Patent Application
20120155960
This disclosure relates generally to a curb forming system, and more particularly to a system of components that can be used to construct a substantially uniform concrete curb.
Curbs are constructed in a variety of manners for use with roads, pathways, landscaping, and structures. Typically, curbs are formed where a raised portion of land or material meets an unraised portion of land or material. However, some curbs can be constructed as raised sections between two unraised portions of land or material. Curbs may be formed to provide draining options, provide borders for roads or paths, provide decorative edges, provide support for portions of raised materials, or provide safety or directional means for pedestrians and a variety of transporting vehicles. Curbs generally are constructed of sturdy materials such as concrete, asphalt, stone, or similar materials. Concrete curbs are especially popular because of the flexibility in shaping them, their relatively reasonable cost, and durability.
The basic method of constructing concrete curbs includes building and setting up forms and pouring malleable concrete in the built forms. These forms are typically made of building materials, such as 2×4 planks, metal strips, or other sturdy building materials. However, building and setting up these traditional forms takes considerable skill to achieve a consistent curb shape. Additionally, building the forms can be time consuming and expensive. Further, the shapes that curbs can take are limited by the shapes that can be created with these building materials.
In large projects, a slip form casting machine can be used to create a seamless concrete curb in a variety of shapes. However, slip form casting machines are very expensive and make little sense for smaller projects. In addition, it is difficult to use slip form casting techniques for curbs that are created in certain locations. For example, a landscape curb positioned away from an accessible road or drivable path often must be constructed using forms. Hence, slip form casting machines and techniques are of little use for a “do-it-yourself” homeowner or contractors that only need a relatively small section of curb on a project.
Embodiments of the present concept provide a curb forming system that addresses the above discussed issues and other problems. In one embodiment, a curb forming system includes a first elongated form and a second elongated form for setting a width of a curb. The curb forming system also includes a shaped trowel that has a handle, a shaping surface, a hook guide to position the trowel on the first elongated form, and a level guide structured to position the trowel on the second elongated form. The hook guide may be structured to slide along the first elongated form while keeping the shaping surface of the trowel at a fixed distance relative to the first elongated form. The level guide may be structured to maintain a vertical position of the trowel relative to the second elongated form. In some embodiments, spacers may be used to ensure that the first and second elongated forms are positioned at substantially consistent distances from each other. Further, form stakes may be used to fix the first and second elongated forms in the ground and form splices may be used to attach other forms to the first and second elongated forms.
Other embodiments of the present concept provide a method of forming a concrete curb. In one embodiment, the method includes setting a first elongated form, positioning a second elongated form relative to the first elongated form, and placing spacers between the first and second elongated forms to set the second elongated form at a consistent distance from the first elongated form. After the first and second elongated forms are set, such as by being staked down, the spacers can be removed and concrete is poured between the first and second elongated forms. A shaping trowel is then attached to one end of the first elongated form with a hook guide and positioned on the second elongated form with a level guide. The trowel is then slid along the elongated forms from the first of the forms to a second end of the forms to create a consistently shaped curb.
The ends 112, 114, 122, 124 of the forms 110, 120 may include splicing devices 170 that allow the multiple forms to be attached together at their ends or the ends of the same form to be attached to one another. The splicing devices 170 may include holes to allow the form ends 112, 114, 122, 124 to be bolted together, or may include dove tail grooves or other apparatuses that allow the ends to be connected. Additional stiffeners (see e.g.,
The shaping trowel 150 includes a handle 152, a shaping surface 155, a hook guide 160, and a level guide 165. The shaping trowel 150 may be constructed of plastic, metal, wood, or other materials, or a combination of materials. For example, the trowel 150 may be entirely formed of a rigid plastic material, or may have a steel shaping surface 155 and a wooden handle 152. The shaping surface 155 is used to form at least the top surface of a curb. The shaping surface 155 can be formed in a variety of shapes to form different style curbs. Additionally the forms 110, 120 may be constructed to provide for different shaped or styled curbs.
The hook guide 160 is structured to fit over a top surface of the first form 110. Additionally, the hook guide 160 allows the trowel 150 to be slid or dragged along the forms 110, 120 while keeping the shaping surface 155 at a substantially consistent distance from the first form 110. The level guide 165 is structured to fit over a top surface of the second form 120. The level guide 165 allows the trowel 150 to be maintained at a consistent vertical position relative to the second form 120. Additionally, because the level guide is not restricted horizontally on the second form 120, small differences in distances between the first and second forms 110, 120 will not prevent the trowel 150 from being slid over the top surfaces of the forms. That is, the level guide 165 allows for at least some horizontal movement of the trowel 150 relative to the second form 120 and prevents the too much friction from occurring when the trowel is slid along the forms where the distances between the first and second forms vary slightly. In other embodiments, a shaping trowel 150 may have hook guides 160 on each side of the trowel, or level guides 165 on each side of the trowel.
The curb forming system 100 may also include spacers 180 that fit over or otherwise attach to the forms 110, 120 so that the forms can be kept at substantially consistent distances from one another. Since the distance between the forms 110, 120 determines the width of the finished curb, having a substantially consistent space between the forms helps the curb have a substantially uniform width. The spacers 180 may be made of plastic, metal, or other rigid materials. Multiple spacers may allow the forms 110, 120 to be spaced at a predefined distance over the length of the forms. This may be especially helpful when forming curbs with curves or bends. In some embodiments, a curb forming system 100 may include multiple different sized spacers to allow for a variety of different width curbs to be formed with the system.
