The present disclosure relates to concrete form systems and devices, and related methods. More specifically, the present disclosure relates to concrete form systems and devices, and related methods that can be used to form structural concrete floors, or flat to slightly pitched roofs.
Concrete is frequently used in the construction industry. For instance, concreate is commonly used in various aspects of building construction, including to form foundations, floors, ceiling, roofs, and walls. In such applications, cast-in-place concreate is frequently used. Concrete can be poured into a form and held in place by the form while the concrete cures. Once the concrete has sufficiently cured, the form may be removed or stripped from the concrete. This may include removing any bracing and form members.
While concrete, especially reinforced concrete, can be used to construct strong, stable buildings, there are some challenges encountered with concrete. For instance, when concrete is used to form a floor/ceiling between different stories of a building, ductwork, piping, and other conduits (e.g., for running cables, etc.) are often attached to the lower surface thereof (i.e., the surface that forms the ceiling). The ductwork, piping, and other conduits are then typically enclosed within drywall or other materials to hide them from sight. However, this can result in ceilings with undesirable appearances due to various portions being lower than other portions.
Additionally, concrete can have relatively low insulative properties (i.e., relatively low R-value), that make it difficult to efficiently control the climate within the building. For instance, it may be difficult to maintain different levels of a building at desired temperatures because heat from lower levels may rise through the concrete floors/ceilings to upper floors.
Accordingly, there are a number of problems in the art that need to be addressed. The subject matter claimed herein is not limited to embodiments that solve any disadvantages or that operate only in environments such as those described above. Rather, this background is only provided to illustrate one exemplary technology area where some embodiments described herein may be practiced.
The present disclosure relates to concrete form systems and devices, and related methods. More specifically, the present disclosure relates to concrete form systems and devices, and related methods that can be used to form structural concrete floors, or flat to slightly pitched roofs.
In one example embodiment of the present disclosure, a concrete form system according to one example embodiment may include a concrete form and a rebar tree. The concrete form may include at least one support column disposed at a lower portion of the concrete form and first and second connection branches disposed at an upper portion or the concrete form. The first and second connection branches may be configured to be connected to second and first connection branches, respectively, of another concrete form. The first and second connection branches may at least partially form one or more channels therebetween. The rebar tree may include a rebar mounting assembly configured to hold one or more pieces of rebar in one or more desired positions. The rebar mounting assembly may be configured to be disposed within at least one of the one or more channels at least partially formed by the first and second connection branches.
In another example embodiment of the present disclosure, a concrete form includes first and second support columns, a bridge portion, and first and second connection branches. The bridge portion may extend upwardly from and between the first and second support columns to connect the first and second support columns to one another. The bridge portion and the first and second support columns may cooperate to define a channel in a lower surface of the concrete form. The first connection branch may extend upwardly from the first support column. The first connection branch and the bridge portion may cooperate to define a first channel in an upper surface of the concrete form. The second connection branch may extend upwardly from the second support column. The second connection branch and the bridge portion may cooperate to define a second channel in an upper surface of the concrete form.
In a further example embodiment of the present disclosure, a rebar tree that includes a shaft and a rebar mounting assembly. The rebar mounting assembly may be selectively and movably disposed on the shaft. The rebar mounting assembly includes one or more branches, each having one or more rebar retention elements configured to hold one or more pieces of rebar in one or more desired positions.
This Summary is provided to introduce a selection of concepts in a simplified form that are further described below in the Detailed Description. This Summary is not intended to identify key features or essential 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. Additional features and advantages of the disclosed embodiments will be set forth in the description which follows, and in part will be obvious from the description, or may be learned by the practice of the disclosure. These and other features will become more fully apparent from the following description and appended claims or may be learned by the practice of the present disclosure.
To further clarify the above and other advantages and features of the present invention, a more particular description of the invention will be rendered by reference to specific embodiments thereof which are illustrated in the appended drawings. It is appreciated that these drawings depict only illustrated embodiments of the invention and are therefore not to be considered limiting of its scope. The invention will be described and explained with additional specificity and detail through the use of the accompanying drawings in which:
The present disclosure relates to concrete form systems and devices, and related methods. More specifically, the present disclosure relates to concrete form systems and devices, and related methods that can be used to form structural concrete floors or flat to slightly pitched roofs.
