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1. Field of the Invention
The present invention relates to concrete construction utilizing foam block forms, more specifically to improvements to the foam sidewalls used to create a longitudinally bi-directional system, improved form sidewall spacing ties which create enhanced concrete flow, enhanced strength, and enhanced fire-break properties, and a corner form that can be used as a right-hand or left-hand form.
2. Description of the Related Art
Concrete forms made of a polymeric foam material are known. Such forms basically comprise a pair of laterally spaced-apart sidewalls presenting a cavity therebetween. A number of these forms are connected to present longitudinally and vertically aligned cavities for pouring concrete therein.
One such form is shown in U.S. Pat. No. 3,788,020, issued on Jan. 29, 1974. This patent discloses a concrete form with a pair of sidewalls, end walls and intermediate partition walls. A plurality of these forms are connected to present vertical cavities for pouring concrete therein to form a plurality of vertical concrete columns or piers. These vertical columns are connected by a horizontal concrete beam formed by filling a channel with concrete, the channel presented upon placing one row of concrete forms atop another.
One problem with existing concrete forms is that the sidewalls must be immobilized so as to resist pressures on the walls during transport and, more importantly, during concrete pouring and curing. If not, the form sidewalls may shift in lateral and/or vertical and/or longitudinal directions. Such displacements make it difficult to easily connect the forms. Also, the forms may separate along the joints respectively presented along the zones of connection between longitudinally and vertically adjacent forms. If the forms are not sufficiently braced, the concrete can cause these joints to separate. The industry refers to such separations as “blow outs”.
During the pouring of the concrete, a hydraulic concrete load acts on the sidewalls of each form as well as on any structure spanning such sidewalls. The load urges the sidewalls from their proper vertical, lateral and longitudinal spatial relationships. Also, during form transport to the job site, the sidewalls may be displaced due to the weight of other forms stacked thereon. In some cases the distance between the sidewalls may vary. Accordingly, problems will arise when attempting to longitudinally and vertically connect forms as the mating lap joint surfaces and/or tongue/groove elements will not be properly aligned.
The closest related publications known to the inventor are U.S. Pat. No. 4,223,501 granted to DeLozier Sep. 23, 1980 and Published U.S. Application 2004/0045237 invented by Coombs et al and published Mar. 11, 2004. Each of these publications shows concrete forms made of opposing panels. The panels are held in spaced relationship by ties. In the patent publication, the tie contains inadequate open space to allow for the free flow of concrete necessary during a pouring operation in order to avoid air pockets which will weaken the resulting wall. In both of these publications, the tie is a single piece bent at each side to form an anchor. This allows for lateral movement during shipping and a corresponding loss of alignment. When this happens the units do not fit together properly on the construction site.
Also, in both of these publications, the tie is made of metal, which conducts heat and can be a mode of transmitting heat during fire. Additionally, in both of these publications there is no predetermined space for connecting the form to studs.
As seen from the above, various devices in the forms of braces and permanent tension members have been proposed so as to maintain the sidewalls in place to preclude such shifting and/or “blow outs” during concrete pouring and subsequent curing. However, such devices have been relatively complex in construction requiring the sidewalls to have special configurations so as to receive the braces and/or ties and have lacked desirable features.
In prior art systems, corners present some problems. Typically a wall form is extended to the end of the wall and a piece of foam plastic is secured over the end of the wall form by wire or the like.
This type of end is difficult to secure to the wall form, frequently breaks during concrete pouring, and is not securely fastened to the wall form. This creates unnecessary labor in fixing breaks, setting up the forms, and affixing exterior sheathing to the corner of the wall.
In another prior art approach, the specific corner form is provided, but it is preformed for a certain specific job and must be either a right-hand corner or a left-hand corner. Right-hand or left-hand orientation is always determined from a top plan view because these forms have by necessity a top end and a bottom end. Therefore, a right-hand corner form cannot be substituted for a left-hand corner and visa versa. This doubles the number of types of molds required to produce the corner forms, doubles the types of corner forms needed in inventory, increases delivery costs, and so forth.
