Concrete forming system

Abstract

A concrete forming system includes a plurality of panels, an inside corner form, an outside corner form and a plurality of fasteners for securing the panels and forms together.

Description

TECHNICAL FIELD

The present invention relates generally to the construction field and, more particularly, to a system for forming poured concrete.

BACKGROUND OF THE INVENTION

Over the years, many different systems have been utilized to form concrete. Examples of such systems are found in U.S. Pat. Nos. 6,916,001 to Pugh, Jr. and 4,006,878 to Dawson et al. The present invention relates to a new and improved lightweight concrete forming system that advantageously utilizes reusable components and provides for the forming of precise corners in a quick and efficient manner.

SUMMARY OF THE INVENTION

In accordance with the purposes of the present invention as described herein, a concrete forming system is provided. The concrete forming system includes a plurality of panels, an inside corner form, an outside corner form and a plurality of fasteners for securing the panels and the forms together. Each of the panels includes a wall having a concrete forming surface, a recessed margin and a projecting margin. The recessed margin is provided along the first and third edges of the panel while the projecting margin is provided along the second and fourth edges of the panel. Reinforcing ribs are provided to support the concrete forming surface and the recessed margin.

The projecting margin has a thickness A and the recessed margin is recessed from the concrete forming surface by the same distance A. The projecting margin also has a width B and the recessed margin has an identical width B. The projecting margin on one panel effectively mates with the recessed margin on a second panel so that the panels effectively interlock and join with overlapping edges that provide a smooth concrete forming surface.

The inside corner form includes a first side wall, a second side wall and a gusset wall connecting the first and second side walls. Similarly, the outside corner form includes a first side wall, a second side wall and a gusset wall connecting the first and second side walls. Further, both the inside corner form and the outside corner form include reinforcing ribs to structurally support the corner forms when subjected to the weight and pressure of poured concrete during the forming process. The inside corner form and outside corner form also include recessed margins and projecting margins to allow them to mate and interlock with similar cooperating structures provided on the panels.

Adjacent panels and corner forms may be secured together by fasteners that comprise resilient clips. Specifically, the reinforcing ribs on the panels and corner forms are engaged by the fasteners to secure the components together. Each resilient clip includes a head and a pair of cooperating lugs defining a fastening channel. Each of the cooperating lugs may include fastening teeth to help secure the clips in position over the reinforcing ribs.

The concrete forming system also includes a plurality of walers which function as vertical and horizontal supports for the panels and corner forms of the concrete forming system. Still further, the concrete forming system includes a series of corner plates. Each corner plate includes a first side wall, a second side wall and a gusset wall connecting the first and second side walls. The corner plates further include a tie aperture in the gusset wall.

Each of the panels and corner forms also includes a tie aperture. The tie apertures in opposing panels and corner forms of the concrete forming system are aligned and receive steel ties of a type known in the art. These steel ties run between the opposing panels and corner forms and also extend through and beyond the supporting walers along the panels and through and beyond the tie aperture of the corner plates. By tightening wedges it is possible to maintain the panels and corner forms of the forming system parallel and a fixed distance apart.

The panels and corner forms may be constructed from a fiber reinforced polymer. The fiber reinforced polymer may include glass fibers and a polyolefin such as polypropylene. The panels and corner forms may use virgin and/or recycled materials.

In the following description there is shown and described one possible embodiment of this invention, simply by way of illustration of one of the modes best suited to carry out the invention. As it will be realized, the invention is capable of other different embodiments and its several details are capable of modification in various, obvious aspects all without departing from the invention. Accordingly, the drawings and descriptions will be regarded as illustrative in nature and not as restrictive.

