Patent Application
20200063451
The subject application generally relates to forms for concrete walls and in particular, to a concrete form tie and a concrete formwork comprising the same.
Conventional forms for forming walls from pourable building material such as concrete consists of two opposed panels, typically fabricated of plywood, that are connected by a rod, trusswork or other connecting structure. More recently, it has become desirable to use insulating material such as expanded polystyrene (EPS) for the form, in order to provide thermal and acoustic insulation to the finished concrete wall. In certain applications, particularly those in which it is desired to utilize the ability of the concrete to retain heat for thermal stabilization, it is desirable to employ forms with insulating material on only one side. The other side of the form, which is typically a sheet of plywood or other material, may or may not be removed after full or partial setting of the concrete.
Concrete formworks comprising insulating material have been previously described. For example, U.S. Pat. No. 5,701,710 to Tremelling describes a freestanding form module for receiving flowable materials that includes a pair of form members, preferably made of styrofoam, joined together by molded plastic rib members. The rib members may be monolithic or formed from plural components. Bearing plates and stabilizing plates are employed to support forces applied to the form module.
U.S. Pat. No. 5,709,060 to Vaughan et al. describes a form tie for joining sidewalls of a polymeric concrete form that comprises a pair of end trusses with an intermediate web truss. Each end truss comprises an interior vertical strut and a longer exterior strut with interior and exterior pairs of horizontal struts extending therebetween. Upper and lower rectangular trusses and an intermediate truss are formed within each truss and rigidified by diagonal struts extending between the ends of the exterior vertical strut and interior vertical strut. The exterior struts of each end truss are coplanar with the exterior sidewall surface with the interior strut of each end truss being coplanar with the interior sidewall surface. The coplanar relationship of the struts serve as a visual gauge that the form with tie has been properly manufactured and assures that the end trusses extend throughout the width of each sidewall. End ties having a height of one-half of the form sidewall are extended between the sidewalls at the ends of each form. The end ties of adjacent forms are vertically offset to enhance concrete flow therebetween. During transport and use the trusses resist the presence of compression, tension, twisting and other forces acting on the forms so as to maintain the desired spatial relationship between the forms. A seat for horizontal rebar is found with each form tie.
U.S. Pat. No. 6,314,694 to Cooper et al. describes one-sided, insulated formwork used in the construction of walls from pourable building material, such as concrete, including an insulating panel connectable to a removable panel by a connecting structure, which may include a permanent reinforcement embedded in the insulating panel. The connecting structure may have a tie removably attachable to the reinforcement, or the reinforcement and tie may constitute a monolithic structure. The tie may be asymmetric in shape to facilitate distribution of loads across the insulating panel, detachment of the removable panel, and enhance the structural integrity of the finished wall.
U.S. Pat. No. 7,059,577 to Burgett describes a method and system for installing an insulated concrete wall includes insulation panels placed in an upright manner. Generally T-shaped wall studs are placed next to the insulation panels such that the front section of the wall stud is on the outside of the insulation panels and an anchoring section of the wall stud extends beyond the insulation panels into the gap into which concrete will later be poured. Concrete pouring forms are placed so as to render the gap into which concrete will be poured a desired thickness. The wall stud may also include slots for receiving cross-ties that secure the concrete pouring forms in proper position and retaining nubs that prevent the insulation panels from floating when concrete is poured. Concrete is then poured into the gap, surrounding the anchoring section the T-shaped wall stud.
U.S. Pat. No. 9,121,166 to Amend describes a panel for a building form made of insulating material such as polystyrene that is integrated with a reinforcing member for enabling the panel to resist deformation due to forces applied against its concrete-facing surface. The reinforcing member may be made of a plastic material such as polypropylene or high-impact polystyrene.
