 36, 45a, 45b, 45c and a delta angle 54. Delta angle 54 is calculated as the degree of angle between horizontal plane 52 and first rails 32, 42a, 42b, and 42c, respectively, and horizontal plane 52 and second rails 34, 44a, 44b, and 44c, respectively. One skilled in the art understands delta angle 54 depends on the shape of the column desired and the number of formwork panels used in column forming system 10. While delta angle 54 may be any angle greater than 0° and less than 90°, delta angle 54 will more typically range from 15° to 85°. For example, delta angle 54 may range anywhere from 30° to 75°; however, more typically delta angle 54 will be 30°, 45° or 60° or within 5° of such angles.

Each of first corner bracket 40a, second corner bracket 40b, and third corner bracket 40c include a first rail 42a, 42b, 42c, a second rail 44a, 44b, 44c, and a chamfered panel 45a, 45b, 45c. In some embodiments, as more specifically shown in FIGS. 5A-8, each of hinge corner bracket 30, first corner bracket 40a, second corner bracket 40b, and third corner bracket 40c include a first end 38a, 46a, 46b, 46c and a second end 39a, 48a, 48b, 48c. Each of first end 38a, 46a, 46b, 46c includes a receiving lip 38b, 47a, 47b, 47c. Each of second end 39a, 48a, 48b, 48c includes a receiving lip 39b, 49a, 49b, 49c. Receiving lips 38b, 47a, 47b, 47c and 39b, 49a, 49b, 49c are configured to receive an edge 22a-d, 24a-d of formwork panels 20a-d and provide additional support to column forming system 10 as cementitious material is introduced into column interior 12.

Each of hinge corner bracket 30 and corner brackets 40a, 40b, 40c are removeable and replaceable. In some embodiments, hinge corner bracket 30 and corner brackets 40a, 40b, 40c are removeable and replaceable with an attachment system 14 configured to connect hinge corner bracket 30 and corner brackets 40a, 40b, 40c to formwork panels 20a, 20b, 20c, 20d. As shown in FIGS. 3 and 4, attachment system 14 is nuts and bolts, where the bolts slide through a number of apertures 15 in first rails 32, 42a, 42b, 42c and second rails 34, 44a, 44b, 44c. In other embodiments, attachment system 14 is wedge bolts or clamps. Once attachment systems 14 are secured, and hinge corner bracket 30 is in the closed position, column forming system 10 is a closed system defining column interior 12 such that cementitious material can be introduced to form a column.

A method of forming a concrete column with column forming system 10 will now be described with reference generally to FIGS. 1-8. For ease of reference, the method will be described in accordance with forming a square column with chamfered corners. However, one skilled in the art understands such method can be used with more or less formwork panels to create the desired shape of the column provide one of the corner brackets is hinge corner bracket 30.

The initial assembly step requires attaching first rail 32 of hinge corner bracket 30 to second edge 24a of first formwork panel 20a, where hinge corner bracket 30 is moveable between the open position and the closed position. Second rail 34 of hinge corner bracket 30 is then attached to first edge 22b of second formwork panel 20b such that, when hinge corner bracket 30 is in the closed position, hinge chamfered panel 36 extends between first formwork panel 20a and second formwork panel 20b. After attaching hinge corner bracket 30 to formwork panels 20a, 20b, the following attachment steps are performed: (i) first rail 42a of first corner bracket 40a is attached to second edge 24b of second formwork panel 20b; (ii) second rail 44a of first corner bracket 40a is attached to first edge 22c of third formwork panel 20c such that chamfered panel 45a extends between second formwork panel 20b and third formwork panel 20c; (iii) first rail 42b of second corner bracket 40b is attached to second edge 24c of third formwork panel 20c; (iv) second rail 44b of second corner bracket 40b is attached to first edge 22d of fourth formwork panel 20d such that second chamfered panel 45b extends between third formwork panel 20c and fourth formwork panel 20d; (v) first rail 42c of third corner bracket 40c is attached to second edge 24d of fourth formwork panel 20d; (vi) second rail 44c of third corner bracket 40c is attached to first edge 22a of first formwork panel 20a such that third chamfered panel 45c extends between fourth formwork panel 20d and first formwork panel 20a.

Prior to step (vi) of the attachment steps, hinge corner bracket 30 is moved into the closed position such that step (vi) creates a closed system of column forming system 10 defining column interior 12. While described with the above specific order, with step (vi) being the last step, those skilled in the art will realize that the method of forming a concrete column with column forming system 10 can use a different order for the attachment steps. For example, step (vi) can occur before moving hinge corner bracket 30 into the closed position, and attachment steps (i), (ii), (iii), (iv), or (v) can be the final attachment step after moving hinge corner bracket 30 into the closed position.

