Patent Application
20110232218
The subject matter disclosed herein relates generally to the erection of concrete walls. More particularly, this invention provides for a reusable concrete form for erecting concrete walls.
In order to construct a concrete foundation, two opposing sets of forms must be erected in order to define a channel that retains a pour of concrete until the concrete hardens. Concrete forms are available in various sizes and configurations. These forms are typically oriented and joined together at a job site in order to create the various lengths, heights and angles needed to erect a concrete foundation. Joining together forms is typically a labor and time intensive task. Standard forms available in the industry typically come in lengths of only a couple feet. Thus, a great number of separate forms must be joined together to erect even the smallest of foundations.
Furthermore, the connection of these forms is accomplished using a plurality of flat ties that are held in position by wedge bolts. In a typical arrangement, a vertically oriented flat tie is inserted into the vertical slot that runs between two adjacent forms of a first set of forms. The flat tie is similarly inserted into the vertical slot that runs between two adjacent forms of an opposing second set of forms. A first wedge bolt is then horizontally inserted into an opening in each of the adjacent forms, and through an opening in the flat tie that is located there between. In order to ensure that the first wedge bolt does not come loose, a second wedge bolt is then inserted vertically through an opening in the first wedge bolt. However, it is sometimes the case that the vertically oriented tie is not aligned with the holes in adjacent forms. If concrete is poured between the first and second set of forms with one or more ties being unattached in this way, the sets of forms may fail. This could result in the necessity to redo the entire project.
Accordingly, an improved concrete form and system would be well received in the art.
According to one aspect of the invention, a form comprises: a wall having a first surface and a second, opposing, material-receiving surface; a slot extending substantially across the wall and between the first surface and the second surface; and a first waler attached to the first side of the wall directly above or directly below the slot, the first waler including a plurality of openings spaced across the length of the first waler, wherein the openings are each configured to receive an inserted wedge bolt.
According to another aspect of the invention, a concrete form includes a wall having a rear surface and an opposing concrete receiving surface; a plurality of vertical studs attached to the rear surface of the wall and spaced across the width of the wall; a pair of walers attached to the rear surface of the wall and extending substantially between at least one pair of adjacent vertical studs; and a slot extending substantially horizontally across the wall, the slot located between each of the pairs of walers, the slot configured to receive a horizontally inserted flat tie.
According to yet another aspect of the invention, a concrete form system comprises: a first form, the first form including: a wall having a first surface and a second opposing concrete-receiving surface; a slot extending substantially across the wall; and a waler integrally attached to the first side of the wall adjacent the slot, the waler including a plurality of openings spaced across the length of the waler; a second form, the second form including: a wall having a first surface and a second opposing concrete-receiving surface; a slot extending substantially across the width of the wall; and a waler integrally attached to the first side of the wall directly adjacent the slot, the waler including a plurality of openings spaced across the length of the waler; wherein the first form and the second form are positioned such that the second opposing concrete-receiving surface of the first form and the second opposing concrete-receiving surface of the second form are facing each other; a flat tie having a first opening at a first end and a second opening at a second end, the flat tie inserted horizontally into the slots of both the first form and the second form; a first wedge bolt inserted vertically through both an opening of the waler of the first form and the first opening of the flat tie; and a second wedge bolt inserted vertically through both an opening in the waler of the second form and the second opening of the flat tie.
According to still another embodiment of the present invention, a method of erecting a foundation comprises: erecting a first concrete form; horizontally inserting a flat tie through a slot in the first concrete form; and vertically inserting a wedge bolt through each of: an opening in a top integral waler of the first concrete form; and an opening in the flat tie.
The subject matter which is regarded as the invention is particularly pointed out and distinctly claimed in the claims at the conclusion of the specification. The foregoing and other features and advantages of the invention are apparent from the following detailed description taken in conjunction with the accompanying drawings in which:
A detailed description of the hereinafter described embodiments of the disclosed apparatus and method are presented herein by way of exemplification and not limitation with reference to the Figures.
