Patent Application
20200018081
The presently disclosed subject matter relates generally to forms used in masonry applications and more particularly to a masonry form system and method including plastic reusable masonry form members.
In building projects, such as residential homes and commercial buildings, concrete can be used for various structural elements, such as footings, foundations, steps, driveways, posts, pillars, columns, and the like. Generally, a wooden form is constructed for a given element and then concrete is poured into the form. Once the concrete is sufficiently set, the form is removed. In this process, the wooden form may be custom built on site, then the concrete is poured into the form, and then once the concrete is set the wooden form is often removed in a destructive manner and is therefore not reusable. Further, steel forms are also in use today. However, steel forms are heavy and difficult to handle, store, and transport. Accordingly, more efficient and cost-effect approaches are needed with respect to constructing and deconstructing masonry forms.
In one embodiment, a masonry form system is provided. The masonry form system may include a plurality of masonry form members, wherein the plurality of masonry form members may include opposing vertical side walls; and a connector mechanism on at least one end of each of the plurality of masonry form members; and wherein, the plurality of masonry form members may be configured to be connected together via the connector mechanisms. The masonry form system may further include one or more anti-spread clips, wherein the anti-spread clips may be configured to engage a pair of opposing masonry form members laterally spaced apart from one another, and wherein the anti-spread clip may be configured to span from a top portion of first vertical wall of a first masonry form member to a top portion of a second vertical wall of a second masonry form member. The one or more anti-spread clips may include a cross member; side members, one extending vertically downward from each end of the cross member; and a lip extending horizontally inward from each of the side members. The plurality of masonry form members may include one or more of any of a straight member, a spacer member, a corner member, and/or a U-shaped member. The plurality of masonry form members may be configurable to provide a masonry form for building footings in a residential or commercial application. The plurality of masonry form members may be configurable to form a first outer perimeter structure and a second inner perimeter structure, wherein the first outer perimeter structure and the second inner perimeter structure are spaced apart and configured to receive concrete to form footings. The plurality of masonry form members may include thermoplastic material. The plurality of masonry form members may be at least partially hollow between the opposing vertical side walls. The one or more of the plurality of masonry form members may be at least partially filled with a structural foam between the opposing vertical side walls. The plurality of masonry form members may include one or more vertical ribs formed between the opposing vertical side walls. The plurality of masonry form members may include one or more horizontal ribs formed between the opposing vertical side walls. The plurality of masonry form members may include one or more horizontal ribs and one or more horizontal ribs formed between the opposing vertical side walls. The plurality of masonry form members may include one or more channels extending vertically through one or more of the plurality of masonry form members. The connector mechanism may include either of a connector tab or a connector slot. The connector tab of a first masonry form member may be configured to slideable engage with the connector slot of an adjacent second masonry form member. The one or more of the plurality of masonry form members may include the connector tab on one end and the connector slot on an opposing end. The one or more of the plurality of masonry form members each may include a connector tab on both ends or a connector slot on both ends. The corner member may be configured to form a substantially 90 degree corner. The masonry form system may include one or more horizontal ribs extending along an exterior surface of one or both of the opposing vertical side walls.
In another embodiment, a method of using a masonry form system is provided. The method may include providing a masonry form system. The masonry form system may include a plurality of masonry form members, wherein the plurality of masonry form members may include opposing vertical side walls; and a connector mechanism on at least one end of each of the plurality of masonry form members; and wherein, the plurality of masonry form members may be configured to be connected together via the connector mechanisms. The method may further include selecting and positioning the selected plurality of masonry form members based on a pre-determined plan to form a desired masonry form; and connecting the selected and positioned plurality of masonry form members together. The method may further include pouring concrete into the formed masonry form. The method may further include securing one or more of the plurality of masonry form members in place via driving rebar vertically through one or more vertical channels formed in the one or more of the plurality of masonry form members, and into the ground. The method may further include installing one or more anti-spread clips across a top portion of two opposing masonry form members spaced laterally apart from one another. The method may further include disassembling the connected plurality of masonry form members.