Therefore, there is a need for a corner form for a concrete wall that is universal, that is, can be used for either a right-hand or left-hand wall corner; that can be securely and easily attached to the wall form; that does not break during concrete pouring; and that is securely fastened to the wall form.
The present invention is directed to maintaining the positive aspects of the advances already made by the prior art while eliminating the problem areas. Thus, the inventor has invented improvements in concrete forms.
A particular object of this invention is to provide a concrete form bi-directional system which enhances on-site assembly of the concrete form walls. This improvement takes the form of a bi-directional insulating concrete form system having novel upper, lower, and side surfaces that provide one-hundred eighty degree rotation of the form creating a bi-directional orientation for corresponding insulating concrete forms. Forty-five and ninety degree corner blocks are also part of this invention.
One improvement disclosed in this invention is a corner form for a concrete wall. This form creates a universal corner form, that is, it can be used to create right-hand or left-hand wall corners in concrete walls. Another feature of this corner form is that it can be securely and easily attached to the wall form. Another feature of this corner form is that it can provide a corner form for a concrete wall that does not break during concrete pouring. This corner form for a concrete wall is securely fastened to the wall form.
Another improvement over the prior art is a form tie, more particularly, novel form ties for maintaining the sidewalls of a concrete form in desired longitudinal, vertical and laterally spaced-apart relationships that also serve as a fire-break. Each form tie generally comprises a pair of plastic vertical side pieces with a pair of metal horizontal pieces spanning the form sidewalls. The ties are formed by connecting a pair of plastic vertical side pieces with a pair of metal horizontal pieces. The horizontal pieces are located at the upper and lower ends of the vertical pieces. The vertical side pieces are embedded in the sidewalls of the forms during the molding process with the horizontal pieces spanning the facing interior surfaces of the sidewalls. The ties preclude lateral, vertical and longitudinal shifting of the sidewalls during transport and use. The ties of the present invention find use in concrete forms and effectively interface with the form sidewalls so as to maintain the walls in a desired spatial relationship during transport as well as concrete pouring and curing. The forms of the present invention also automatically present a longitudinally enhanced fire-break resulting from the innovative use of metal band horizontal pieces and thermoplastic vertical side pieces. During a fire, the thermoplastic vertical side pieces melt and do not conduct heat to the horizontal pieces. Thus, the heat stays on one side of the enclosed concrete. Also, the ties are oriented to reduce downward stress on the ties, as a whole, during the pouring of plastic concrete in the cavity formed between the sidewalls.
The ties resist loads that impart tension, compression, bending, twisting and lateral stresses acting thereon. The ties also diminish the lateral, vertical and longitudinal displacement of adjacent sidewalls of a concrete form during transport and use. The ties of the present invention further enhance on-site assembly of the concrete forms, inclusive of the installation of exterior finish materials attached thereto. These ties effectively resist the forces arising from concrete flow but without interference with the concrete flow in the cavity between the form sidewalls and between adjacent forms.
Other objects and advantages of this invention will become apparent from the following description taken in connection with the accompanying drawings, wherein is set forth by way of illustration and example, now preferred embodiments of this invention.
The invention will now be described with reference to the above drawings wherein like reference numerals refer to like parts throughout the description.
Turning more particularly to the drawings,
As shown best in
Referring to
It is known that the courses of the forms 2 may be selectively configured so as to present walls of various configurations. Also, door frames, window frames, bucks, bulkheads, and the like may interrupt the courses of forms 2 so as to provide openings for insertion of doors, windows and the like therein while precluding spillage of poured concrete from the forms 2.
Referring to
As can best be seen in
With reference to the sidewall form 2 shown in
In order to make a left corner using the above form, the open right-hand side 34 of the corner form 30 as shown in
In a like manner, to form a right corner using the above corner form 30, the open left-hand side 32 of the corner form 30 shown in
Should the straight form 2 be in place such that the outer sidewall 4′ contains an upper longitudinal surface 6 having a raised portion 20 along inner surface 12 and a non-raised portion 22 along the outer surface 14, the corner form 30 may simply be turned over so that the former upper longitudinal surface 6 is now the lower longitudinal surface 8. The corner form 30 will then have an outer sidewall 4′ which contains an upper longitudinal surface 6 having a raised portion 20 along inner surface 12 and a non-raised portion 22 along the outer surface 14. This allows the corner form 30 of the present invention to be a universal corner form as it can form a left corner or right corner regardless of the configuration of the vertical surfaces of the sidewalls 4 of the form 2.