U.S. Patent Application Publication No. 2001/029717 to Spakousky describes a composite modular building block with a connective structure between the outer and inner wall. The inner and outer walls of the composite modular block units may be made of cement, clay brick, or similar materials. The connective structure is made of a different material than the walls of the composite block and may be formed per the requirements of each block. In one embodiment, the connective structure may comprise two or more individual connective struts connecting an outer and an inner wall of a modular block. A panel member cooperating with the struts may be inserted between the outer and inner walls to form two separate cavities between the blocks when these are assembled into a wall.
Improvements are generally desired. It is therefore at least an object to provide a novel concrete form tie and a novel concrete formwork comprising the same same.
It should be appreciated that 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 be used to limit the scope of the claimed subject matter.
Accordingly, in one aspect, there is provided a tie for a concrete formwork, the tie comprising: a tie anchor configured to be embedded in a block of insulating material, the tie anchor having a first connecting feature accessible from a concrete-facing surface of the block; and a tie member having a second connecting feature configured to connect to the first connecting feature of the tie anchor, the tie member having at least one connector for connecting to an abutting tie member.
The first connector may comprise features defining a channel that is sized to receive the second connector. The features may comprise a base plate and a plurality of angled tabs extending therefrom and defining the channel. The second connector may comprise features configured to be received in the first connector. The features may comprise a rail including one or more longitudinal tabs.
The first connector may comprise a longitudinal rib having features defining a channel that is sized to receive the second connector. The features may comprise a base plate and a plurality of angled tabs extending therefrom and defining the channel. The second connector may comprise features configured to accommodate at least a portion of the first connector. These features may comprise a longitudinal guide defining a longitudinal channel that is sized to accommodate at least a portion of the first connector. The longitudinal guide may have a generally “C-shaped” section along its length, defining the channel. The longitudinal guide may comprise a series of angled tabs extending from a longitudinal baseplate, defining the channel.
The tie member may further comprise a panel fastening plate defining an elongate panel fastening surface; and a central web connecting the panel fastening plate and the second connecting feature. The tie may further comprise flanges extending laterally from the panel fastening plate and defining a portion of the panel fastening surface. The panel fastening surface may extend the length of the panel fastening plate. The web may have a linking feature formed in an edge thereof, the linking feature being sized to engage a connecting rod for linking the tie member to an adjacent tie member. The linking feature may be a notch formed in the edge of the web, the notch being sized to receive the connecting rod. The linking feature may be a pin formed in the edge of the web, the pin being sized to engage a bore formed in the connecting rod. The at least one connector may comprise a connector at each longitudinal end of the panel fastening plate. The at least one connector may be configured to prevent relative lateral movement of the abutting tie members. The at least one connector may comprise a connector at each end of the second connecting feature. The at least one connector may be configured to prevent separation of the abutting tie members in a longitudinal direction.
In another aspect, there is provided a concrete formwork, comprising: a plurality of blocks of insulating material arranged to define a side of the formwork, each block comprising at least two tie anchors embedded therein, each tie anchor having a first connecting feature accessible from a concrete-facing surface of the block; a plurality of tie members, each tie member having a second connecting feature connected to the first connecting feature of the tie anchor; a connecting rod seated horizontally on two or more adjacent tie members, the connecting rod linking the two or more tie members; and a panel fastened to the tie members, the panel and the blocks defining a volume into which concrete is to be poured.
The panel may be spaced from ends of the tie members by a plurality of spacers. The panel may be fastened to the tie members by fasteners extending through the spacers.
In another aspect, there is provided a method of constructing a concrete wall and a concrete floor slab of a building, comprising: arranging a plurality of blocks of insulating material, each block comprising at least two tie anchors embedded therein, each tie anchor having a first connecting feature on a concrete-facing surface of the block; connecting tie members to the tie anchors, each tie member having second connecting feature matingly engaging the first connecting feature of a respective one of the tie anchors; fastening an insulating panel to the tie members, the insulating panel being fabricated of insulating material; pouring concrete into a volume defined by the blocks and the insulating panel to form the concrete wall; removing the panel from the concrete wall after the concrete has set; laying the insulating panel on ground; and pouring concrete onto the insulating panel to form the concrete floor slab.