Having thus described the presently disclosed subject matter in general terms, reference will now be made to the accompanying Drawings, which are not necessarily drawn to scale, and wherein:
The presently disclosed subject matter now will be described more fully hereinafter with reference to the accompanying Drawings, in which some, but not all embodiments of the presently disclosed subject matter are shown. Like numbers refer to like elements throughout. The presently disclosed subject matter may be embodied in many different forms and should not be construed as limited to the embodiments set forth herein; rather, these embodiments are provided so that this disclosure will satisfy applicable legal requirements. Indeed, many modifications and other embodiments of the presently disclosed subject matter set forth herein will come to mind to one skilled in the art to which the presently disclosed subject matter pertains having the benefit of the teachings presented in the foregoing descriptions and the associated Drawings. Therefore, it is to be understood that the presently disclosed subject matter is not to be limited to the specific embodiments disclosed and that modifications and other embodiments are intended to be included within the scope of the appended claims.
In some embodiments, the presently disclosed subject matter may provide a masonry form system and method including plastic reusable masonry form members. Examples of reusable masonry form members may include, but are not limited to, straight members, increment members (or spacers), corner members, U-shaped members, and anti-spread clips. Further, a method of using the masonry form system is provided.
Referring now to
The reusable masonry form members, such as straight members 110, increment members 112, corner members 114, U-members 116, and anti-spread clips 130, may be polymer-based members that are durable, moisture resistant, washable, and lightweight. In one example, the reusable masonry form members may be formed of thermoplastic material. The thermoplastic masonry form members may be substantially hollow, and may include a gap of about two (2) inches between its opposing vertical walls 111a and 111b. With reference to
Referring still to
Alternatively, and with reference to
With reference to
Connector tab 120 and connector slot 122 is just one example of how adjacent form members may be connected together. Any other suitable technique or mechanism for connecting adjacent form members may alternatively be used.
Anti-spread clip 130 is designed to span across, for example, a pair of straight members 110 as shown in
At a step 210, the reusable members of masonry form system 100 may be provided. For example, an assortment of straight members 110 of various lengths, an assortment of increment members 112 of various lengths, corner members 114, U-members 116, and anti-spread clips 130 may be provided at the job site.
At a step 215, the first two reusable members of masonry form system 100 may be selected (according to plan), positioned (according to plan), and then connected together. In one example, two straight members 110 may be selected, positioned, and then connected together using their respective connector tabs 120 and connector slots 122. In another example, a straight member 110 and an increment member 112 may be selected, positioned, and then connected together using their respective connector tabs 120 and connector slots 122. In yet another example, a straight member 110 and a corner member 114 may be selected, positioned, and then connected together using their respective connector tabs 120 and connector slots 122.
At a decision step 220, it is determined whether the masonry form is complete according to plan. If the masonry form is not complete, then method 200 may proceed to method step 225. However, if the masonry form is complete then method 200 may proceed to method step 230.
At a step 225, the next reusable member of masonry form system 100 may be selected (according to plan), positioned (according to plan), and then connected to one of the previously installed reusable members. For example, according to plan, a straight member 110 of a certain length, an increment member 112 of a certain length, a corner member 114, or a U-member 116 may be selected, positioned (according to plan), and then connected to one of the previously installed reusable members. In another example, one or more anti-spread clips 130 may be selected and installed. Method 200 may then return to decision step 220.
At a step 230, concrete 150 may be poured into the reusable masonry form built using masonry form system 100 and then allowed to set.
At a step 235, the reusable masonry form built using masonry form system 100 may be disassembled and then stored and/or transported away. For example, all of the used reusable members of masonry form system 100 (e.g., straight members 110, increment members 112, corner members 114, U-members 116, and anti-spread clips 130) may be disengaged from one another, cleaned of any excess concrete, and then stored and/or transported away for reuse at another time and/or another job site.
Referring again to
In masonry form system 100, the reusable masonry form members (e.g., straight members 110, increment members 112, corner members 114, and U-members 116) may be placed vertically as they measure 2 inches×12 inches and placed, pulling off of corners that have been staked by a surveyor, which would be based on blueprints for a particular house or building. The reusable masonry form members may be placed in a trench based on the building plan. The reusable masonry form members may be connected by sliding male ends (e.g., connector tabs 120) and into female ends (e.g., connector slots 122). Forms (e.g., straight members 110) may be provided, for example, at from about 2 feet to about 12 feet in length and spacers (e.g., increment members 112) may be provided to achieve any length required that conform to typical form.
Once the reusable masonry form members have been placed, they may be secured by driving rebar vertically through the channels 148 provided, which may be a formed plastic through-hole, or could alternatively be a galvanized metal or stainless steel sleeve. A string line or transit may be used to keep the alignment of the form straight and level using material such as slate or other shimming material. In one example, masons pins may be placed on the outside of the reusable masonry form members to prevent the weight of the concrete from pushing out the forms or spreading them.