BRIEF DESCRIPTION OF THE DRAWING

The accompanying drawing incorporated in and forming a part of the specification, illustrates several aspects of the present invention and together with the description serves to explain certain principles of the invention. In the drawing:

FIG. 1 a is a front perspective view illustrating an outside corner of the concrete forming assembly of the present invention;

FIG. 1 b is a rear perspective view of the assembly shown in FIG. 1a illustrating the inside corner;

FIG. 2 a is a front perspective view of a panel used in the concrete forming assembly to form straight walls of poured concrete;

FIG. 2 b is a rear perspective view of the panel illustrated in FIG. 2a;

FIG. 3 is a detailed cross sectional view illustrating how two adjacent panels interlock with overlapping edges;

FIG. 4 is a rear perspective view of an inside corner form;

FIG. 5 is a rear perspective view of an outside corner form;

FIG. 6 a is a front perspective view of a corner plate;

FIG. 6 b is a cross sectional view of the corner plate of FIG. 6a illustrating the inclined mounting track;

FIG. 7 is a perspective view of the resilient clip utilized to fasten the panels and corner forms together;

FIG. 8 a is a detailed cross sectional view through a complete concrete form of a straight wall showing how a steel tie extends through the forming assembly holding the poured concrete;

FIG. 8 b is a detailed cross sectional view through a complete concrete form of a corner showing how a steel tie extends through the forming assembly holding the poured concrete; and

FIG. 9 is a perspective view of a wedge used to lock the panels and corner forms in position over steel ties.

DETAILED DESCRIPTION OF THE INVENTION

Reference is now made to FIGS. 1a and 1b illustrating the concrete forming system 10 of the present invention. As illustrated in these figures, the system 10 is being utilized to form two walls and a corner of a building foundation from poured concrete. Specifically, a series of straight wall panels 12, inside corner forms 14 and outside corner form 16 are held together by fasteners 58 and structurally supported by a series of walers 68,70 and corner plates 72 as will be described in greater detail below.

As illustrated in FIGS. 2a and 2b each panel 12 includes a wall 24 having a concrete forming surface 26, a recessed margin 28 and a projecting margin 30. The recessed margin 28 is provided along at least a first edge of the wall 24 and the projecting margin 30 is provided along at least the second, opposite edge. In another possible embodiment and as illustrated, the recessed margin 28 is provided along the first and third edges of the wall 24 that form a first corner. Similarly, the projecting margin 30 is provided along the second and fourth edges of the wall that form a second, opposite corner.

A series of reinforcing ribs 32 support the concrete forming surface 26 and the recessed margin 28. As illustrated the projecting margin 30 has a thickness A and the recessed margin 28 is recessed from the concrete forming surface 26 by the same distance A. Further, both the projecting margin 30 and recessed margin 28 have a width B.

This structural arrangement of the recessed and projecting margins 28, 30 allows the panels 12 to be interlocked: that is, the projecting margin 30 of a first panel 12 mates or nests with and is received in the recessed margin 28 of a second panel 12 so that a continuous concrete forming surface 26 is provided by the adjacent panels (note particularly FIGS. 3 and 8a). Where each panel 12 includes recessed margins 28 along the first and third edges and projecting margins 30 along the second and fourth edges, overlapping joints may be provided between panels in two perpendicular directions (i.e. horizontally and vertically).

As illustrated in FIG. 4, each inside corner form 14 includes a first side wall 34, a second side wall 36 and a gusset wall 38 connecting the first and second side walls. The first side wall 34 includes a recessed margin 40 identical in dimension to the recessed margin 28 along at least one and preferably two edges (i.e. with a recessed distance A and a width B). The recessed margin 40 also extends across one end of the gusset wall 38. The second side wall 36 includes a projecting margin 42 identical in size and shape to the projecting margin 30 along at least one and preferably two edges (i.e. with a thickness A and a width B). The projecting margin also extends across one end of the gusset wall 38. A series of reinforcing ribs 44 are provided to support the first side wall 34, second side wall 36 and gusset wall 38 everywhere except behind the projecting margin 42. This structural arrangement allows the recessed margin 40 of the inside corner form 14 to mate and interlock with the projecting margin 30 of a panel 12 and the projecting margin 42 of the inside corner form to mate and interlock with the recessed margin 28 of a panel 12 in the same manner as illustrated in FIG. 3. Accordingly, a smooth continuous concrete forming surface 26 is provided along an interior wall fully around a corner to a second interior wall utilizing the concrete forming system 10 of the present invention (see also FIG. 8b).