The concrete wall may be formed on a concrete footing.
The laying may further comprise: laying a vapour barrier on the ground; and laying the insulating panel on the vapour barrier.
Embodiments will now be described more fully with reference to the accompanying drawings in which:
The foregoing summary, as well as the following detailed description of certain examples will be better understood when read in conjunction with the appended drawings. As used herein, an element or feature introduced in the singular and preceded by the word “a” or “an” should be understood as not necessarily excluding the plural of the elements or features. Further, references to “one example” or “one embodiment” are not intended to be interpreted as excluding the existence of additional examples or embodiments that also incorporate the described elements or features. Moreover, unless explicitly stated to the contrary, examples or embodiments “comprising” or “having” or “including” an element or feature or a plurality of elements or features having a particular property may include additional elements or features not having that property. Also, it will be appreciated that the terms “comprises”, “has”, “includes” means “including by not limited to” and the terms “comprising”, “having” and “including” have equivalent meanings.
As used herein, the term “and/or” can include any and all combinations of one or more of the associated listed elements or features.
It will be understood that when an element or feature is referred to as being “on”, “attached” to, “connected” to, “coupled” with, “contacting”, etc. another element or feature, that element or feature can be directly on, attached to, connected to, coupled with or contacting the other element or feature or intervening elements may also be present. In contrast, when an element or feature is referred to as being, for example, “directly on”, “directly attached” to, “directly connected” to, “directly coupled” with or “directly contacting” another element of feature, there are no intervening elements or features present.
It will be understood that spatially relative terms, such as “under”, “below”, “lower”, “over”, “above”, “upper”, “front”, “back” and the like, may be used herein for ease of description to describe the relationship of an element or feature to another element or feature as illustrated in the figures. The spatially relative terms can however, encompass different orientations in use or operation in addition to the orientation depicted in the figures.
Turning now to
Concrete formwork 30 comprises a plurality of blocks 32 fabricated of an insulating material, a plurality of panels 34, and a plurality of ties 40 connecting the blocks 32 and the panels 34. When connected by the ties 40, the blocks 32 and the panels 34 define a volume 42 into which the concrete is to be poured. Each block 32 is fabricated of expanded polystyrene (EPS) foam by molding. The panels 34 may be fabricated of EPS foam, or of a rigid sheet material such as plywood, oriented strand board (OSB), and the like.
The tie anchor 44 may be better seen in
Each strut 56 of the tie anchor web is in the form of a flat strip that is connected to the base plate 58 of the tab guide 52 and to the anchor plate 54. As will be understood, the flat shape of the strut 56 provides resistance to bending, and has a large interfacial area to provide better bonding between the tie anchor 44 and the material of the block 32 while utilizing less material, as compared to other shapes such as circular or square. The anchor plate 54 has a generally longitudinal, planar shape.
The tie member 46 may be better seen in
The tie member 46 also comprises a plurality of connectors for enabling vertically abutting tie members 46 to be connected. In the example shown, each tie member 46 comprises a first connector 124 at each end of the panel fastening plate 84. As will be understood, each first connector 124 is configured to engage the first connector 124 of a vertically abutting tie member 46. In the example shown, each first connector 124 comprises a longitudinally extending tongue 126, and an angled tab 128 and sidewall 132 defining a recess 136 sized to receive the tongue 126 of another connector 124. As will be understood, when vertically adjacent tie members 46 abut, the tongue 126 of one connector 124 is received in the recess 136 of another connector 124, and relative lateral movement of tie members 46 is prevented. Each tie member 46 also comprises a second connector 138 at each end of the longitudinal base 92 of the rail 82. The second connector 138 is configured to engage a second connector 138 of a vertically abutting tie member 46. In the example shown, each second connector 138 is in the form of a hook-shaped clip. As will be understood, when vertically adjacent tie members 46 abut, the second connector 138 of one tie member 46 engages the second connector 138 of another tie member 46, and relative vertical movement of the tie members 46 is prevented. Vertically abutting tie members 46, connected in this manner by connectors 124 and 138, yield columns 140 of connected tie members 46.