Referring firstly to
The wall 12 of the concrete form 10 may comprise one or more panels 32, 34, 36, 38 that extend across the length of the concrete form 10. The slots 18 may be located between each of these panels 32, 34, 36, 38. While the embodiment depicted in the Figures includes three slots 18 located between four panels 32, 34, 36, 38 it should be understood that any number of slots 18 and panels are contemplated. In another embodiment, for example, a single slot may divide two panels. The number of slots 18 and panels 32, 34, 36, 38 may be determined by the required height of the concrete form 10 and the amount of support that is necessary to be provided by the ties 20 during the pouring of concrete. Furthermore, the panels 32, 34, 36, 38 may not have the same width. As shown, the bottom panel 32 may be narrower. The lower middle panel 34 may be wider than the bottom panel 32 but narrower than the upper middle panel 36. The top panel 38 may be similarly dimensioned than the lower middle panel 34. However, it should be understood that the invention is not limited to these panel sizes. Furthermore, the entire wall 12 may comprise a single panel having slots that extend less than the entire length of the wall 12.
The panels 32 of the wall 12 may be made from ½ inch thick form plywood. However, it should be understood that other materials and thicknesses are contemplated. For example, the wall 12 may also be made from a plastic, metallic, or composite material. Other durable and robust materials that are configured to withstand one or more pours of concrete may also be used for the panels 32 of the wall 12.
In the embodiment depicted in the Figures, the three slots 18 are shown extending across the width of the wall 12. The slots 18 may each have a thickness that is greater than the thickness of one of the flat ties 20 such that flat ties 20 may be inserted horizontally there through. For example, the slots 18 may each have a thickness between ¼ and ¾ of an inch. In one embodiment, the slots 18 have a thickness of 5/16 of an inch. This thickness may allow for self sealing of concrete. Thus, when concrete is poured between two opposing concrete form sets, only a minimum amount of concrete may escape between the slots 18 before a seal is formed. Other slot thicknesses are contemplated. For example, in the case that a thicker flat tie 20 is required, the slots 18 may have a greater thickness. However, the slots 18 should allow for the slideable insertion of a flat tie 20.
Five vertical studs 22 are shown integrally attached to the rear surface 14 of the wall 12. The studs 22 may also be referred to as a beam, brace, post, stanchion, column, bar, scantling or the like. The vertical studs 22 may be attached by any appropriate attachment means. For example, the vertical studs may be attached with weld, rivets, bolts, or a similar attachment means. Adhesives are also contemplated. The vertical studs 22 are shown extending from the bottom side to the top side of the wall 12. However, in other embodiments, the vertical studs 22 may not extend the entire height of the wall 12. The vertical studs 22 are shown spaced about two feet apart from each other. However, the spacing of the vertical studs 22 is not limited to this embodiment. The vertical studs 22 may be made of a robust and metallic material, such as iron, steel or stainless steel. However, other materials are contemplated. Whatever the material, the vertical studs 22 should help support the structure of the concrete form 10 during concrete pours.
Along each of the slots 18 between each of the vertical studs 22 is a pair of walers 24a, 26a that are integrally attached to the rear surface 14 of the wall 12.
It should be understood that the flat ties 20 may be standard flat ties known to those skilled in the art. The flat ties may have a thickness of between ⅛-¼ inches. Flat ties may be manufactured in different lengths depending on the thickness of the concrete foundation to be erected. In other embodiments, the flat ties 20 may have rounded or tapered ends, and may be reusable. Furthermore, the flat ties 20 may include one or more holes 82 at each end through which a wedge bolt may be inserted. In an embodiment with more than one hole 82, the holes 82 may range in different thicknesses for differently sized wedge bolts. Flat ties may be fashioned from a metallic material such as steel, iron, or the like. Alternately, the flat ties 20 may be a fiberglass or a plastic flat tie. Preferably, the flat tie 20 should be inexpensive, as it may only be used once in most circumstances due to the fact that it is generally submerged in concrete that is poured during the erection of a concrete foundation.