As illustrated in FIG. 5, the outside corner form 16 includes a first side wall 48, second side wall 50 and gusset wall 52 for connecting the first and second side walls 48, 50. The first side wall 48 includes a recessed margin 54 along at least one and preferably two edges (with a recessed distance A and a width B) while the second side wall 50 includes a projecting margin 56 along at least one and preferably two edges (with a thickness A and a width B). The recessed margin 54 also extends across one end of the gusset wall 52 (hidden from view in FIG. 5). Similarly, the projecting margin 56 also extends across the opposite end of the gusset wall 52 (hidden from view in FIG. 5). Reinforcing ribs 57 are provided to support the walls 48, 50 and 52 everywhere except behind the projecting margin 56. These margins 54, 56 function to mate and interlock with cooperating margins on the panels 12 in the same manner described above with respect to the inside corner form 14. The only difference is the outside corner form 16 and adjacent panels 12 function to provide a smooth, continuous concrete surface 26 about the outside corner of two walls of poured concrete (see also FIG. 8b).

As illustrated in FIG. 1a, various panels 12 and inside corner forms 14 are arranged in position together in order to form an inner wall forming assembly 100. The illustrated inner wall assembly 100 is constructed from panels 12 and corner forms 14, 16 that are four feet in height. Thus, two such panels 12 and corner forms 14, 16 are stacked to provide a wall eight feet in height. The inner wall assembly 100 provides a smooth concrete forming surface 26 for the interior of a poured concrete foundation. Fasteners in the form of resilient clips 58 are utilized to secure adjacent panels 12 and inside corner forms 14 together. As illustrated in FIG. 7 each resilient fastener 58 includes a head 60 with a reinforcing rib 63 and a pair of cooperating lugs 62 that define a fastening channel 64. One or both of the lugs 62 may be provided with fastening teeth 66 to aid in maintaining the clips 58 in engagement with juxtaposed reinforcing ribs 32, 44 or 57 of the adjacent panels 12 and corner forms 14, 16.

As illustrated in FIG. 1b, various panels 12 and outside corner forms 16 are positioned together to form an outer wall forming assembly 200 to provide a continuous concrete forming surface 26 for the exterior face of the poured concrete foundation. More specifically, the panels 12 and outside corner forms 16 of the outer wall forming assembly 200 are positioned a desired distance from the panels 12 and inside corner forms 14 of the inner wall forming assembly 100. Clips 58 are used to hold the panels 12 and outer corner forms 16 together. The space or gap G between the continuous concrete forming surfaces 26 of the inner and outer walls forming assemblies 100, 200 is provided to receive the poured concrete.

It should be appreciated that poured concrete is quite heavy and significant pressure is placed upon the panels 12 and corner forms 14, 16 during wall construction. Horizontal walers 68, vertical walers 70, corner plates 72 and wedges 74 are utilized to reinforce the inner and outer wall forming portions of the concrete forming system 10 against these forces.

More specifically, as illustrated in FIGS. 2a, 2b, 4 and 5 tie apertures 76 are provided at spaced locations along the panels 12, inside corner forms 14 and outside corner forms 16. As the inner and outer wall forming assemblies 100, 200 are built from the panels 12, inside corner forms 14 and outside corner forms 16, these tie apertures 76 are aligned across the gap G between the assemblies. Steel ties T, of a type well known in the art with an elongated body and an enlarged head H at each end, are positioned through these aligned tie apertures 76 so as to extend across the gap G and project outwardly from the cooperating panels 12, inside corner forms 14 and outside corner forms 16.

Next, the horizontal walers 68 are positioned along the outer side of the panels 12, inside corner forms 14 and outside corner forms 16 (i.e. the reinforcing rib side). Specifically, the walers 68 include apertures that are received over the steel ties T. Next, vertical walers 70 are provided over the horizontal walers 68 in order to provide additional rigidity and support to the inner and outer wall forming assemblies 100, 200. As illustrated in FIG. 1a, two vertical walers 70 are provided on the outer wall forming assembly 200 adjacent the corner thereof. Specifically, each vertical waler 70 also includes spaced apertures that are received over the steel ties T projecting from the apertures in the horizontal walers 68.