During fabrication of the block 32, a mold (not shown) of a molding machine (not shown) is filled at least partially with EPS particles, commonly referred to in the art as EPS “beads”. Prior to introducing the EPS particles, the tie anchors 44 are positioned in the mold such that the tie anchors 44 become embedded at a desired position within the fabricated block 32. In particular, the tie anchors 44 are positioned such that outer surfaces of the second tab portions 74 of the angled tabs 62 and 64 are flush with a concrete-facing surface 160 of the fabricated block 32, such that channel 70 is accessible from the concrete-facing surface 160 of the fabricated block 32, and such that at least one of the first end 76 and the second end 78 of the channel 70 is accessible from an adjacent surface of the fabricated block 32, as shown for example in
With the tie anchors 44 and the EPS particles in the mold, the molding machine is configured to apply heat to the mold, such as for example by passing hot air or steam through the mold, so as to heat the EPS particles to above their melting point. The applied heat causes the EPS particles therein to form a continuous foam body (not shown) in which the tie anchors 44 are embedded.
Each block 32 has interlocking features that enable it to be fitted with other blocks 32 during assembly of the concrete formwork 30. In the example shown in
In use, the concrete formwork 30 is assembled by arranging a plurality of blocks 32 end-to-end such that tongues 164 engage grooves 166 of horizontally abutting blocks, and by stacking the blocks 32 in a staggered manner such that pedestals 168 engage recesses of vertically abutting blocks 32. Tie members 46 are then slideably inserted into the channels of the tie anchors 44, to connect the tie members 46 and the tie anchors 44. Vertically abutting tie members 46 are connected using first connectors 124 by inserting the tongues 126 into the recesses 136, and by engaging the second connectors 138 to yield columns 140 of connected tie members 46. A connecting rod 120 is then seated on three (3) horizontally adjacent tie members 46, such that the notches 142 of the connecting rod 120 engage the notches 118 of the tie members 46. With the connecting rod 120 positioned in this manner, the horizontally adjacent tie members 46, and the tie members 46 below and connected within columns 140, are linked, as shown in
Spacers 150 are then embedded into the panels 34, and the panels 34 are fastened to the fastening plates 74 of the tie members 46 using fasteners F, which in the example shown are screws. With the panels 34 fastened to the tie members 46, the blocks 32 and the panels 34 define the volume 42 into which concrete is to be poured to form the wall. Reinforcement bar may be laid in the recesses 114 of the webs 86 of the tie members 46 prior to pouring of the concrete. Concrete is then poured into the volume 42, and is allowed to set. Once the concrete has set, concrete wall 170 is formed. The panels 34 may then be removed, exposing an interior surface of the concrete wall 170 on which the spacers 150 are visible, as shown in
If the panels 34 are expanded polystyrene (EPS) foam panels, the removed panels 34 can be reused as an insulating layer during subsequent construction of a concrete floor slab. For example,
As will be appreciated, the flanges 98 of the tie members 46 are configured to facilitate fastening of the panel 34 by providing a laterally enlarged area for fastening, and by impeding rotation of the tie member 46 relative to the panel 34 during fastening. As will be understood, this advantageously allows the panels 34 to be fastened more easily by workers at the construction site, and advantageously allows to the panels 34 to be fastened to the tie members 46 in a perpendicular manner more quickly, as compared to prior art tie members forming part of prior art concrete form ties.
