Patent Application
20100193662
The present invention relates generally to form systems for poured concrete structures, and more particularly, relating to an improved form system including modular form panels with integrated furring strips for receiving fasteners and with a reinforcing steel supporting system.
It is well known in the construction industry to utilize insulated concrete forms for use in the construction of poured concrete walls, floors, roofs, ceilings and the like. The use of insulated concrete forms (ICFs) have experienced increasingly widespread use because they are lightweight, easily cut, excellent insulators, and good barriers to air and moisture. Insulated concrete forms are typically manufactured from plastic foams. Manufacturers create many different foams by varying ingredients and manufacturing methods. IFCs are routinely made from expanded polystyrene (EPS), extruded polystyrene (XPS), polyurethane, a cement-foam composite, or other resins. The insulated concrete forms may either be removed once the concrete has hardened, or left in place to provide a thermal barrier and sound insulation to the concrete structure.
It is known in the art to attach furring strips of wood to the concrete structure for receiving fasteners, such as drywall fasteners, in the attachment of interior finishing to the hardened concrete structure. The furring strips are attached or anchored to the concrete structure during forming of the structure or once the concrete has hardened. There are several inherent problems with either of these methods, in the first method, the wooden furring strips are exposed to prolonged moisture as the concrete sets and often warp as a result, and thus making the fastening of interior finishing difficult. In the second method, the furring strips are attached using penetrating fasteners that are driven through the furring strip and into the concrete structure. The driving of the penetrating fasteners often results in chipping, cracking, or otherwise damaging at least the surface of the concrete structure to which the furring strips are attached. In both methods, the anchors or fasteners used to attached the furring strips to the concrete structure may protrude outwardly from the furring strip making flush and smooth attachment of finishing to the concrete structure difficult.
At least one attempt has been made to try and solve these problems with an insulated concrete panel system and a plastic stud. In this existing form system at least two separate insulating panels are placed side-by-side at a spaced distance into a rectangular outer form with a gap between the insulating panels. A plastic stud is then placed within the gap with the sides of the stud abutted against the facing surfaces of the insulating panels, and thus forming a complete surface onto which concrete may be poured to form a concrete panel having an elongated beam with the stud embed therein. The plastic stud must be anchored in place to ensure it does not move during pouring of the concrete. An additional insulating strip may be placed along the top of the plastic stud prior to the pouring of concrete to provide a barrier between the plastic stud and the elongated beam. Reinforcing steel may be positioned in the rectangular form and may be supported by separate supports positioned within the form.
While this existing form system does provide a solution to the above problems, the existing form system is complicated and requires a considerable amount of labor in setting up for the pouring of a structural concrete panel, and thus cost of using the system could be prohibitively expensive. In addition, a potential drawback to the existing form system is that it does not provide a thermal barrier to the plastic stud. Another potential drawback is the existing form system is not easily adaptable to form structural concrete panels of different dimensions. Further yet, another potential drawback is the existing form system cannot be used to create a cast-in-place structural concrete panel. Further yet, another potential drawback is utility chases cannot be easily cut into the insulating panels.
Accordingly, there is a need for an improved form panel system that overcomes the drawbacks of the existing form system, is inexpensively manufactured, and includes an improved reinforcing steel support system.
To achieve these and other advantages, in general, in one aspect, a form panel for poured concrete is provided. The form panel includes a body of an insulating material having opposing first and second surfaces, opposing first and second ends, and opposing first and second sides. The body is provided with a longitudinally extending beam channel formed through the first surface of the body from the first end to the second end and parallel to the first and second sides for housing a concrete beam. A furring strip longitudinally extends in the body between the first and the second ends. The furring strip has a lower fastener receiving portion and at least one vertical portion. The lower fastener receiving portion extends at least in part parallel to the second surface at an inwardly spaced distance therefrom. The at least one vertical portion extends at least in part into the longitudinally extending beam channel. The body is provided with a marking on the second surface indicating the perimeter of the lower fastener receiving portion.