The curb forming system 100 may also include stake brackets 190 that can be attached to the forms 110, 120. The stake brackets 190 may be fixed to the forms 110, 120 with rivets or other substantially permanent attachment means, or may be removable so they can be moved to desired locations on the forms. The stake brackets 190 allow stakes 195 to be used to fix the forms 110, 120 to a work surface, such as the ground.
Referring to
A second elongated form is then set on a work surface in process 530. The second form is set at a predefined distance from the first form, where the predefined distance corresponds to a desired width of the curb. The second form may be set on the work surface in a similar manner to setting the first form on the work surface. Spacers may optionally be used in process 530 to set the second form at a consistent distance from the first form. After the first and second form are set, such as by being staked or bolted down to the work surface, the spacers may be removed.
In process 540, a curb material is disposed between the first and second forms on the work surface. In embodiments where the curb is a concrete curb, process 540 includes pouring mixed concrete between the first and second forms. Process 540 may also include removing excess wet concrete that above the top surfaces of the forms.
In process 545, the hook guide of a shaping trowel is aligned with the top surface of the first form. The hook guide of the shaping trowel may be structured to correspond to the top surface of the first form so that when the shaping trowel is moved along the first form, it is maintained in a substantially consistent position relative to the first form. In process 550, a level guide of the shaping trowel is positioned on the top surface of the second form. The level guide of the shaping trowel may maintain the shaping trowel at a consistent vertical position relative to the second form while allowing the shaping trowel to slide over the first and second forms even when there are small inconsistencies in the distance between the first and second forms.
The shaping trowel is then slid along the top surfaces of the first and second forms to shape a top surface of the curb by patterning the curb material between the first and second forms in process 555.
In optional process 510, the method may further include preparing the work surface for the curb. Process 510 may include, for example, compacting dirt on the ground or laying a base surface of concrete or asphalt that the curb will be formed on. The method may also include optional process 515, where the desired location for the curb is laid out. Here, the desired positions of the curb edges may be set drawn out or otherwise designed. Measurements may be taken to ensure the curb is located in an optimal position. Additionally, stakes, string, markers, paint, or other devices may be used to mark the work surface with a desired location of the curb.
The first and second elongated forms may be prepared prior to being set in optional process 520. Here, the forms may be modified as needed to complete a desired curb. For example, if a circular curb (such as the one shown in
Although plastic and steel are shown as materials used in the trowels shown in
These and other embodiments of the curb forming system can be used to construct all types of curbs, and is especially suited for making decorative or distinctive concrete curbs. The curb forms may be made of polyethylene, polyvinyl chloride (PVC) plastic, other plastic materials, sheet metal, or other flexible or semi-flexible materials. The flexibility of the form material allows for the creation of curved and/or decorative curb orientations. The curb forms may be available in five foot, ten foot, or other lengths. The splicing devices discussed above may allow a user to construct continuous curbs that are longer than the length of individual forms.
The forms may be set with the form stakes, which may be available in multiple sizes to fit different form heights, or different terrain. For example, sandy terrain may require longer stakes than clay to secure the forms in place. The stakes may be made of steel or other rigid materials to allow them to be hammered into the ground. Additionally, a top portion of the stakes may be bent or have a horizontal portion to allow a wide area for hammering. The spacers discussed above may be provided in multiple different widths to allow construction of curbs with differing specified widths.
The concrete for the curbs can be made of a standard concrete mix of gravel, sand and cement; a premixed bagged concrete; or a premixed Type-S mortar with fiber mesh mixed in. The Type-S mortar works best for a stiffer mix and smoother finish and is extra strong with the addition of fiber mesh. Using a concrete with a very stiff mix may provide better results in some circumstances as it will better hold its shape when troweled.
When setting the forms, establishing a lay out for the curb by marking out portions of the ground can be helpful. For straight curbs, using separate stakes and a string line will help ensure the straightness of the curb. Once the layout is established, then the forms can be set using the provided stakes and spacers. Preparation work may be required on the dirt, such as leveling and/or compacting the land.
In one formation method, after the forms are set and the mix is ready, the mix is shoveled into the forms (square point shovel works best). Excess mix can then be raked off of the forms prior to using the trowel or shovel. The spacers are removed as the concrete is worked into the forms. The shaped trowel may then be used to begin troweling. Here, as discussed above, the hook guide of the trowel is set on one end of the forms and trowel is moved back and forth along the forms to create a desired curb shape. Once the pour is smooth and the concrete has started setting but is still wet, the forms can be removed. After the forms are removed, a cut for expansion can be made at intervals in the curb, such as at every four feet. Once the cuts are made, a brush can be used to create a “brush finish” on all surfaces.
Some embodiments of the invention have been described above, and in addition, some specific details are shown for purposes of illustrating the inventive principles. However, numerous other arrangements may be devised in accordance with the inventive principles of this patent disclosure. Further, well known processes have not been described in detail in order not to obscure the invention. Thus, while the invention is described in conjunction with the specific embodiments illustrated in the drawings, it is not limited to these embodiments or drawings. Rather, the invention is intended to cover alternatives, modifications, and equivalents that come within the scope and spirit of the inventive principles set out in the appended claims.
This application claims priority to U.S. Provisional Application No. 61/424,490 filed Dec. 17, 2010, entitled CURB FORMING SYSTEM, the contents of which are hereby incorporated by reference.
| Number | Date | Country | |
|---|---|---|---|
| 61424490 | Dec 2010 | US |