As will be appreciated, the first connectors 124 of the tie members 46 enable the free ends (i.e. the ends of the tie members 46 distal from the tie anchors 44) of vertically abutting tie members 46 to be connected, which prevents relative lateral movement of the members 46. As will be understood, this connection unifies the panel fastening surfaces 96 of the tie members 46 within the columns 140, which advantageously allows the panels 34 to be fastened more easily by workers at the construction site, and advantageously allows to the panels 34 to be fastened to the tie members 46 in a perpendicular manner more quickly, as compared to prior art tie members forming part of prior art concrete form ties.
As will be appreciated, when the connecting rod 120 is seated on three (3) tie members 46 within the concrete formwork 30, the connecting rod 120 links the free ends of the three (3) tie members 46, and the tie members 46 below and connected within columns 140, and maintains parallel alignment of the tie members 46 of the linked columns 140. As will be understood, this alignment advantageously ensures that the panel fastening surfaces 96 of i) the tie members 46 on which the connecting rod 120 is seated and ii) the tie members 46 below and connected within columns 140, are all parallel. As will be understood, this parallel alignment of all panel fastening surfaces 96 advantageously allows the panels 34 to be fastened more easily by workers at the construction site, and advantageously allows to the panels 34 to be fastened to the tie members 46 in a perpendicular manner more quickly, as compared to prior art tie members forming part of prior art concrete form ties.
The concrete formwork 30 and components thereof are not limited to the configuration described above, and in other embodiments, other configurations are possible. For example,
Similar to tie member 46, the tie member 246 also comprises the plurality of connectors for enabling vertically abutting tie members 246 to be connected. Each tie member 246 comprises the first connector 124 at each end of the panel fastening plate 84, and the second connector 138 at each end of the longitudinal base 92 of the rail 82.
Still other configurations are possible. For example,
Concrete formwork 430 comprises a plurality of blocks 432 fabricated of an insulating material, the plurality of panels 34, and a plurality of ties connecting the blocks 432 and the panels 34. When connected by the ties, the blocks 432 and the panels 34 define the volume into which the concrete is to be poured. In this embodiment, each block 432 is fabricated of expanded polystyrene (EPS) foam by molding.
Each tie comprises a tie anchor 444 and a tie member 446, which are separately fabricated. The tie anchor 444 is configured to be embedded in a respective block 432 during fabrication of the block 432. The tie member 446 is configured to be connected to the embedded tie anchor 444 during assembly of the concrete formwork 430. The tie anchor 444 and the tie member 446 are each fabricated of a single piece of material, and in particular the tie anchor 444 and the tie member 446 are each fabricated of polyurethane by injection molding.
The tie anchor 444 may be better seen in
The tie member 446 may be better seen in
The tie member 446 also comprises a plurality of connectors for enabling vertically abutting tie members 446 to be connected. In the example shown, each tie member 446 comprises the first connector 124 at each end of the panel fastening plate 84. As discussed above for tie member 46, when vertically adjacent tie members 446 abut, the tongue 126 of one connector 124 is received in the recess 136 of another connector 124, and relative lateral movement of tie members 446 is prevented. Each tie member 446 also comprises the second connector 138 at each end of the longitudinal guide 482. The second connector 138 is configured to engage a second connector 138 of a vertically abutting tie member 46. In the example shown, each second connector 138 is in the form of the hook-shaped clip. As will be understood, when vertically adjacent tie members 46 abut, the second connector 138 of one tie member 46 engages the second connector 138 of another tie member 46, and relative vertical movement of the tie members 46 is prevented. Vertically abutting tie members 446, connected in this manner by connectors 124 and 138, yield columns 540 of connected tie members 446.
Although in the embodiments described above, the panels are fabricated of EPS foam, or of a rigid sheet material such as plywood, oriented strand board (OSB), and the like, in other embodiments, the panels may alternatively be fabricated of other suitable foam materials, such as for example extruded polystyrene (XPS) foam, or of other suitable rigid sheet materials, such as for example drywall. Still other materials or combinations of materials may alternatively be used.