After creating the closed system of column forming system 10, cementitious material is introduced into column interior 12. The cementitious material is then given a sufficient time period to cure to create a cementitious column. After sufficient time to cure has passed, one of either first rail 42a, 42b, 42c or second rail 44a, 44b, 44c of one of corner brackets 40a, 40b, 40c is detached. In some embodiments, the corner bracket 40a, 40b, 40c directly opposite hinge corner bracket 30 will be selected for detachment in the step of detaching one of either first rail 42a, 42b, 42c or second rail 44a, 44b, 44c of one of corner brackets 40a, 40b, 40c. For example, as shown in FIGS. 1, 2 and 4, one of either first rail 42b or second rail 44b of second corner bracket 40b is detached. Hinge corner bracket 30 is then moved into the open position to allow manipulation of formwork panels 20a, 20b, 20c, 20d relative to one another. Once hinge corner bracket 30 is in the open position, formwork panels 20a, 20b, 20c, 20d are manipulated relative to one another such that column forming system 10 is removed to expose the cementitious column and move column forming system 10 to the next location.

Therefore, the present disclosure is well adapted to attain the ends and advantages mentioned, as well as those that are inherent therein. The particular embodiments disclosed above are illustrative only, as the present disclosure may be modified and practiced in different but equivalent manners apparent to those skilled in the art having the benefit of the teachings herein. Furthermore, no limitations are intended to the details of construction or design herein shown, other than as described in the claims below. It is therefore evident that the particular illustrative examples disclosed above may be altered or modified, and all such variations are considered within the scope and spirit of the present disclosure. While apparatus and methods may be described in terms of “comprising,” “containing,” “having,” or “including” various components or steps, the apparatus and methods can also, in some examples, “consist essentially of” or “consist of” the various components and steps. Also, the terms in the claims have their plain, ordinary meaning unless otherwise explicitly and clearly defined by the specification.

Claims

1. A column forming system comprising: a first formwork panel having a first edge and a second edge;a second formwork panel having a first edge and a second edge;a third formwork panel having a first edge and a second edge;a hinge corner bracket moveable between an open position and a closed position, the hinge corner bracket having a first rail and a second rail, wherein the first rail of the hinge corner bracket is attached to the second edge of the first formwork panel and the second rail of the hinge corner bracket is attached to the first edge of the second formwork panel, and wherein in the closed position the hinge corner bracket forms a hinge chamfered panel extending between the first formwork panel and the second formwork panel;a first corner bracket having a first rail, a second rail, and a first chamfered panel extending between the first rail and the second rail, wherein the first rail of the first corner bracket is attached to the second edge of the second formwork panel and the second rail of the first corner bracket is attached to the first edge of the third formwork panel such that the first chamfered panel extends between the second formwork panel and the third formwork panel; anda second corner bracket having a first rail, a second rail, and a second chamfered panel extending between the first rail and the second rail, wherein the first rail of the second corner bracket is attached to the second edge of the third formwork panel;wherein the open position of the hinge corner bracket is configured to allow manipulation of the first formwork panel, the second formwork panel, and the third formwork panel relative to one another; andwherein in the closed position of the hinge corner bracket, the column forming system defines a column interior.

2. The column forming system of claim 1, wherein the hinge corner bracket further comprises: a first portion of the hinge chamfered panel is integrally formed with the first rail of the hinge corner bracket;a second portion of the hinge chamfered panel is integrally formed with the second rail of the hinge corner bracket, wherein the first portion and the second portion are pivotally connected;wherein in the closed position, the first portion and the second portion form the hinged chamfered panel extending between the first formwork panel and the second formwork panel; andwherein the open position of the hinge corner bracket is configured to allow manipulation of the first portion and the second portion relative to one another.

3. The column forming system of claim 1, wherein each of the hinge corner bracket, the first corner bracket, and the second corner bracket are removable and replaceable.

4. The column forming system of claim 3, wherein each of the hinge corner bracket, the first corner bracket, and the second corner bracket are removable and replaceable with an attachment system selected from the group consisting of wedge bolts, nuts and bolts, and clamps.

5. The column forming system of claim 4, wherein each of the first rail and the second rail of the hinge corner bracket, the first rail and the second rail of the first corner bracket, and the first rail and the second rail of the second corner bracket include apertures for connection of the attachment system.

6. The column forming system of claim 1, wherein the second rail of the second corner bracket is attached to the first edge of the first formwork panel such that the second chamfered panel extends between the third formwork panel and the first formwork panel to create a closed system of the column forming system.

7. The column forming system of claim 1, wherein each of the hinge corner bracket, the first corner bracket, and the second corner bracket further comprise: a first end having a first receiving lip;a second end having a second receiving lip, wherein the first receiving lip and the second receiving lip are configured to receive either the first edge or the second edge of the first formwork panel, the first edge or the second edge of the second formwork panel, or the first edge or the second edge of the third formwork panel.

8. The column forming system of claim 1, wherein each of the first rail and the second rail of the hinge corner bracket, the first rail and the second rail of the first corner bracket, and the first rail and the second rail of the second corner bracket extend from the hinge chamfered panel, the first chamfered panel, or the second chamfered panel, respectively, to form a wing shape.

9. The column forming system of claim 8, wherein the wing shape is formed by each of the first rail and the second rail of the hinge corner bracket, the first rail and the second rail of the first corner bracket, and the first rail and the second rail of the second corner bracket having a delta angle of about 30 degrees to about 75 degrees.

