Concrete form & stake assembly and method of making same

Information

  • Patent Grant
  • 6705582
  • Patent Number
    6,705,582
  • Date Filed
    Wednesday, August 29, 2001
    23 years ago
  • Date Issued
    Tuesday, March 16, 2004
    20 years ago
  • Inventors
  • Examiners
    • Lee; Jong-Suk (James)
    Agents
    • Laurenzo; Brian J.
    • Hunt; Jason M.
    • Gilchrist; Michael C.
Abstract
An assembly of concrete forms for use in the placement of concrete, the assembly having a pair of longitudinal form members and a ground engaging member that is in contact with at least one of the longitudinal form members. A first longitudinal form member slidably overlaps a second longitudinal form member such that the length of the combination of longitudinal form members is adjustable. Inverted U-shaped channels are provided at the top of each of the longitudinal form members which allow a male/female overlapping relationship and provide a location to receive the ground engaging member. A radius form member includes a longitudinal form member with a horizontal component or inverted U-shaped channel having successively spaced apart slots thereon, so that the radius form member is flexible. To create an angle, a corner forming bar is also provided for the assembly, extending between two of the longitudinal form members. A ground engaging member with a guide slot and locking mechanism is also provided for securing the longitudinal form members in place. A ground engaging member is provided for use with a footing. A method of forming the concrete form assembly is also disclosed.
Description




BACKGROUND OF INVENTION




The invention relates to the field of concrete form work. In particular, the present invention provides a novel form, stake, and form assembly, and method of making the same, for use in the placement of concrete.




Concrete form and stake assemblies are used extensively for the placement of concrete in order to shape and contain the concrete, to create such things as sidewalks, driveways, footings, and concrete slabs. Preparation of a site for the placement of concrete, involves, after leveling off the area, erecting a frame to contain the concrete. Erecting the frame for concrete placement commonly involves: the placement of stakes; attaching the form members to the stakes by nailing the form into place; and ultimately forming a cavity within the completed assembly of forms into which concrete is placed. To cover a length larger than any one form, forms in the past have been abutted end-to-end to cover the additional length necessary. The concrete is placed into the cavity within this frame. The frame is then removed once the concrete has set.




Frames erected for the placement of concrete conventionally are constructed of lumber. Often, in order to accommodate the various dimensions of frames, the lumber must be cut to shorter lengths to accommodate specific projects, making it unlikely the lumber will be used on a subsequent project of differing dimensions. Further, the necessary nailing or other means of attaching the wooden forms to the stakes results in damage to the lumber—the end result being that the lumber is likely consumed in the placement of one slab of concrete. Another problem with using lumber is that it does not bend well to form a radius. As a result, other materials may be necessary to form a radius or significant time is expended in shaping the wood. Furthermore, because concrete tends to stick to the wood, the wood forms cannot be removed at the end of the day. Instead, the worker must return on a second day to retrieve the forms after the concrete has sufficiently set.




Some alternatives to wooden forms have been used. One such alternative is to use a flexible plastic form. These forms have the ability to flex to accommodate various grades of land and to accommodate slight curves. However, to accommodate lengths longer than any one form, the plastic forms are abutted end-to-end. Thus, in order to accommodate a specific length it may be necessary to purchase a specific length form or to cut a form to the specific length, both of which are inefficient and costly.




One solution to the drawbacks of both the wooden and plastic forms has been to provide a metal formwork board that will not be consumed during one project and can therefore be used in subsequent projects. Traditionally, these metal formwork boards were abutted end-to-end, as was the case with the wooden forms, to accommodate lengths longer than a single form board. However, the problem with such an assembly is that without specific lengths of metal forms, it is difficult to modify the forms to accommodate the various lengths necessary to build an appropriate size frame.




Thus, as disclosed in U.S. Pat. No. 5,655,336, one attempt to accommodate specific length frame sizes was to use a telescopic metal form board that extends to various lengths. As a telescopic form, the form can be expanded to a desired length within a limited range to accommodate various frame sizes. A problem with telescopic frames is, however, that the frames are generally of a C-shaped cross-section and consist of successively smaller C-shaped components fitting within a larger C-shaped component. Due to the C-shape and function of the telescopic components, the successive telescopic forms must be either abutted end-to-end or slid within each other to accommodate lengths greater than any one telescopic form. As a result, the assembly and disassembly of the forms, particularly for forms that are slid within one another, requires sliding the C-shapes together or apart before securing the forms in place. Unless these forms are kept extremely clean, the C-shape forms will not slide within one another, adding unwanted additional time and energy for a worker to thoroughly clean the form and to slide the forms together before securing the form to the ground. These forms, due to the C-shaped cross-section cannot be used to create a radius, or curved portion for the frame. Furthermore, the telescopic forms are quite bulky, due to the series of components that must be slid within one another, requiring significant space for transport and storage, as well as adding additional weight. Additionally, the C-shape of these forms is difficult to manufacture.




Problems also exist with respect to the stakes and the structure for securing the stakes to the form boards. Various types of stakes and methods of securing the stakes to the form boards have been used to secure the form boards in place on the ground. For example, simple metal stakes of various lengths have been used. These stakes are driven into the ground, and often have holes drilled through them so as to allow a nail to be driven through the stake and into the wooden form board to secure the board in place. Wooden stakes could also be used with nails driven through them and into the form boards to secure the forms in place. Alternative stake systems that have been used consist of holes vertically spaced throughout the form members so that a stake may be inserted into the hole and subsequently driven into the ground to secure the form in place, or alternatively, using a clip or other means to attach the stake at the outside of the form member.