Referring to
Each side piece 40 generally comprises a vertical holder 44 having a proximal edge 46 and a distal edge 48. The proximal edge 46 is of lesser length than the distal edge 48. The vertical holder 44 contains a plurality of holes 50 to allow the passage of polystyrene beads and to avoid the buildup of air pockets in the vicinity of the tie 38. The side piece 40 contains a vertical flange 52 laterally displaced from each side of the proximal edge 46 of the vertical holder 44. The presence of two flanges 52 gives added dimensional stability and strength to the prepared form 2.
A horizontal piece 42 in the form of a thin metal band extends between approximately the midline between the proximal edge 46 and the distal edge 48 of a first vertical holder 44 and approximately the corresponding midline of a second vertical holder 44 at the lower ends 54 thereof. Likewise, upper ends 56 of first and second vertical holders 44 are similarly joined by a metal horizontal piece 42. The horizontal pieces 42 may be secured to the vertical holders 44 by common fastening devices, preferably rivets. Dimensional stability may be assured by having the horizontal pieces 42 fit into grooves 58 in the vertical holders 44. Complimentary notches 60 and protrusions 62 in the horizontal pieces 42 and the vertical holders 44 serve to increase lateral and vertical dimensional stability of the tie 38 and any form 2 containing the tie 38. The thin metal band horizontal piece 42 is located such that the upper 64 and lower surfaces 66 are narrow and the two side surfaces 68 are wide.
In the event of a fire on a first side of a concrete wall prepared using the ties 38 and forms 2 of the present invention, the thermoplastic side pieces 40 melt and cannot transfer sufficient heat to the metal horizontal pieces 42 to allow the fire to spread to the opposite side of the concrete wall.
As is known in the prior art, two bipartite molds are used for forming the sidewalls of the polymeric concrete form. Polystyrene beads are blown into the respective sidewall molds at a first temperature with the beads expanding upon cooling so as to fill the mold. Upon the beads being reheated at an elevated temperature, a second expansion occurs so that the foam fills the mold. Upon removal of the mold the sidewalls 4 are presented.
One problem which has arisen with the use of form ties is that the sidewall molds must have openings therein to allow for insertion of the ends of the tie in each mold and extension of the tie between the sidewall molds. In turn, the expanding foam may escape from these mold openings. Such a leakage/seepage of the foam from the mold may impair form integrity and lead to undesirable ruptures, cracks, etc. in the forms. Such defects may not be visibly apparent until the form sidewalls are subjected to the hydraulic loads presented by the poured concrete between the form sidewalls.
In response to such a problem, the vertical side pieces 40 of the ties 38 of this invention are configured to seal the mold openings. The forms 2 are prepared as a unit with the ties 38 being embedded in the sidewalls 4. Thus, the vertical side pieces 40 preclude escape of the expanding polystyrene foam from the mold. Also, the distance between these vertical side pieces 40 defines the length of the horizontal pieces 42 and thus the resulting lateral displacement between the sidewalls 4. Accordingly, the coplanar relationship of the opposed, interior surfaces 12 of the sidewalls 4 presents a visual gauge of a common lateral displacement between the sidewalls 4 of the forms 2.
Thus, the horizontal pieces 42 fix and maintain a desired lateral distance between the interior surfaces 12 of the sidewalls 4 of the form 2. This common lateral modularity assures the builder that the stacked forms will present even exterior surfaces
As best shown in
The ties 38, as above described, resist tension, compression, bending, twisting and lateral forces acting thereon during transport as well as during concrete pouring and curing.
Thus, longitudinal shifting of the sidewalls 4 of the form 2 is particularly precluded. Such preclusion also contributes to the elimination or reduction in the width modularity during form use.
Referring to
As best seen in
It is to be understood that while certain forms of this invention and dimensions have been illustrated and described, the invention is not limited thereto except insofar as such limitations are included in the following claims and allowable functional equivalents thereof.
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