The L-beam angle iron integral walers 24a, 26a may be mirrored in orientation about the slot 18, as shown in the Figures. The first leg 40 of the top waler 24a may extend away from the slot 18 and the first leg 42 of the bottom waler 26a may also extend away from the slot 18. The second legs 44, 46 of the walers 24a, 26a may be parallel and may be spaced apart with the same spacing as the slot 18. For example, the space between the second legs 44, 46 may be about 5/16 inches in the case that the slot thickness is about 5/16 inches. In other words, the length of the perpendicularly extending second legs 44, 46 may extend the width of the slot 18 through which the flat ties 20 may be inserted. It should be understood that other configurations of the walers 24a, 26a may be apparent to those skilled in the art. For example, the cross sectional shape of the walers 24a, 26a does not have to be an L. U-beams, I-beams, T-bars and the like are also contemplated. Furthermore, in another embodiment (not shown) a single waler may be attached next to each of the slots 18, above or below the slot 18. In this embodiment, the single waler may be more robust in order to sufficiently carry the load of the pair of walers 24a, 26a shown in the embodiment depicted in the Figures.
The walers 24a, 26a may include a plurality of rivet holes 48 in order to accommodate fastening to the rear surface 14 of the wall 12 by a plurality of rivets 50. The rivet holes may also be referred to as openings, gaps, bores, or the like. Likewise, the rivets may also be referred to as screws, bolts, fasteners, staples, studs or the like. As shown in the Figures, each of the two foot walers 24a, 26a may each include four rivets 50. However, other dimensions and number of rivet holes 48 and rivets 50 are contemplated. The walers 24a, 26a may also be attached with other attachment means such as bolts, welding, an adhesive, or the like. It may be preferable that the attachment means does not protrude into the concrete receiving surface 16 to assure a smoother concrete foundation. In one embodiment, the walers 24a, 26a are welded to the vertical studs 22 to enhance the structural integrity of the concrete form 10.
The openings 28 of the walers 24a, 26a may be located on the perpendicularly extending second legs 44, 46. In the embodiment shown in the Figures each waler 24a, 26a includes eleven openings 28 spaced about two inches apart. The openings 28 of the top waler 24a and the bottom waler 26a may be aligned such that a wedge bolt 30 is vertically insertable simultaneously into each of the walers 24a, 26a (as shown in
Shown in
Referring back to
The angle deflection braces 56 may be vertically spaced on the rear surface 14 of the wall 12 at regular intervals between the walers 24a, 24b, 24c, 26a, 26b, 26c Like the walers 24a, 24b, 24c, 26a, 26b, 26c, each of the angle deflection braces 56 may fully extend between two vertical studs 22. The angle deflection braces 56 may be attached with rivets and rivet holes, similar to the walers 24a, 24b, 24c, 26a, 26b, 26c. Alternately, the angle deflection braces 56 may be adhered, welded, or otherwise attached to the rear surface 14 of the wall. The angle deflection braces 56 may also be welded to the vertical studs 22 to enhance the structural integrity of the concrete form 10.
The concrete form 10 may also include end rails 58 running along the top, bottom and sides. The end rails 58 may be made from a robust metallic material such as iron, steel, stainless steel or the like. However, other materials are contemplated. Like the previous metallic components of the concrete form 10, the end rails 58 may be adhered, welded or otherwise attached to the rear surface 14 of the wall 12. Furthermore, the end rails 58 may be similarly attached to the vertical studs 22, the walers 24a, 24b, 24c, 26a, 26b, 26c, the angle deflection braces 56, and any additional structural components of the concrete form 10.