The problems with these prior stakes are various. First of all, stakes that require nails to be driven through same result in damage to the form boards as already discussed. Furthermore, these stakes require the worker to have additional materials available while constructing the frame. Stakes that require vertically driven holes in the forms require that the stakes be placed in certain exact locations, not allowing for the adjustments needed for variations in terrain or other factors. Additionally, for those telescopic forms that require the stake to be driven through the form member, the placement of the holes in the form boards limits the distances the form boards can be extended in order to insert the stakes through the forms. Finally, for stakes that are set to the side of the forms, two problems arise. First, the weight of the forms is not balanced properly on the stake, resulting, if the stake is not driven in far enough, in the possibility that the form and stake assembly may lean to one side. Second, the side attachments for the stakes are additional components that the worker must carry and have available for assembly of the frame, creating additional set-up time, the requirement of more storage space, and more items to transport.




Furthermore, the above described stakes are not adequate to be used simultaneously for placement of concrete in a trench footing and the creation of a concrete slab. Prior stakes typically are straight, not including any angles or offset, resulting in the attachment of a concrete form board directly above the location of placement of the stake into the ground. Typically, in creation of a footing, a trench is first formed and concrete is placed into the trench. Subsequently, the concrete slab is created above the filled trench by the use of concrete form members and stakes. However, this is a two step process, requiring additional time and materials. To limit this to a single step process the above-mentioned stakes are placed into the ground prior to filling the trench. The result is that the side wall of the trench is likely to collapse due to the close proximity of the stake to the trench to create a concrete slab above the footing. Therefore, to create a trench footing simultaneously with the creation of a concrete slab, an offset is needed in the stake to provide space between the wall of the trench and the location of insertion of the stake into the ground to avoid this problem of trench cave in.




In view of the foregoing, therefore, a need exists for a concrete form assembly that is light weight, easy to clean, easy to manufacture, reusable, easy and quick to assemble and disassemble, and capable of conforming to any length, for use with a ground engaging member that does not result in damage to the form, is simple to use, and comprises few parts. A need also exists for radius forms to be used with such an assembly, and for stakes for use in the creation of a trench footing simultaneously with the creation of a concrete slab without the cost of additional materials or time.




The difficulties encountered in the prior art are substantially eliminated by the present invention.




SUMMARY OF THE INVENTION




An object of the present invention is to provide a novel form, stake, and form assembly for use in the placement of concrete.




A second object of the present invention comprises form members that overlap one another, allowing simple and quick assembly and disassembly of the concrete form and stake assembly.




A third object of the present invention comprises form members that overlap so as to adjust to any length necessary for frames of a particular dimension.




Another object of the present invention is to provide thin concrete form members so that the forms may be overlapped without forming a significant ridge on the concrete face of the form.




A further object of the present invention comprises overlapping metal forms that are easy to clean, but still function effectively with debris remaining on the form.




An additional object of the present invention comprises concrete form members that are light weight, and thin, to accommodate easy and compact storage and transport.




A still further object of the present invention comprises radius form members that function in the same manner as non-radius forms, yet provide the ability to flex or bend in either direction.




One more object of the present invention comprises stakes that fit functionally within an extension of a concrete form member for resting the form on the stake and for easy assembly and disassembly of the concrete form and stake assembly.




Another object of the present invention comprises ground engaging members that have attached locking mechanisms to provide for securing the ground engaging member in place without separate additional materials.




A further object of the present invention comprises providing a novel stake for use with a footing.




By the present invention, it is proposed to overcome the difficulties encountered heretofore. To this end, an assembly for concrete forms for use in the placement of concrete, in which the concrete forms are light weight, easy to manufacture, easy to clean, and capable of being stacked in a compact fashion, is provided. The concrete form assembly comprises a first longitudinal form member with a first end and a second end; a second longitudinal form member with a first end and a second end; a ground engaging member in contact with at least one of the first and second longitudinal form members; and the second end of the first longitudinal form member slidably overlapping the first end of the second longitudinal form member, allowing the combination of first and second overlapping longitudinal form members to be adjusted for length by varying the amount of longitudinal overlap.




These and other objects will become apparent upon reference to the following specification, drawings, and claims.











BRIEF DESCRIPTION OF THE DRAWINGS





FIG. 1

shows a perspective view of a preferred embodiment of the assembly of the present invention.





FIG. 2

shows a cross-sectional view of the assembly of

FIG. 1

along axis


2





2


.





FIG. 3

shows a cross-sectional view of an alternative embodiment of a concrete form member with an inverted L-shaped cross-section.





FIG. 4

shows an end elevational view of several concrete form members stacked together for transport and storage.





FIG. 5

shows a perspective view of the assembly of

FIG. 1

with the ground engaging member having a guide slot and locking mechanism thereon.





FIG. 6

shows a perspective view of the assembly of the present invention, with first and second concrete form members in an extended position.





FIG. 7

shows a perspective view of the assembly of the present invention, with first and second concrete form members in a retracted position.





FIG. 8

shows a perspective view of the assembly of

FIG. 1

, showing the top overlapping concrete form member lifted off of the lower concrete form member.





FIG. 9

shows a side elevational view of the ground engaging member of the present invention.





FIG. 10

shows a side elevational view of an alternative embodiment of the ground engaging member, including a guide slot and tightening means, in which the tightening means extends through the ground engaging member.





FIG. 11

shows a side elevational view of an alternative embodiment of the ground engaging member, including a guide slot and tightening means, in which the tightening means is a bent rod.





FIG. 12

shows a side elevational view of an alternative embodiment of the ground engaging member, including a guide slot and tightening means, in which the tightening means extends through the guide slot.