Although in the embodiments described above, each of the tie anchor and the tie member is fabricated of a single piece of material, in other embodiments, one or both of the tie anchor and the tie member may alternatively be fabricated of more than one (1) piece of material.
Although in the embodiments described above, each of the tie anchor and the tie member is fabricated of polyurethane by injection molding, in other embodiments, one or both of the tie anchor and the tie member may alternatively be fabricated of another material, and/or by another suitable fabrication method.
Although in the embodiments described above, the tie anchor comprises a web comprising a plurality of struts, in other embodiments, the tie anchor may alternatively comprise a web having a different configuration, such as a web having a generally planar shape and comprising a central aperture. Still other configurations are possible.
Although in an embodiment described above, the tie anchor comprises the guide comprising the base plate and the angled tabs which define a channel that is sized to receive the portion of the tie member, in other embodiments, the tie anchor may alternatively comprise other features that define a channel that is sized to receive the portion of the tie member.
Although in an embodiment described above, the tie anchor comprises a longitudinal rib having a series of spaced knobs formed thereon, in other embodiments, the tie anchor may alternatively be comprise another configuration configured to be slideably received in the longitudinal slot of the tie member. For example, in one such embodiment, the tie anchor may alternatively comprise a longitudinal rib having a longitudinal tab or rail formed thereon. Other configurations are possible.
Although in an embodiment described above, the tie member comprises a longitudinal guide having a generally “C-shaped” section along its length and defining a longitudinal channel that is sized to accommodate a portion of the tie anchor, in other embodiments, the tie member may alternatively be comprise another configuration configured to accommodate a portion of the tie anchor. For example, in one such embodiment, the tie member may alternatively comprise a series of angled tabs extending from a longitudinal baseplate, which define a channel that is sized to accommodate a portion of the tie anchor. Other configurations are possible.
Although in the embodiments described above, the tie member has a panel fastening plate comprising two (2) pairs of laterally extending flanges, in other embodiments, the tie member may alternatively have a panel fastening plate comprising one (1) pair, or greater than two (2) pairs, of laterally extending flanges, with each flange defining a portion of the fastening surface.
Although in an embodiment described above, the connecting rod is in the form of a longitudinal angled rod, in other embodiments, the connecting rod may alternatively be in another form, such as in the form of a notched strip, for example.
Although in the embodiments described above, the concrete formwork comprises a connecting rod having linking features, in other embodiments, the concrete formwork may alternatively comprise a generic rod such as a length of reinforcement bar (“rebar”), or other rod or length or strip of material, and each tie member may alternatively have a clip for securing the rod to the tie member. In still other embodiments, the connecting rod may alternatively comprise clips, with each clip being securable to a respective tie member.
Although in the embodiments described above, each block has interlocking features comprising a tongue formed on a first side, and a groove formed in a second, opposing side for enabling horizontally abutting blocks to engage each other in an end-to-to end manner, in other embodiments, each block may alternatively have other provisions for enabling adjacent blocks to engage each other in an end-to-end manner. Similarly, although in the embodiments described above, each block has interlocking features comprising two (2) pedestals formed on a top side, and two (2) corresponding recesses formed on a bottom side for enabling blocks to be stacked, in other embodiments, each block may alternatively have other provisions for enabling blocks to be stacked.
Although in the embodiments described above, the concrete formwork comprises spacers embedded in the panel such that each spacer creates a fixed space between the concrete-facing surface of the panel and the tie member, in other embodiments, the concrete formwork may alternatively comprise spacers not embedded in the panel but rather inserted between the panel and the tie member, which may optionally held in place by the fasteners. In still other embodiments, the concrete formwork may alternatively comprise no spacers between the concrete-facing surface of the panel and the tie member.
Although embodiments have been described above with reference to the accompanying drawings, those of skill in the art will appreciate that variations and modifications may be made without departing from the scope thereof as defined by the appended claims.