The end rails 58 may include openings 60 for attachment of the concrete form 10 to other concrete forms. To attach two of the concrete forms 10 next to each other, the wedge bolts 30 may used. Other attachment means are contemplated, however. For example, bolts, fasteners, screws, or other suitable attachment means may be utilized to secure two adjacent concrete forms 10. Furthermore, the openings 60 are located on the top and bottom end rails 58 in order to allow for stacking of the concrete forms 10 in the case that a higher concrete foundation is required.
Furthermore, the concrete form 10 may include cat walk anchors 62 having openings 64. The catwalk anchors 62 may be vertically oriented angle irons. However, other embodiments are contemplated. Whatever, the embodiment, the catwalk anchors 62 may be attached to the rear surface 14 of the wall 12 at an upper vertical location. The catwalk anchors 62 should be configured for attachment of a catwalk (not shown) for bracing the concrete form 10 during the pouring of concrete. For example, the catwalk (not shown) may be a metallic or wooden beam that is leaned against the ground and extends to the catwalk anchor 62 at a supporting angle to prevent the concrete form 10 from falling outwardly with respect to the concrete. Various embodiments of catwalk anchors 62 and corresponding catwalks will be apparent to those skilled in the art.
The concrete form 10 may further include a lifting bracket 66. The lifting bracket 66 is configured to allow the concrete form 10 to be machine handled by a crane, boom truck, excavator or the like. The lifting bracket includes an opening 68 through which a hook at the end of a crane rope or line may be inserted. The crane (not shown) may then lift the concrete form 10 into position. A crane, boom truck, excavator, or the like may be necessary because of the expansive size of the concrete form 10 compared to concrete forms of the prior art. However, the size of the concrete forms 10 of the present dimension allow for a faster and less labor intensive erection of a concrete form system than prior art systems. The lifting bracket 66 may also be attachable and detachable to the concrete form 10. This may be used, for example, in the case where stacking is required. In this case, the lifting bracket 66 may be removed in order to provide a flat surface to place a stacked concrete form 10 on a lower concrete form 10.
Still further, the concrete form 10 may include a plurality of tabs 70 with rivet holes 72, and a plurality of corner braces 74 with rivet holes 76. The tabs 70 and corner braces 74 may be located on the rear surface 14 of the wall 12. The tabs 70 may be a metallic component that is configured to help bind the end rails 58 to the rear surface 14 of the wall 10. In one embodiment, the tabs 70 are an integral component of the end rails 58. Alternately, the tabs 70 may be a separate component that is attachable to both the end rail 58 and the rear surface 14 of the wall 12. Whatever, the embodiment, these tabs 70 may be attached with rivets and may be periodically spaced along the length of the top and bottom end rails 58. As shown in the Figures, a single tab may be located at a midpoint between two adjacent vertical studs 22.
Likewise, the corner braces 74 may further be utilized to attach the end rails 58 and the vertical studs 22 to the rear surface 14 of the wall 12. The corner braces 74 are shown located at each corner where a vertical stud 22 or vertical end rail 58 meets the top and bottom end rails 58. The tabs 70 and corner braces 74 may or may not be necessary, and other supporting attachment mechanisms are contemplated. Additional attachments may also be necessary or desirable. Alternate attachments are also contemplated instead of the corner braces 74 and tabs 70.
The entire concrete form 10 may be about two and a half inches thick. In other words, the structure comprising the end rails 54, vertical studs 22, integral walers 24a, 24b, 24c, 26a, 26b, 26c, and angle deflection braces 52 may each be about two inches of the total thickness, while the wall 12 may comprise about a half inch of the total thickness. Because of this thin structure, an entire system of concrete forms 10 may be conveniently carried on a single truck bed. However, the concrete form is not limited to this thickness. For example, in the case that a more resilient structure is required the concrete form 10 may utilize larger structural components, resulting in thicker dimensions. Any concrete form 10 thickness is contemplated.