The concrete form system 100 may also include temporary shoring elements 104 and/or roll bucks 106 that may be designed to support the concrete forms 102 while the concrete forms 102 are put into place, while concrete is poured therein/thereon, and while the concrete cures.
As in the illustrated embodiment, the temporary shoring elements 104 may include beams that are held in horizontal positions to support the concrete forms 102 thereon at a desired height. Although not illustrated, the temporary shoring elements 104 may be held in place by one or more posts or other temporary or permanent support elements.
The roll bucks 106 may be disposed at least partially within a channel or recess formed within a single concrete form 102 or a channel or recess formed by adjacent concrete forms 102. As can be seen in
Once the concrete has sufficiently cured, the temporary shoring elements 104 and the roll bucks 106 may be removed, leaving in place the concrete forms 102 and the cured concrete. With the temporary shoring elements 104 and the roll bucks 106 removed from underneath the concrete forms 102, various components may be secured to or within the underside of the concrete forms 102. For instance, HVAC ductwork, plumbing pipes, electrical conduits, etc. may be attached to or run through the concrete forms 102. Additional details regarding this aspect of the concrete form system 100 will be provided below.
With continued attention to
As can be seen in
The first and second connection branches 112a, 112b and the bridge portion 114 cooperate to define an upper surface of the concrete form 102. The channels 116a, 116b are recessed from the upper surface of the concrete form 102 so as to be able to receive concrete therein.
The first and second connection branches 112a, 112b include connection feature 118a, 118b, respectively. When multiple concrete forms 102 are positioned adjacent to one another, the connection feature 118a on one concrete form 102 may mate with the connection features 118b on an adjacent concrete form 102, as illustrated in
In some embodiments, the connection features 118a, 118b may facilitate a secure temporary or permanent connection between adjacent concrete forms 102. In other embodiments, the connection features 118a, 118b may facilitate alignment between adjacent concrete forms 102 when the concrete form system 100 is being assembled. In still other embodiments, the connection features 118a, 118b may facilitate both alignment and secure connections between adjacent concrete forms 102.
In the illustrated embodiment, the connection feature 118a of the first connection branch 112a is a tongue and the connection feature 118b of the second connection branch 112b is a groove. In other embodiments, the connection features may include any mating or other features that facilitate connection and/or alignment between adjacent concrete forms 102. For instance, the connection features 118a, 118b may include mortise and tenons, dovetails, mating under and overlaps, and the like.
The first and second support columns 110a, 110b cooperate to define a lower surface of the concrete form 102. As can be seen in
Similarly, when two concrete forms 102 are positioned adjacent to one another, the two concrete forms 102 may cooperate to form another channel 120. That is, the first support column 110a and first connection branch 112a from one concrete form 102 may form a portion (e.g., half) of a channel 120. The second support column 110b and the second connection branch 112b from another concrete form 102 may form another portion (e.g., half) of a channel 120. More specifically, the first support column 110a and first connection branch 112a from one of the concrete forms 102 and the second support column 110b and second connection branch 112b from the other concrete form 102 may cooperate to form a channel 120. The channel 120 formed by two concrete forms 102 may be recessed from the lower sides of both concrete forms 102. As will be discussed in greater detail below, HVAC ductwork, plumbing, and/or electrical conduit may be run through the channels 120.
As can best be seen in
As illustrated in
While the concrete form 102 is described and illustrated as having a W or connected YY end profile, this is merely exemplary. In other embodiments, a concrete form may include a Y end profile. In such embodiments, the concrete form may include a single support column similar or identical to support columns 110a, 110b. Extending upwardly from the support column, the concrete form may include first and second connection branches similar or identical to connection branches 112a, 112b. In such an embodiment, the concrete form would have a single channel (similar to channels 116a, 116b) recessed into the upper surface of the concrete form. The concrete form would be configured to cooperate with one or more other concrete forms for form one or more lower channels (similar to channels 120).