In an embodiment, the body is made of an expanded plastic material, including expanded polystyrene or of extruded polystyrene.
In an embodiment, the furring strip is provided with opposite ends that terminate at an inwardly spaced distance from the opposing first and second ends of the body to provide a region that can be cut out to create a chase for utilities.
In an embodiment, the at least one vertical portion of the furring strip extends at least in part into the longitudinally extending beam channel centered therein.
In an embodiment, the at least one vertical portion extends into the longitudinally extending beam channel along a continuous length of the furring strip between opposite ends thereof.
In an embodiment, the at least one vertical portion is provided with a plurality of openings to permit the concrete casting to migrate through and around the furring strip during poring of the concrete to more readily anchor and hold the furring strip in the hardened concrete casting.
In an embodiment, the concrete form panel includes at least one reinforcing steel supporting member engagable with the at least one vertical portion of the furring strip such that the at least one reinforcing steel supporting member is enabled to support a reinforcing steel member within the longitudinally extending beam channel.
In an embodiment, the at least one reinforcing steel supporting member is engagable with an edge of the at least one vertical portion.
In an embodiment, the furring strip is provided with two transversely spaced vertical portions and is U-shaped in transverse cross section.
In an embodiment, the at least one reinforcing steel supporting member is engagable with the two vertical portions of the furring strip such that the at least one reinforcing steel supporting member is enabled to support a reinforcing steel member within the longitudinally extending beam channel.
In an embodiment, the furring strip is T-shaped in transverse cross section, and the at least one vertical portion can be positioned centrally within the longitudinal beam channel.
In general, in another aspect, a concrete form panel for poured concrete is provided. The concrete form panel includes a body of an expanded plastic material having opposing first and second surfaces, opposing first and second ends, and opposing first and second sides. The body is provided with a longitudinally extending beam channel formed through the first surface of the body from the first end to the second end and parallel to the first and second sides for housing a concrete beam. A furring strip longitudinally extends in the body between the first and the second ends. The furring strip has a lower fastener receiving portion and at least one vertical portion. The lower fastener receiving portion extends at least in part parallel to the second surface at an inwardly spaced distance therefrom. The at least one vertical portion extends at least in part into the longitudinally extending beam channel. The furring strip is provided with a plurality of reinforcing steel supporting members longitudinally spaced along the at least one vertical portion within the longitudinally extending beam channel for supporting reinforcing steel within the longitudinally extending beam channel. The body provided with a marking on the second surface indicating the perimeter of the lower fastener receiving portion.
There has thus been outlined, rather broadly, the more important features of the invention in order that the detailed description thereof that follows may be better understood and in order that the present contribution to the art may be better appreciated.
Numerous objects, features and advantages of the present invention will be readily apparent to those of ordinary skill in the art upon a reading of the following detailed description of presently preferred, but nonetheless illustrative, embodiments of the present invention when taken in conjunction with the accompanying drawings. The invention is capable of other embodiments and of being practiced and carried out in various ways. Also, it is to be understood that the phraseology and terminology employed herein are for the purpose of descriptions and should not be regarded as limiting.
As such, those skilled in the art will appreciate that the conception, upon which this disclosure is based, may readily be utilized as a basis for the designing of other structures, methods and systems for carrying out the several purposes of the present invention. It is important, therefore, that the claims be regarded as including such equivalent constructions insofar as they do not depart from the spirit and scope of the present invention.
For a better understanding of the invention, its operating advantages and the specific objects attained by its uses, reference should be had to the accompanying drawings and descriptive matter in which there is illustrated preferred embodiments of the invention.