FIG. 13

shows a side elevational view of an alternative embodiment of the ground engaging member with a guide slot and cam type lever.





FIG. 14

shows a cross-sectional view of a concrete form member received within the guide slot and locked with the tightening means shown in FIG.


12


.





FIG. 15

shows a side elevational view of the ground engaging member for use with a footing.





FIG. 16

shows a side elevational view of an alternative embodiment of the ground engaging member for use with a footing, including a guide slot and locking mechanism thereon.





FIG. 17

shows a perspective view of the assembly of the present invention, including a ground engaging member for use with a footing.





FIG. 18

shows a perspective view of an embodiment of the radius concrete form member with tapered horizontal extensions.





FIG. 19

shows a perspective view of a radius concrete form member.





FIG. 20

shows a top plan view of a radius concrete form member that is straight.





FIG. 21

shows a top plan view of the radius concrete form member of

FIG. 20

, curved in an inward direction.





FIG. 22

shows a top plan view of the radius concrete form member of

FIG. 20

, curved in an outward direction.





FIG. 23

shows a perspective view of an assembly of the present invention with a radius concrete form member.





FIG. 24

shows a perspective view of an assembly of the present invention, with the addition of a third concrete form member angled away from the second concrete form member and a corner bar extending from the second concrete form member to the third concrete form member, forming an outside corner.





FIG. 25

shows a perspective view of a concrete form member with a notch for forming an inside corner.





FIG. 26

shows a perspective view of an inside corner.





FIG. 27

shows a top elevational view of the concrete form members connected so as to form a cavity within the forms.





FIG. 28

shows the cavity of

FIG. 24

with the addition of concrete placed into the cavity.











DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS




The Figures show an assembly of concrete forms


30


for use in the placement of concrete, in which the concrete form members


32


,


34


are light weight, easy to manufacture, easy to clean, and capable of being stacked in a compact fashion. The concrete form members


32


,


34


, due to the thinness of the form material used, are capable of being stacked in a compact fashion (see

FIG. 4

) for both transport and storage. The assembly of concrete forms


30


has a first longitudinal form member


32


(see FIGS.


1


&


2


), a second longitudinal form member


34


engaging the first longitudinal form member


32


so that the first longitudinal form member


32


slidably overlaps the second longitudinal form member


34


, allowing the combination of the first


32


and second


34


longitudinal form members to be adjusted for length by varying the amount of longitudinal overlap (see FIGS.


6


&


7


), and at least one ground engaging member


36


is also present that is both in contact with at least one of the first


32


and second


34


longitudinal form members and in contact with the ground


38


.




The first longitudinal form member


32


and the second longitudinal form member


34


in a preferred embodiment are constructed of 18-gauge galvanized steel, although it is contemplated by this invention that other types of metal, such as for example, stainless steel, steel with epoxy resin overlay, or aluminum, and gauges of metal, such as 16-gauge galvanized steel, may be used, as well as other materials, such as plastic or wood shaped as the forms of the present invention. In a preferred embodiment each longitudinal form member is ten (10) feet in length. Although those of ordinary skill in the art will understand that any length longitudinal form member is functional with the assembly


30


. As a steel form, concrete does not stick to the form as much as the wood forms of the prior art, and therefore the form is easier to clean and can be removed from the assembly much sooner than wood. More particularly, at the end of the day, after the concrete has been placed, the worker may remove the concrete form members. Therefore, a return trip to the job site at a later date to remove the forms is often not required. Secondly, as a thin gauge of metal, the forms are relatively light weight and capable of being stacked in a compact fashion (FIG.


4


). In a preferred embodiment, up to twenty (20) forms can be stacked and carried at once. Furthermore, as a thin steel form with very few bends or extensions, the longitudinal form members are easy to manufacture.




As best seen in

FIG. 8

, the first longitudinal from member


32


has a first end


40


and a second end


42


, and a top portion


48


and a bottom portion


50


. Similarly, the second longitudinal form member


34


has a first end


44


and a second end


46


, and a top portion


52


and a bottom portion


54


. In each of the first


32


and second


34


longitudinal form members, a forming component


55


is present. The forming component


55


has a face


57


that, when the concrete is placed into the frame, faces and is in contact with the concrete. This forming component


55


can be varied in height by using different forms to accommodate different depths of concrete. A preferred embodiment uses varying heights of two (2) inches to ten (10) inches, generally 2, 4, 6, 8, 10 inches, though those of ordinary skill in the art will understand that the exact measurements are not crucial.




Extending from the top portion


48


,


52


of each of the first


32


and second


34


longitudinal form members is a horizontal component


53


,


56


with a downward extension


58


,


59


forming an inverted U-shaped channel


60


,


62


on each of the longitudinal form members. In a preferred embodiment, the horizontal component


53


,


56


for each respective form member is the equivalent width of the associated downward extension


58


,


59


of each respective form. However, those of ordinary skill in the art will understand that the exact measurements are not crucial, so long as a downward extension


58


,


59


exists to create an inverted U-shaped channel. More specifically, each longitudinal form member has four frame elements: a generally vertical first frame element or downward extension


58


,


59


; a generally horizontal second frame element, or horizontal component


53


,


56


; a generally vertical third frame element or upper vertical section


49


,


51


; and a generally vertical fourth frame element or lower vertical section


50


,


54


. These four sections are interconnected, forming the respective longitudinal form members


32


,


34


. Particularly, the first frame element


58


,


59


is integrally connected with the second frame element


53


,


56


so that the first frame element


58


,


59


extends below the second frame element


53


,


56


. The opposing end of the second frame element


53


,


56


is integrally connected to the third frame element


49


,


51


, which also extends below the second frame element


53


,


56


, resulting in the second frame element


53


,


56


positioned between the first frame element


58


,


59


and the third frame element


49


,


51


. Finally, the fourth frame element


50


,


54


, or bottom portion of the longitudinal form member


42


,


34


, is connected to the third frame element


49


,


51


. The fourth frame element


50


,


54


extends axially below the third frame element


49


,


51


so that it extends beyond the length of the first frame element


58


,


59


. The combination of the first frame element


58


,


59


, the second frame element


53


,


56


, and the third frame element


49


,


51


forms the inverted U-shaped channel


60


,


62


.