Attention is now directed to
When creating a concrete floor with the concrete form system 100, the system 100 is assembled and concrete is poured over the top of the concrete forms 102. The concrete fills the channels 116a, 116b. When cured, the concrete in the channels 116a, 116b may act as floor joists or beams. To provide the floor joists or beams sufficient strength, rebar or other reinforcement elements can be disposed within the channels 116a, 116b prior to pouring the concrete. To properly position the rebar within the channels 116a, 116b, a rebar tree 140 as shown in
In the illustrated embodiment, the rebar tree 140 includes a shaft 142, a rebar mounting assembly 144 disposed on a first end or portion of the shaft 142, and a connection element 146 connected to a second end of the shaft 142. The rebar mounting assembly 144 may be movably connected to or mounted on the shaft 142. The connection element 146 may be permanently or otherwise connected to the second end of the shaft 142 such that the shaft 142 and connection element 146 are fixedly connected together.
In the illustrated embodiment, the rebar mounting assembly 144 includes a sleeve 148 that is disposed at least partially around the shaft 142. The sleeve 148 may be slidably disposed on the shaft 142 such that the sleeve 148 (and the rest of the rebar mounting assembly 144) may slide along at least a portion of the length of the shaft 142. The shaft 142 may include a threaded first end 150. A bolt 152 may be threaded onto the first end 150 of the shaft 142. As the bolt 152 is threaded further onto the shaft 142, the bolt 152 may engage the sleeve 148 and cause the sleeve 148 (and the rest of the rebar mounting assembly 144) to move down the shaft 142 towards the second end thereof (e.g., the end with the connection element 146).
The rebar mounting assembly 144 may include multiple branches connected to the sleeve 148, each with one or more rebar retention elements. In the illustrated embodiment, the rebar mounting assembly 144 includes four branches 154a, 154b, 154c, 154d. Each branch extends from opposing sides of the sleeve 148. Each branch includes one or more rebar retention elements 156. In the illustrated embodiment, the rebar retention elements 156 are channels mounted on or formed in upper surfaces of the branches 154a-154d. The channels may open upwardly such that rebar may be set into the channels. In other embodiments, the rebar retention elements 156 may be apertures that extend through the branches 154a-154d, such that the rebar may be slid into the apertures. In still other embodiments, the rebar retention elements 156 may extend downwardly from the branches 154a-154d and be configured to hold the rebar. Thus, it will be appreciated that the rebar retention elements 156 may take substantially any form so long as they can hold rebar in place while concrete is poured and cured.
The rebar tree 140 can be used in conjunction with the concrete form 102. For instance, as shown in
With the rebar mounting assembly 144 securely disposed within the channel 116a, 116b, rebar 158 may be disposed on or in the rebar retention elements 156, as shown in the channel 116a in
Attention is now directed to
Once the floor is complete and any desired conduits are run through the concrete forms 102 (or before), a ceiling or ceiling components may be attached to the underside of the concrete form system 100. The ceiling or ceiling components may be attached to the concrete form system 100 via the connection elements 146 of the rebar tree 140.
While the previous embodiments have focused on a system that uses a concrete form 102 and a rebar tree 140, it will be appreciated that this is merely exemplary. In other embodiments, a concrete form 102 may be used without a rebar tree 140. In such embodiments, the concrete form 102 may omit the one or more apertures 124 since they would not be needed for the shafts 142 of the omitted rebar tree 140. Similarly, the channels 126 in the concrete form 102 may be omitted or modified since the connection elements 146 of the omitted rebar trees 140 would not be present.
In such embodiments, the ceiling components 170 may be molded into or otherwise connected to the concrete forms 102 (e.g., with mechanical fasteners, adhesives, etc.). Additionally, rather than using a rebar mounting assembly 144 to position rebar within the channels 116a, 116b of the concrete form 102, rebar cages (such as pre-tied rebar cages) may be positioned within the channels 116a, 116b and used to reinforce the concrete disposed therein.