The accompanying drawings, which are included to provide further understanding of the invention and are incorporated in and constitute a part of this specification, illustrate preferred embodiments of the invention and together with the description serve to explain the principles of the invention, in which:
Reference will now be made in detail to the preferred embodiments of the present invention, examples of which are illustrated in the accompanying drawings. With reference to
In
Sides 24 and 26 can be, respectively, provided laterally with a tongue 36 and a groove 38 having a mating shape longitudinally extending along at least part of the length of the body 14. In this manner, a plurality of form panels 12 arranged side-by-side can be securely connected to one another in a joint-wise coupling so as to assemble a form system 10 for the manufacture of a poured concrete panel 40, as shown in
A typical panel 12 will have a depth, as measured from the top surface 18 to the bottom surface 34, of between 6 to 16 inches, a width measured from side 24 to side 26, of between 16 to 48 inches, and a length measured from end 20 to end 22, of between 12 and 96 inches. A typical panel 12 will have, as measured from the top surface 18 to the bottom of the beam slot 16, a pier height of between 4 to 12 inches. A typical panel will have beam slot width of between 4 to 8 inches.
The body 14 can be provided with one or more utility chases 42 longitudinally formed through one or both piers 28 and 30 permitting the running of utilities, such as, but not limited to, cabling, electrical wiring, and plumbing.
The form panel 12 comprises a longitudinal furring strip 44 extending in the body 14 between ends 20 and 22, and vertically between the top and bottom surfaces 18 and 34. The furring strip 44 can be integrated in the material of the body 14 during the molding, casting or extruding of the body 14. The furring strip 44 is made of a material having suitable structural characteristics, for example expanded metal, cold-rolled metal, galvanized steel, welded wire or plastics.
The furring strip 44 is longitudinally extending in the body 14 along the length of the body between ends 20 and 22. The furring strip 44 extends at least in part upwardly from web 32 into the beam channel 16 between piers 28. In this manner, the furring strip 44 is incorporated by a beam 60 of the concrete casting 40 and is firmly held in place once the casting has hardened. Preferably, the furring strip 44 extends at least in part upwardly from web 32 into the beam channel 16 along a continuous length of the furring strip between opposite ends 48 and 50 thereof to be incorporated in the casting.
As best seen in
In one embodiment, as best seen in
In additional embodiments, it is contemplated, the furring strip 44 could have other cross-sectional shapes, for example the furring strip could have a cross-sectional shape of an inverted T, a Z, or an I, other shapes are also conceivable possible. As seen in
As shown in
With reference to
The furring strip 44 can be provided with at least one reinforcement structure hanger 70 for supporting a reinforcement structure such as rebar 58 within the longitudinally extending beam slot 16 at an evenly spaced distance from the top surface 18 of the body 14. The at least one reinforcement structure hanger 70 can be integral with the furring strip 44. Alternatively, at least one reinforcement structure hanger 70 can be removably supported by the furring strip 44. In an embodiment, at least one reinforcement structure hanger 70 is supported by and extends across the vertical portions 52 and 54 of the furring strip 44. The at least one reinforcement structure hanger 70 can be provided with one or more seats 72 for receiving or engaging edges of either or both of the vertical portions 52 and 54 for supporting the at least one reinforcement structure hanger. A plurality of reinforcement structure hangers 70 can be provided at spaced positions longitudinally along the furring strip 44. The at least one reinforcement structure hanger 70 can be of various forms, and should not be limited in way to a bent wire configuration as illustrated. For example, the at least one reinforcement structure hanger 56 could also be a continuous flange longitudinally extending along the furring strip 44. The at least one reinforcement structure hanger 56 could be injected molded by a suitable material. The furring strip 44 in any number of different cross sectional geometries can be provided with the reinforcement structure hanger 70 as describe above. Particularly, as shown in
Other embodiments are possible, for example form panel 12 can be provided with transverse beam slots formed through the top surface 18 and extending transversely across the entire width of body 14 between sides 24 and 26. The vertical portions 52 and 54 of the furring strip 44 could be expanded metal or welded wire form. The furring strip 44 could be extruded or molded by a suitable material.
A number of embodiments of the present invention have been described. Nevertheless, it will be understood that various modifications may be made without departing from the spirit and scope of the invention. Accordingly, other embodiments are within the scope of the following claims.