Wedges 74 of a type known in the art are then positioned over the steel ties T along the inner and outer wall forming assemblies 100, 200. More specifically, each wedge 74 includes an enlarged aperture 80 at one end of an inclined mounting track 81 including an elongated slot 82. The enlarged aperture 80 is of sufficient diameter to allow the head H at the end of a steel tie T to pass. The wedge 74 is then shifted laterally so that the steel tie T is received in the inclined slot 82. The inclined slot 82 is dimensioned to allow free sliding movement of the main body of the steel tie T but will not allow passage of the head H. By sliding a wedge 74 laterally until the head H firmly engages the top of the wedge it is possible to secure the inner and outer wall forming assemblies 100, 200 together and provide a gap G between the assemblies of consistent dimension all along the straight walls and through the corners. Specifically, wedges 74 are tightened against the heads H at each end of a tie T to complete the fabrication of the system 10 (see particularly FIG. 8a). In FIG. 8b, the vertical walers 70 and wedges 74 have not yet been installed over the steel ties T along the inner assembly 100.

As further illustrated in FIGS. 1a, 1b and 8b, the corners may be further reinforced with reversible corner plates 72. Each corner plate 72 includes a first wall 86, a second wall 88 and a gusset wall 90 connecting the first and second walls 86, 88 (see FIGS. 6a and 6b). Each gusset wall 90 includes an aperture 92 for receiving a steel tie T.

As illustrated in FIG. 1a, the corner plates 72 are positioned along the inside corners of the inside corner forms 14 with the first and second walls 86, 88 thereof overlying the ends of the horizontal walers 68. As illustrated in FIG. 1b, the corner plates 72 are oriented in reverse and positioned over the outer corner of the outside corner forms 16 with the first and second walls 86, 88 thereof overlying the horizontal walers 68. During this positioning process the head H of the cooperating steel tie T is inserted through the aperture 92 in the corner plate 72. A wedge 74 is then used to snug the assembly together. More specifically, the head H of the tie T is inserted through the large aperture 80. Next, the wedge 74 is shifted laterally until the head H firmly engages the top of the wedge. By tightening the corner plates 72 on each side of the system 10 with wedges 74 in this fashion, the assemblies 100, 200 are made ready for the pouring of concrete. It should be appreciated that the concrete forming system 10 of the present invention allows the use of steel ties T in the corners as well as along the straight walls to better insure the pouring of a concrete wall of consistent thickness.

In accordance with an additional aspect of the present invention, the panels 12, the inside corner forms 14 and the outside corner form 16 may all be constructed from a fiber reinforced polymer. Specifically, these components 12, 14 and 16 may be molded from fiber reinforced polymer including, for example, glass fibers and a polyolefin such as polypropylene. In fact, recycled glass fibers and/or polyolefin may be utilized. Advantageously, panels 12, inner corner forms 14 and outer corner forms 16 constructed from such a material provide a smooth, olefin-rich concrete forming surface 26 that does not stick to concrete thereby eliminating the need to use oil or release compounds. The panels 12, inside corner forms 14 and outside corner forms 16 made from this material are also reusable. Further, they are light in weight, even lighter than aluminum and, accordingly, are very easy to use. The walers 68, 70 may also be formed from fiber reinforced polymer as a pultrusion. Thus, the walers 68, 70 may also be made lightweight and reusable. In the alternative, the walers 68, 70 may be made from wood, a composite or other appropriate materials.

The foregoing description of a preferred embodiment of the present invention has been presented for purposes of illustration and description. It is not intended to be exhaustive or to limit the invention to the precise form disclosed. Obvious modifications or variations are possible in light of the above teachings. For example, while the panels 12 and the corner forms 14, 16 illustrated and described in FIG. 1a are four feet in height, they could be made of any size including, for example, in heights of eight, nine and ten feet. Further, the panels 12 may be made of substantially any width (e.g. six, eight or ten inches) as well so that they may be pieced together to make a wall of substantially any desired length. A typical panel 12 used in the system 10 may, for example, be eight feet by two feet in dimension. In addition, while a smooth concrete forming face 26 has been illustrated and described, it should be appreciated that the face may be textured if desired to provide the concrete with, for example, a brick or sandstone surface appearance.

The embodiment was chosen and described to provide the best illustration of the principles of the invention and its practical application to thereby enable one of ordinary skill in the art to utilize the invention in various embodiments and with various modifications as are suited to the particular use contemplated. All such modifications and variations are within the scope of the invention as determined by the appended claims when interpreted in accordance with the breadth to which they are fairly, legally and equitably entitled. The drawings and preferred embodiments do not and are not intended to limit the ordinary meaning of the claims and their fair and broad interpretation in any way.