Furthermore, in one embodiment the longitudinal form member


32


,


34


includes a stiffener


64


, at the bottom portion


50


,


54


of the concrete form member to decrease the flexibility of the thin metal form (See FIG.


2


). This stiffener


64


in a preferred embodiment is typically either material added to the thin metal longitudinal form member


32


,


34


, or a folding-over of the bottom portion


50


,


54


of the longitudinal form member


32


,


34


, which strengthens the form and reduces the flexibility. This addition of the stiffener


64


is done so as to not interfere with the overlapping of the longitudinal form members


32


,


34


. In other words, the advantages created by the thinness of the first


32


and second


34


longitudinal form members are retained.




The inverted U-shaped channels


60


,


62


are of slightly different widths (FIG.


2


). The first inverted U-shaped channel


60


, extending from the first longitudinal form member


32


, is of a slightly larger width than the second inverted U-shaped channel


62


, extending from the second longitudinal form member


34


, so that the second longitudinal form member


34


fits slidably within the first longitudinal form member


32


in a male/female relationship (FIGS.


1


&


2


). More specifically, the horizontal component


53


of the first longitudinal form member


32


is of a greater width than the horizontal component


56


of the second longitudinal form member


34


. As a result, the second end


42


of the first longitudinal form member


32


can be matingly and slidably overlapped with the first end


44


of the second longitudinal form member


34


, allowing the form members to be adjusted for varying frame lengths by sliding the longitudinal form members or lifting the first longitudinal form member


32


off of the second longitudinal form member


34


(

FIG. 8

) and repositioning it, so as to vary the amount of longitudinal overlap. Similarly, the lifting off and/or repositioning of the first longitudinal form member


32


provides for quick assembly and disassembly of the frame. Furthermore, this male/female relationship provides for a close engagement between the first


32


and second


34


longitudinal form members so that no sizeable ridge on the concrete face is created from the overlap of forms. Alternatively, the first and second longitudinal form members could be of an inverted L-shaped cross-section


66


(see FIG.


3


), in which there would be no need for varying the width of the horizontal extension


68


. Instead, the form members would simply be overlapped so that the horizontal extensions


68


would rest upon the top of one another.




The inverted U-shaped channel


60


,


62


of either the first longitudinal form member


32


or the second longitudinal form member


34


receives a ground engaging member


36


(FIGS.


2


&


5


). The ground engaging member


36


is of a sufficient width or diameter so that it fits within the narrower inverted U-shaped channel


62


of the second longitudinal form member


34


. In a preferred embodiment, the ground engaging member is a one (1) inch round stake. It is also contemplated that any stake currently used in the art upon which the form members could sit is functional with the assembly. Furthermore, the ground engaging end


70


of the ground engaging member


36


is in contact with the ground


38


. Preferably, the ground engaging end


70


is inserted or pounded into the ground


38


. Alternatively, it is contemplated that a ground engaging member could be used in which the ground engaging member is not inserted into the ground, but in contact with the surface of the ground, using a wide flat base or a weighted base to prevent the ground engaging member from moving. The form engaging end


72


of the ground engaging member is in contact with one of the horizontal components


53


,


56


of either inverted U-shaped channel


60


,


62


. As a result, the longitudinal form members


32


,


34


are supported by the contact between the horizontal component


56


and the ground engaging member


36


, and, therefore hang from the ground engaging member. This hanging of the longitudinal form member allows for quick assembly and disassembly of the concrete form and stake assembly because there is no need to nail anything in place or to attach any locking devices to the form or ground engaging member. It is noted that the second longitudinal from member


34


and its horizontal component


56


are used here merely for illustrative purposes, and the equivalent contact and support is also possible for the first longitudinal form member


32


with horizontal component


53


, when placed in contact with the ground engaging member


36


.




Alternatively, an embodiment of the ground engaging member


36


with an attached guide slot


74


and locking mechanism


76


for securing either of the longitudinal form members


32


,


34


in place on the ground engaging member


36


is provided (FIGS.


10


-


14


). The guide slot


74


comprises a horizontal extension


75


that extends from the ground engaging member


36


and has at the end of the horizontal extension


75


opposite the ground engaging member


36


a vertical lip


77


extending above the horizontal extension


75


. The combination of horizontal extension


75


and vertical lip


77


forms a channel, or guide slot


74


, that is capable of receiving at least one of the longitudinal form members. In one embodiment, as shown in

FIG. 10

, the form engaging end


72


of the ground engaging member


36


is milled down to provide a better fit with the longitudinal form member. Generally, the guide slot and locking mechanism provide the advantage of the ability to secure the forms without the need for additional materials and without damaging the forms.