Referring now to
In another embodiment, a method of erecting a foundation is contemplated. The method of erecting a foundation may first comprise erecting a first concrete form, such as the concrete form 10. The method may include bracing the first concrete form with one or more catwalk anchors that runs from the top edge of the first concrete form to the ground. The form may then be unhooked. Next, an opposing form may be put into place in the same way as the first concrete form. The method further includes horizontally inserting a flat tie, such as the flat tie 20, through a slot in the concrete form, such as the slot 18. The horizontally inserted flat tie may be inserted through both the first concrete form and the opposing concrete form. The method further includes vertically inserting a wedge bolt, such as the wedge bolt 30, through an opening in a top integral waler of the first concrete form. The opening may be an opening such as the openings 28 described hereinabove, while the top integral waler may be a waler such as the top walers 24a, 24b, 24c described hereinabove. The method may further include inserting the wedge bolt through an opening in the flat tie. Still further, the wedge bolt may be inserted through an opening in a bottom waler of the first concrete form, such as one of the bottom walers 26a, 26b, 26c described hereinabove. The flat tie may also be inserted into an opening in the opposing vertical waler, in addition to one or more retaining wedge bolts through the opposingly inserted side of the flat tie. After this first tie is inserted into both concrete forms and secured, the opposing concrete form may be unhooked and the remainder of the flat ties may be put into place.
The method of erecting a foundation of claim 21 may further comprise twisting the flat tie so that a first end of the flat tie is oriented 90 degrees from a second end of the flat tie. In other words, the flat tie may be twisted into one of the twisted flat ties 80. In this embodiment, the method may comprise vertically inserting an end of the flat tie between a vertical slot located between two adjacent concrete forms that oppose the first concrete form.
Still further, the method may include pouring a hardenable material between the first concrete form and the opposing concrete form or forms. The hardenable material may be concrete, or another material such as as geopolymers, hemperete, mudcrete, papercrete and Portland cement.
The present invention offers several advantages over the prior art concrete forms, systems and methods. First, the integrated walers 24a, 24b, 24c, 26a, 26b, 26c provide a robust structure that keeps the walls 12 of the concrete form 10 straight when used for the erection of a plurality of structures. The structure of the forms 10 is also fairly thin so that more square feet of the forms 10 may be included on the bed of a truck for transportation between jobs. Furthermore, using the present forms, the form ends on the inside of the foundation need not align with the form ends on the outside of the foundation. This is because of the several openings 28 along the walers 24a, 24b, 24c, 26a, 26b, 26c through which the flat ties may be inserted. The versatility of tie locations of the present invention also make special fillers in many places, such as T walls and outside fillers unnecessary. Moreover, if more ties are necessary, the tie spacing may be easily decreased in the case of heavy concrete, or other hardenable material. Even further, the present invention reduces the number of wedge bolts needed at each connection by 50%. This is because a single wedge bolt may be inserted into each hole because it is vertically inserted. Still further, the concrete forms 10 are compatible with prior art forms 78, as described hereinabove.
Elements of the embodiments have been introduced with either the articles “a” or “an.” The articles are intended to mean that there are one or more of the elements. The terms “including” and “having” and their derivatives are intended to be inclusive such that there may be additional elements other than the elements listed. The conjunction “or” when used with a list of at least two terms is intended to mean any term or combination of terms. The terms “first” and “second” are used to distinguish elements and are not used to denote a particular order.
While the invention has been described in detail in connection with only a limited number of embodiments, it should be readily understood that the invention is not limited to such disclosed embodiments. Rather, the invention can be modified to incorporate any number of variations, alterations, substitutions or equivalent arrangements not heretofore described, but which are commensurate with the spirit and scope of the invention. Additionally, while various embodiments of the invention have been described, it is to be understood that aspects of the invention may include only some of the described embodiments. Accordingly, the invention is not to be seen as limited by the foregoing description, but is only limited by the scope of the appended claims.