Claims

1. A concrete forming system, comprising: a plurality of interlocking panels; an inside corner form; an outside corner form; and a plurality of fasteners for securing said panels and forms together.

2. The system of claim 1, wherein each panel of said plurality of panels includes (a) a wall having a concrete forming surface, a recessed margin along a first edge of said wall and a projecting margin along a second, opposite edge of said wall and (b) reinforcing ribs supporting said concrete forming surface and said recessed margin.

3. The system of claim 2, wherein said projecting margin has a thickness A and said recessed margin is recessed from said concrete forming surface by a distance A.

4. The system of claim 3, wherein said projecting margin has a width B and said recessed margin has a width B.

5. The system of claim 4, wherein each panel of said plurality of panels includes at least one tie aperture.

6. The system of claim 5 wherein said recessed margin is also provided along a third edge of said panel and said projecting margin is also provided along a fourth edge of said panel.

7. The system of claim 1, wherein said inside corner form includes a first side wall, a second side wall, a gusset wall connecting said first and second side walls and reinforcing ribs.

8. The system of claim 7, wherein said first side wall includes a recessed margin, said second side wall includes a projecting margin and said inside corner form includes at least one tie aperture.

9. The system of claim 8, wherein said at least one tie aperture is provided in said gusset wall.

10. The system of claim 9, wherein said recessed margin is provided along two edges of said first side wall and said projecting margin is provided along two edges of said second side wall.

11. The system of claim 1, wherein said outside corner form includes a first side wall, a second side wall, a gusset wall connecting said first and second side walls and reinforcing ribs.

12. The system of claim 11, wherein said first side wall includes a recessed margin, said second side wall includes a projecting margin and said outside corner form includes at least one tie aperture.

13. The system of claim 12, wherein said at least one tie aperture is provided in said gusset wall.

14. The system of claim 13, wherein said recessed margin is provided along two edges of said first side wall and said projecting margin is provided along two edges of said second side wall.

15. The system of claim 1, wherein said each fastener of said plurality of fasteners comprises a resilient clip.

16. The system of claim 15, wherein said resilient clip includes a head and a pair of cooperating lugs defining a fastening channel.

17. The system of claim 16, wherein said pair of cooperating lugs include fastening teeth.

18. The system of claim 1, wherein said system further includes a corner plate including a first side wall, a second side wall and a gusset wall connecting said first and second side wall.

19. The system of claim 18, wherein a tie aperture is provided in said gusset wall.

20. The system of claim 19, wherein said system further includes a plurality of walers.

21. The system of claim 1, wherein said plurality of interlocking panels and corner forms are constructed from a fiber reinforced polymer.

22. The system of claim 21 wherein said fiber reinforced polymer includes glass fibers and a polyolefin.

23. The system of claim 22, wherein said polyolefin is polypropylene.

24. The system of claim 22, wherein said polyolefin is recycled polyolefin.

25. A concrete forming element, comprising: a panel including (a) a wall having a concrete forming surface, a recessed margin at a first side of said wall and a projecting margin at a second side of said wall and (b) reinforcing ribs supporting said concrete forming surface and said recessed margin.

26. The concrete forming element of claim 25, wherein said projecting margin has a thickness A and said recessed margin is recessed from said concrete forming surface by a distance A.

27. The concrete forming element of claim 26, wherein said projecting margin has a width B and said recessed margin has a width B.

28. The concrete forming element of claim 27, further including at least one tie aperture.

29. A concrete forming element, comprising: an inside corner form including a first side wall, a second side wall, a gusset wall connecting said first and second side walls and reinforcing ribs.

30. The concrete forming element of claim 29 further including at least one tie aperture in said gusset wall.

31. A concrete forming element, comprising: an outside corner form including a first side wall, a second side wall, a gusset wall connecting said first and second side walls and reinforcing ribs.

32. The concrete forming element of claim 31 further including at least one tie aperture in said gusset wall.

33. A corner plate for a concrete form, comprising: a first side wall; a second side wall; a gusset wall connecting said first and second side walls; and an aperture in said gusset wall.