An embodiment of the locking mechanism


76


comprises, as shown in

FIG. 10

, a tightening means


78


, such as for example a screw, that extends through the ground engaging member


36


. Other possible tightening means are a screw extending through the guide slot


74


, a bent rod


69


, a cam type lever


80


, a hammer tapered wedge, a tapered friction fit device, or other tightening means known in the art. The guide slot


74


and locking mechanism


76


function by one of the longitudinal form members


32


,


34


, preferably the longitudinal form member that receives the ground engaging member


36


, mating with the guide slot


74


and locking in place with the locking mechanism


76


. More particularly, the locking mechanism


76


functions by inserting the forming component


55


of one of the longitudinal form members


32


,


34


into the guide slot


74


for the ground engaging member


36


, then tightening, for example, the screw


78


, which extends through the ground engaging member


36


, so that the threaded end


79


of the screw


78


presses against the forming component


55


of the form member, wedging the forming component


55


between the guide slot


74


and the tightening means


78


.




A preferred embodiment of the ground engaging member


36


with attached guide slot


74


and locking mechanism


76


is shown in FIG.


11


. In this embodiment, the locking mechanism


76


is an bent rod


69


. This bent rod


79


is threaded similar to a screw, and has a form contact end


71


which extends through the vertical lip


77


of the guide slot


74


, an operational end


73


, and a rod angle


67


between the form contact end


71


and the operational end


73


. The bent rod


69


locking mechanism functions by inserting the form engaging end


72


of the ground engaging member


36


into the inverted U-shaped channel


60


,


62


of either longitudinal form member


32


,


34


, the downward extension


58


,


59


of either inverted U-shape channel


60


,


62


inserting into the guide slot


74


. Subsequently, the operational end


73


of the bent rod


69


is rotated so as to bias the downward extension


58


,


59


between the form contact end


71


of the bent rod


69


and the ground engaging member


36


.




A third embodiment of the locking mechanism


76


includes, as shown in

FIGS. 12 & 14

, a tightening means, or screw


78


, as described above, that extends through the guide slot


74


of the ground engaging member


36


. This locking mechanism


76


functions by inserting the downward extending portion


58


,


59


of either inverted U-shaped channel


60


,


62


into the guide slot


74


of the ground engaging member


36


, then tightening the tightening means


78


so that the threaded end


79


of the screw


78


presses against the downward extending portion


58


,


59


of either inverted U-shaped channel


60


,


62


, wedging the downward extending portion


58


,


59


of the inverted U-shaped channel between the ground engaging member


36


and the tightening means


78


. Alternatively, the forming component


55


of one of the longitudinal form members


32


,


34


may be inserted within the guide slot


74


and locked in place in the same manner.




A fourth embodiment of the locking mechanism involves, as shown in

FIG. 13

, a cam type lever


80


. The cam type lever


80


functions by inserting the downward extending portion


58


of either of the inverted U-shaped channels


60


,


62


, or the forming component


55


of one of the longitudinal form members


32


,


34


, into the guide slot


74


, then rotating the lever


80


away from the stake into the engaging position, which in turn causes the downward extending portion


58


,


59


of an inverted U-shaped channel


60


,


62


or the forming component


55


of the longitudinal form member


32


,


34


, whichever is inserted into the guide slot


74


of the ground engaging member


36


, to be biased against the guide slot


74


between the form engaging end


82


of the cam type lever


80


and the guide slot


74


.




It is further contemplated that the guide slot


74


could be used without a locking mechanism


76


or without tightening the locking mechanism


76


. Alternatively, a locking mechanism


76


might be used without the guide slot


74


. Furthermore, the guide slot


74


could operate by receiving both of the longitudinal form members


32


,


34


or their inverted U-shaped channels


60


,


62


.




An additional embodiment of the ground engaging member


36


is an offset ground engaging member


84


for use when placing concrete into a trench


81


to create a footing simultaneously with the creation of a concrete slab (FIGS.


15


-


17


). While it is not necessary to use this offset ground engaging member


84


with the concrete form assembly


30


, the offset ground engaging member


84


is functional with the assembly


30


(FIG.


17


). The offset ground engaging member


84


includes a top portion


86


, or form engaging arm, which is placed in contact with one of the longitudinal form members; an offset arm


94


connected to the form engaging arm


86


at the offset side


96


of the offset arm


94


; and a bottom portion


88


, the ground engaging arm, which is connected to the offset arm


94


at the ground engaging side


98


of the offset arm


94


, and which ground engaging arm


88


is placed in contact with the ground


38


.




In a preferred embodiment of the offset ground engaging member


84


, the offset arm


94


is substantially perpendicular to the form engaging arm


86


and includes a first angle


90


. The first angle


90


is generally a ninety (90) degree angle formed between the offset arm


94


, which is substantially horizontal, and the form engaging arm


86


. The form engaging arm


86


is substantially vertical, therefore the first angle


90


is formed above the offset arm


94


when the ground engaging arm


88


of the offset ground engaging member


84


is in contact with the ground


38


. The offset ground engaging member


84


also includes a second angle


92


. The second angle


92


is generally a ninety (90) degree angle formed between the offset arm


94


and the ground engaging arm


88


. The ground engaging arm


88


is substantially vertical, therefore the second angle


92


is formed below the offset arm


94


when the ground engaging arm


88


of the offset ground engaging member


84


is in contact with the ground


38


. As a result of the first angle


90


and the second angle


92


, the form engaging arm


86


is offset from the ground engaging arm


88


, and when the ground engaging arm


88


of the offset ground engaging member


84


is placed in contact with the ground


36


, the first


32


or second


34


longitudinal form member in contact with the form engaging arm


86


will be offset from the location of contact of the offset ground engaging member


84


with the ground


38


(see FIG.


17


). Alternatively, this offset ground engaging member


84


can be used with the guide slot


74


and any of the locking mechanisms previously described. As a result, the offset provides for the creation of a trench footing simultaneously with the creation of a concrete slab above the footing without additional time or materials.