In light of the above, a concrete form system according to one example embodiment may include a concrete form and a rebar tree. The concrete form may include at least one support column disposed at a lower portion of the concrete form and first and second connection branches disposed at an upper portion or the concrete form. The first and second connection branches may be configured to be connected to second and first connection branches, respectively, of another concrete form. The first and second connection branches may at least partially form one or more channels therebetween. The rebar tree may include a rebar mounting assembly configured to hold one or more pieces of rebar in one or more desired positions. The rebar mounting assembly may be configured to be disposed within at least one of the one or more channels at least partially formed by the first and second connection branches.
In some embodiments, the at least one support column comprises first and second support columns.
In some embodiments, the concrete form also includes a bridge portion extending between and connecting the first and second support columns.
In some embodiments, the first and second support columns and the bridge portion cooperate to define a channel in a lower side of the concrete form.
In some embodiments, the one or more channels at least partially formed by the first and second connection branches comprise first and second channels.
In some embodiments, the first channel is formed by the first connection branch and the bridge portion and the second channels is formed by the second connection branch and the bridge portion.
In some embodiments, the concrete form also includes an aperture extending through the at least one support column between the at least one of the one or more channels and a lower end of the at least one support column.
In some embodiments, the rebar tree also includes a shaft having a first portion on which the rebar mounting assembly is selectively mountable, the shaft being configured to extend through the aperture in the at least one support column.
In some embodiments, the rebar tree also includes a connection element disposes at a second end of the shaft.
In some embodiments, the at least one support column includes a channel in a lower end thereof, the channel in the lower end of the at least one support column being configured to receive at least partially therein the connection element of the rebar tree.
In some embodiments, the rebar mounting assembly includes one or more branches, each of the one or more branches comprising one or more rebar retention elements.
In some embodiments, the at least one support column includes one or more apertures that extend laterally therethrough between opposing sides thereof, the one or more apertures being configured to have ductwork, pipes, or other conduit passed therethrough.
In another example embodiment, a concrete form includes first and second support columns, a bridge portion, and first and second connection branches. The bridge portion may extend upwardly from and between the first and second support columns to connect the first and second support columns to one another. The bridge portion and the first and second support columns may cooperate to define a channel in a lower surface of the concrete form. The first connection branch may extend upwardly from the first support column. The first connection branch and the bridge portion may cooperate to define a first channel in an upper surface of the concrete form. The second connection branch may extend upwardly from the second support column. The second connection branch and the bridge portion may cooperate to define a second channel in an upper surface of the concrete form.
In some embodiments, each of the first and second connection branches comprises a connection feature that can be configured for connection to second and first connection branches, respectively, of another concrete form.
In some embodiments, at least one of the first and second support columns includes one or more apertures extending laterally therethrough between opposing sides thereof and configured to have ductwork, pipes, or other conduits passed therethrough.
In some embodiments, the first support column includes one or more apertures extending therethrough between the first channel and a lower end of the first support column and/or the second support column includes one or more apertures extending therethrough between the second channel and a lower end of the second support column.
Another example embodiment includes a rebar tree that includes a shaft and a rebar mounting assembly. The rebar mounting assembly may be selectively and movably disposed on the shaft. The rebar mounting assembly includes one or more branches, each having one or more rebar retention elements configured to hold one or more pieces of rebar in one or more desired positions.
In some embodiments, the rebar mounting assembly also includes a sleeve that is configured to be movably disposed on the shaft and the one or more branches are connected to and extending from the sleeve.
In some embodiments, one end of the shaft has a connection element connected thereto.
In some embodiments, an opposite end of the shaft is threaded and the rebar tree includes a bolt configured to be threaded onto the threaded end of the shaft.
In some embodiments, threading the bolt onto the threaded end of the shaft is configured to move the rebar mounting assembly along the shaft towards the connection feature.
The present invention may be embodied in other specific forms without departing from its spirit or essential characteristics. The described embodiments are to be considered in all respects only as illustrative and not restrictive. The scope of the invention is, therefore, indicated by the appended claims rather than by the foregoing description. All changes which come within the meaning and range of equivalency of the claims are to be embraced within their scope.
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