10. The column forming system of claim 1 further comprising: a fourth formwork panel having a first edge and second edge;wherein the second rail of the second corner bracket is attached to the first edge of the fourth formwork panel such that the second chamfered panel extends between the third formwork panel and the fourth formwork panel; anda third corner bracket having a first rail, a second rail, and a third chamfered panel extending between the first rail and the second rail, wherein the first rail of the third corner bracket is attached to the second edge of the fourth formwork panel;wherein the open position of the hinge corner bracket is configured to allow manipulation of the first formwork panel, the second formwork panel, the third formwork panel, and the fourth formwork panel relative to one another.

11. The column forming system of claim 10, wherein the hinge corner bracket further comprises: a first portion of the hinge chamfered panel is integrally formed with the first rail of the hinge corner bracket;a second portion of the hinge chamfered panel is integrally formed with the second rail of the hinge corner bracket, wherein the first portion and the second portion are pivotally connected;wherein in the closed position, the first portion and the second portion form the hinged chamfered panel extending between the first formwork panel and the second formwork panel; andwherein the open position of the hinge corner bracket is configured to allow manipulation of the first portion and the second portion relative to one another.

12. The column forming system of claim 10, wherein each of the hinge corner bracket, the first corner bracket, and the second corner bracket are removable and replaceable with an attachment system selected from the group consisting of wedge bolts, nuts and bolts, and clamps.

13. The column forming system of claim 10, wherein the second rail of the third corner bracket is attached to the first edge of the first formwork panel such that the third chamfered panel extends between the fourth formwork panel and the first formwork panel to create a closed system of the column forming system.

14. The column forming system of claim 10, wherein each of the hinge corner bracket, the first corner bracket, the second corner bracket, and the third corner bracket further comprise: a first end having a first receiving lip;a second end having a second receiving lip, wherein the first receiving lip and the second receiving lip are configured to receive either the first edge or the second edge of the first formwork panel, the first edge or the second edge of the second formwork panel, the first edge or the second edge of the third formwork panel, or the first edge or the second edge of the fourth formwork panel.

15. The column forming system of claim 10, wherein each of the first rail and the second rail of the hinge corner bracket, the first rail and the second rail of the first corner bracket, the first rail and the second rail of the second corner bracket, and the first rail and the second rail of the third corner bracket extend from the hinge chamfered panel, the first chamfered panel, or the second chamfered panel, respectively, to form a wing shape having a delta angle of about 30 degrees to about 75 degrees.

16. The column forming system of claim 10, wherein in the open position, one of either the first rail or the second rail of the second corner bracket is detached to allow manipulation of the first formwork panel, the second formwork panel, the third formwork panel, and the fourth formwork panel relative to one another.

17. The column forming system of claim 1, wherein the first formwork panel, the second formwork panel, the third formwork panel, the hinge corner bracket, the first corner bracket, and the second corner bracket are comprised of a material selected from the group consisting of aluminum and steel.

18. A method of forming a concrete column comprising: attaching a first rail of a hinge corner bracket to a second edge of a first formwork panel, the hinge corner bracket moveable between an open position and a closed position;attaching a second rail of the hinge corner bracket to a first edge of a second formwork panel such that when the hinge corner bracket is in the closed position a hinge chamfered panel extends between the first formwork panel and the second formwork panel;performing the following attachment steps: (i) attaching a first rail of a first corner bracket to a second edge of the second formwork panel;(ii) attaching a second rail of the first corner bracket to a first edge of a third formwork panel such that a first chamfered panel extends between the second formwork panel and the third formwork panel;(iii) attaching a first rail of a second corner bracket to a second edge of the third formwork panel;(iv) attaching a second rail of the second corner bracket to a first edge of a fourth formwork panel such that a second chamfered panel extends between the third formwork panel and the fourth formwork panel;(v) attaching a first rail of a third corner bracket to a second edge of the fourth formwork panel; and(vi) attaching a second rail of a third corner bracket to a first edge of the first formwork panel such that a third chamfered panel extends between the fourth formwork panel and the first formwork panel;moving the hinge corner bracket into the closed position, wherein one of the attachment steps (i)-(vi) occurs after the hinge corner bracket is moved to the closed position so as to create a column forming system which defines a column interior;introducing a cementitious material into the column interior;allowing the cementitious material to cure into a cementitious column;detaching one of either the first rail or the second rail of one of the first corner bracket, the second corner bracket, or the third corner bracket;moving the hinge corner bracket into the open position allowing manipulation of the first formwork panel, the second formwork panel, the third formwork panel, and the fourth formwork panel relative to one another; andmanipulating the first formwork panel, the second formwork panel, the third formwork panel, and the fourth formwork panel relative to one another such that the column forming system can be removed to expose the cementitious column and moved to a new location.

19. The method of forming a concrete column of claim 18, wherein the step of detaching one of either the first rail or the second rail of one of the first corner bracket, the second corner bracket, or the third corner bracket is detaching one of either the first rail or the second rail of the second corner bracket.