In creating an assembly of concrete forms for use in the placement of concrete it is often necessary to include a radius form to accommodate curved portions of the frame. Therefore, it is advantageous to have a radius form member compatible and functional with the concrete form and stake assembly that requires minimal additional time and materials. This radius form member would be used in place of a longitudinal form member


32


,


34


, or in addition to the assembly


30


. Therefore, a radius form member


100


functional with the present invention is provided (FIG.


19


), which can be used as an alternative to either longitudinal form member


32


,


34


, or in addition to the assembly


30


of these longitudinal form members.




The radius form member


100


includes a forming component


102


equivalent to the forming component


55


of the first


32


and second


34


longitudinal form members, an upper vertical section


104


, a lower vertical section


106


extending axially below the upper vertical section


104


, a first end


108


and a second end


110


. From the upper vertical section


104


of the radius form member


100


extends a plurality of horizontal extensions


112


spaced evenly apart along the upper vertical section


104


from the first end


108


of the radius form member


100


to the second end


110


. The series of individual horizontal extensions


113


are spaced apart so that alternating between individual horizontal extensions


113


are spaces with no material, or slots


114


. Furthermore, downward extending lips


116


extend from the individual horizontal components


113


, so that the slots


114


are maintained between the horizontal extensions


113


with attached downward extending lips


116


. These horizontal extensions


113


with attached downward extending lips


116


in combination with the upper vertical section


104


form an inverted U-shaped channel


118


extending from the first end


108


to the second end


110


of the radius form member


100


with a plurality of spaced apart slots


114


. As a result of this plurality of spaced apart slots, the radius form member


100


is bendable or flexible. It is further contemplated that a single slot


114


could be used to provide the necessary flexibility.




Radius form members with different width inverted U-shaped channels


118


are provided, to allow a radius form member


100


to be used in an overlapping relationship with either the first longitudinal form member


32


or the second longitudinal form member


34


. In an alternative embodiment of the radius form member


100


no downward extending lip


116


is present, creating an inverted L-shape cross section for the radius form member. It is also contemplated that a form with no horizontal extensions


113


could be used to create a radius. Alternatively, the horizontal extensions


113


could be tapered at the end furthest from the forming component


102


of the radius form member


100


, to provide a greater degree of flexibility for the radius form member


100


(FIG.


18


).




The plurality of spaced apart slots


114


on the inverted U-shaped channel


118


of the radius form member


100


(

FIG. 20

) or even a single slot


114


on the inverted U-shaped channel


118


, allows the radius form member to be bent or flexed around a vertical axis. To form the inward bend of a curve, as shown in

FIG. 21

, the radius form member


100


is flexed so that the outer edges


120


of the individual successively spaced apart horizontal extensions


113


move closer together as the radius becomes smaller. At its smallest, the radius form member


100


is flexed so that the outer edges


120


of the plurality of individual spaced apart horizontal components


113


are in contact with one another, in a preferred embodiment, this radius is a twelve (12) inch radius. The radius form member


100


may also be flexed in the opposite direction, forming the outward bend of a curve (see FIG.


22


). In forming the outward bend of a curve, the radius form member


100


is flexed so that the outer edges


120


of the individual spaced apart horizontal extensions


113


move further and further apart, the maximum point of the outward bend being the point at which the forming component


102


of the radius form member


100


can no longer flex.




While it is not necessary to use the radius form member


100


with an assembly, it may be used with a radius forming assembly


122


similar to either the first longitudinal form member


32


or the second longitudinal form member


34


. A radius form member


100


with a wider inverted U-shaped channel


118


, when used as part of a radius forming assembly


122


, as shown in

FIG. 23

, overlaps a second longitudinal form member


34


. In other words, the inverted U-shaped channel


62


on the second end


46


of the second longitudinal form member


34


is received within the inverted U-shaped channel


118


on the first end


108


of the radius form member


100


, so that the combination of form members may be slidably extended or retracted for length by varying the amount of longitudinal overlap, and so that the radius form member


100


may be lifted off of the second longitudinal form member


34


. Either before or after this overlap is achieved, the radius form member


100


may then be flexed to form an inward or an outward bend (see FIGS.


21


-


23


). Alternatively, a radius form member


100


with a narrower inverted U-shaped channel


118


may be received within the U-shaped channel of the first longitudinal form member


32


, so that the first longitudinal form member


32


may be lifted off of the radius form member


100


. Similarly, the radius form member


100


as part of the radius forming assembly may be flexed to form either an inward or an outward bend. The radius form member


100


also, if necessary, receives a ground engaging member


36


within the inverted U-shaped channel


118


as part of the assembly


122


. This ground engaging member


36


is also in contact with the ground


38


. It is further contemplated that two or more radius form members


100


could be used to form the assembly


122


, as opposed to a single radius form member


100


in combination with one of the first


32


or second


34


longitudinal form members.




In preparing an assembly of concrete forms to create a cavity within which to place concrete, it is often necessary to provide corners, or sharp angles, as opposed to curves that are provided by radius forms. In doing so, it is helpful to have a means by which the angle is maintained throughout the assembly of the frame or creation of the cavity, and throughout the placement of the concrete within the cavity. Therefore with the present invention is provided a means of maintaining an angle. In particular, as shown in

FIG. 24

, a corner forming assembly


124


is provided with a first longitudinal form member


32


slidably overlapping a second longitudinal form member


34


and ground engaging members


36


, as in the concrete form assembly


30


shown in

FIG. 1. A

third longitudinal form member


126


is also provided which is angled away from the first


32


and second


34


longitudinal form members. In a preferred embodiment the third longitudinal form member


126


is oriented substantially perpendicular to the first


32


and second


34


longitudinal form members. Furthermore, ground engaging members


36


, if necessary, support the third longitudinal form member


126


and are in contact with the ground


38


. Additionally, a corner forming bar


138


, with a first end


139


and a second end


141


, extends from the second longitudinal form member


34


to the third longitudinal form member


126


. The first end


139


of the corner forming bar


138


engages the second longitudinal form member


34


, while the second end


141


of the corner forming bar


138


engages the third longitudinal form member


126


. This corner forming bar


138


is of a sufficient length so that an angle


144


is maintained between the second longitudinal form member


34


and the third longitudinal form member


126


. Furthermore, the corner forming bar


138


may be attached to the second


34


and third


126


longitudinal form members by any means known in the art, and can be made of any material known in the art, so long as it is acceptable for the purposes provided.




The third longitudinal form member


126


in the preferred embodiment, is the equivalent of the first


32


and second


34


longitudinal form members, having a first end


128


and a second end


130


, a generally vertical first frame element


135


, a generally horizontal second frame element


132


, a generally vertical third frame element


133


, and a generally vertical fourth frame element


134


. The second frame element


132


is integrally connected between the first


135


and third


133


frame elements so as to form an inverted U-shaped channel


136


. The fourth frame element


134


extends axially below the third frame element


133


. Depending upon the width of the inverted U-shaped channel


136


of the third longitudinal form member


126


, this third longitudinal form member


126


is the equivalent of either the first longitudinal form member


32


or the second longitudinal form member


34


, allowing slideable overlapping of additional longitudinal form members and capable of receiving a ground engaging member


36


within its inverted U-shaped channel


136


. As shown in

FIG. 24

, to form an outside corner the third longitudinal form member


126


is oriented, in a preferred embodiment, so that the first end


128


of the third longitudinal form member


126


is in contact with the second end


46


of the second longitudinal form member


34


and so the outside angle


144


is formed on the face


57


of the forming component


55


facing the concrete of the second longitudinal form member


34


and the face


142


of the forming component


140


of the third longitudinal form member


126


facing the concrete. Therefore, the inverted U-shaped channels of each form


60


,


62


,


136


extend away from the outside angle


144


and the cavity


146


for the concrete. It is further contemplated that the second


34


and third


126


longitudinal form members contact at any point, not exclusively the ends


46


,


128


, so long as an angle is maintained between the two longitudinal form members.




As shown in

FIG. 26

, in a preferred embodiment for the creation of an inside corner, either the second longitudinal form member


34


or the third longitudinal form member


126


is provided with a notch


137


in the inverted U-shaped channel


62


,


136


at the end of one of the longitudinal form members


46


,


128


(

FIG. 25

) forming the inside angle


145


. The longitudinal form member without the notch is inserted into the notch


137


, so that the first end


128


of the third longitudinal form member


126


is flush with the second end


46


of the second longitudinal form member


34


and the inverted U-shaped channels


60


,


62


,


136


extend toward the inside angle


145


and away from the cavity for the concrete. The notch


137


of the inverted U-shaped channel


62


,


136


is a location on the inverted U-shaped channel


62


,


136


in which a section of the downward extension or first vertical frame element


59


,


135


of the inverted U-shaped channel is absent. Typically, the absence of the downward extension


135


is the equivalent width of the horizontal component or second horizontal frame element


56


,


132


of the second horizontal frame element which is inserted into the notch


137


. However, any width greater than the width of the horizontal component may be used.




Alternative embodiments and combinations may be used with the corner forming bar


138


. For example, it is contemplated that other longitudinal form members could be used, such as a form with an inverted L-shaped cross-section. Additionally, the corner may be formed between the first


32


and third


126


longitudinal form members or even by the use of only two longitudinal form members, as opposed to three. In a preferred embodiment, an angle


144


,


145


of ninety (90) degrees between the two longitudinal form members


34


,


126


in contact with the corner forming bar


138


is preferred. However, it is contemplated that any angle could be maintained using the corner forming bar


138


simply by adjusting the placement or length of the corner forming bar


138


.




The method of making a concrete form assembly for use in the placement of concrete using the present invention further illustrates the ease and usefulness of the concrete form assembly


30


. In making the assembly


30


, first lines are marked from a first point to a second point, as is common in the art. For example, a string line could be used to mark off the location where the concrete forms are to be placed (not shown). Secondly, the ground engaging members


36


are spaced along this line and the ground engaging end


70


of the ground engaging member


36


is set in contact with the ground


38


(FIG.


1


). In the case of a stake, the stake would be driven into the ground. These ground engaging members


36


can be placed at any point along this line to accommodate for variations in terrain and other obstacles. Third, the second longitudinal form member


34


is placed in contact with form engaging end


72


of the ground engaging member


36


(FIGS.


1


&


2


). The form engaging end


72


of the ground engaging member


36


is received within a second inverted U-shaped channel


62


of the second longitudinal form member


34


. As a result, the second longitudinal form member


34


hangs from the ground engaging member


36


(FIG.


2


). Then, the first longitudinal form member


32


is placed in contact with the second longitudinal form member


34


, so that a second inverted U-shaped channel


62


of the second longitudinal form member


34


is received within a first inverted U-shaped channel


60


of the first longitudinal form member


32


(FIGS.


2


&


5


). The first longitudinal form member


32


can therefore partially (

FIG. 6

) or substantially (

FIG. 7

) overlap the second longitudinal form member


34


. The first longitudinal form member


32


may be lifted off of the second longitudinal form member


34


and readjusted to accommodate the length of the frame necessary (FIG.


8


), or the longitudinal form members


32


,


34


, due to their overlapping nature, may be slid together or apart, extending or retracting, to accommodate the same task (FIGS.


6


&


7


).




The assembly as just described is sufficient for the placement of concrete. However, if further security of the longitudinal form members is desired, a ground engaging member


36


with a guide slot


74


and locking mechanism


76


may be used (FIG.


5


). In this embodiment, the guide slot


74


receives either the first longitudinal form member


32


, the second longitudinal form member


34


, or both longitudinal form members


32


,


34


. The locking mechanism


76


is then tightened to secure the longitudinal form member in place (FIG.


14


).




Once a first concrete form assembly is created by either method discussed, additional longitudinal form members, ground engaging members, angles, and radius form members may be added to create a frame or cavity


146


. Further, an opposing barrier also must be present (

FIG. 27

) to provide a cavity


146


for the placement of concrete within the completed assembly. The concrete


148


is then placed within the cavity


146


(FIG.


28


).




The assembly of concrete forms of the present invention is adaptable to fit a wide variety of frame or cavity shapes and sizes and can be interchanged with a wide variety of components.




The embodiments shown are especially well suited for quick and easy assembly and disassembly of the concrete form assembly on the job site, and for compact storage and transport to the site. However, the invention is in no way so limited. For instance, it would be obvious to modify the invention to create interlocking components which secure the form members to each other and to the ground engaging members. It would also be obvious to include any combination of form members and ground engaging members provided.




The foregoing description and drawings merely explain and illustrate preferred embodiments of the invention, and the invention is not limited thereto, except insofar as the claims are so limited. Those skilled in the art, who have the disclosure before them, will be able to make modifications and variations therein without departing from the scope of the invention. For example, while ground engaging members


36


are used to suspend the longitudinal form members


32


,


34


in place, it is contemplated that other means could be used to hold the longitudinal form members in place, and contemplated that the longitudinal form members could be placed directly in contact with the ground.



Claims
  • 1. An assembly for concrete forms for use in the placement of concrete, in which the concrete forms are light weight and capable of being stacked in a compact fashion, the assembly comprising:a. at least one longitudinal form member having a single inverted U-shaped channel; b. at least one radius form member having a single slotted inverted U-shaped channel with at least one spaced apart slot, said radius form member capable of being bent to form a radius; c. a ground engaging member having a first end in contact with the ground and a second end vertically disposed opposite said first end; d. at least one of said longitudinal and radius form members hung from said second end of said ground engaging member, said contact between said form member and said second end of said ground engaging member occurring at said inverted channel of said form member; e. at least one of said longitudinal and radius form members overlapped and hung from said form member in contact with said second end of said ground engaging member, said contact between said longitudinal and radius form members occurring at said inverted channel, wherein one of said longitudinal and radius form members can be removed from said assembly without sliding said form members apart, and whereby the combination of said overlapping longitudinal and radius form members may be adjusted for length by varying the amount of longitudinal overlap.
  • 2. The assembly for concrete forms of claim 1, in which said ground engaging member is a stake.
  • 3. The assembly for concrete forms of claim 2, in which said stake is of uniform construction and comprises:i. a ground engaging arm; ii. an offset arm integrally connected to said ground engaging arm; and iii. a form engaging arm integrally connected to said offset arm, said form engaging arm offset from said ground engaging arm, whereby the stake for use with a footing is formed.
  • 4. The assembly for concrete forms of claim 1, in which said ground engaging member includes a guide slot and locking mechanism thereon for securing said first and second longitudinal form members in place.
  • 5. The assembly for concrete forms of claim 4, in which said locking mechanism is selected from the group consisting of a bent rod, a screw, and a cam type lever.
  • 6. The assembly for concrete forms of claim 1, in which said longitudinal form member has a stiffener attached.
  • 7. The assembly for concrete forms of claim 1, further comprising:i. a third form member angled away from said longitudinal and radius form members; ii. a corner forming bar with a first end and a second end, said first end of said corner forming bar engaging one of said longitudinal form member and said radius form member, and said second end of said corner forming bar engaging said third form member, whereby an angle is maintained between one of said longitudinal and radius form members and said third form member.
  • 8. The assembly for concrete forms of claim 7, in which at least one of said inverted channels of said form members contains at least one notch.
  • 9. The assembly for concrete forms of claim 8, in which said angle is maintained by said end of said longitudinal form member without said notch being inserted into said notch.
  • 10. A method of making a concrete form assembly comprising:a. providing a longitudinal form member having a single inverted U-shaped channel; b. providing a radius form member having a single slotted inverted U-shaped channel with at least one spaced apart slot; c. providing a ground engaging member having a first end in contact with the ground, and a second end vertically disposed opposite the first end; d. placing said first end of said ground engaging member in contact with the ground; e. placing said inverted U-shaped channel of at least one of said longitudinal and said radius form members in contact with said second end of said ground engaging member, hanging said form member from said ground engaging member; and f. at least partially overlapping and hanging one of said longitudinal and radius form members over said form member in contact with said ground engaging member, wherein said overlapped longitudinal form member can be removed from said assembly without sliding said form members apart, whereby the combination of said longitudinal and radius form members may be adjusted for length by varying the amount of longitudinal overlap, and said overlapping form member may be lifted off for disassembling the assembly.
  • 11. A method of making a concrete slab comprising the steps of claim 10 and the additional steps of providing an opposing barrier to create a cavity and placing concrete into said cavity.
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Entry
Jun. 1999 Product Brochure for Durand Forms, Footing Form System (including pictures).
Jun. 1998 Dee Streamlined Steel Forms and Stakes Brochure.
1999 Metal Forms Corp. Brochure.
Concrete Construction Article—Feb. 1990 —Title: Flatwork Forming is a Snap Using Plastic Formwork System.