At this point, if the building plan calls for horizontal and/or vertical rebar, the rebar may be placed inside the reusable masonry form members. The rebar usually sit on metal chairs, the number and size of such rebar would be specified in the building plans. After rebar is in place, it could be connected to the vertical rebar in the reusable masonry form members, which has been placed, for example, at about every 2 feet.
Once the masonry form is level, dimensions checked, and rebar installed, anti-spread clips 130 may optionally be installed with the masonry form. The anti-spread clips 130 may, for example, be about 24 inches long and may snap onto the vertical form members to prevent the concrete from pushing out the form members. The anti-spread clips 130 may be installed as needed, usually about 4 feet on center. 16-inch anti-spread clips 130 may be provided for smaller footings. Once the concrete has been poured and starts to set, the anti-spread clips 130 may be removed, cleaned of any excess concrete, and reused.
After pour, e.g., one day after pour, the reusable masonry form members (e.g., straight members 110, increment members 112, corner members 114, and U-members 116) may be removed while trying not to damage them, although they are formed of durable, moisture resistant material that can stand reuse. A benefit of the presently disclosed masonry form system 100 including plastic reusable masonry form members is that it is lighter than wood or steel, easier to remove and clean than wood or steel, and because it can be used again and again it saves natural resources.
The reusable masonry form members may further be foam filled to provide added structural strength. In one example, the reusable masonry form members may be filled with a foam, for example, Polycel Structural Foam, or other suitable foam filler.
The reusable masonry form members may have one or more horizontal ribs 152 along their exterior walls that may be, for example, 8 inches and/or 10 inches high based on the required footing depth. The one or more horizontal ribs 152 may extend about a 0.5 inch out from the exterior surface of the reusable masonry form members to allow for a trowel to be run along it to ensure a level footing.
Following long-standing patent law convention, the terms “a,” “an,” and “the” refer to “one or more” when used in this application, including the claims. Thus, for example, reference to “a subject” includes a plurality of subjects, unless the context clearly is to the contrary (e.g., a plurality of subjects), and so forth.
Throughout this specification and the claims, the terms “comprise,” “comprises,” and “comprising” are used in a non-exclusive sense, except where the context requires otherwise. Likewise, the term “include” and its grammatical variants are intended to be non-limiting, such that recitation of items in a list is not to the exclusion of other like items that can be substituted or added to the listed items.
For the purposes of this specification and appended claims, unless otherwise indicated, all numbers expressing amounts, sizes, dimensions, proportions, shapes, formulations, parameters, percentages, quantities, characteristics, and other numerical values used in the specification and claims, are to be understood as being modified in all instances by the term “about” even though the term “about” may not expressly appear with the value, amount or range. Accordingly, unless indicated to the contrary, the numerical parameters set forth in the following specification and attached claims are not and need not be exact, but may be approximate and/or larger or smaller as desired, reflecting tolerances, conversion factors, rounding off, measurement error and the like, and other factors known to those of skill in the art depending on the desired properties sought to be obtained by the presently disclosed subject matter. For example, the term “about,” when referring to a value can be meant to encompass variations of, in some embodiments, ±100% in some embodiments ±50%, in some embodiments ±20%, in some embodiments ±10%, in some embodiments ±5%, in some embodiments ±1%, in some embodiments ±0.5%, and in some embodiments ±0.1% from the specified amount, as such variations are appropriate to perform the disclosed methods or employ the disclosed compositions.
Further, the term “about” when used in connection with one or more numbers or numerical ranges, should be understood to refer to all such numbers, including all numbers in a range and modifies that range by extending the boundaries above and below the numerical values set forth. The recitation of numerical ranges by endpoints includes all numbers, e.g., whole integers, including fractions thereof, subsumed within that range (for example, the recitation of 1 to 5 includes 1, 2, 3, 4, and 5, as well as fractions thereof, e.g., 1.5, 2.25, 3.75, 4.1, and the like) and any range within that range.
Although the foregoing subject matter has been described in some detail by way of illustration and example for purposes of clarity of understanding, it will be understood by those skilled in the art that certain changes and modifications can be practiced within the scope of the appended claims.
This application is related and claims priority to U.S. Pat. App. Ser. No. 62/697,604, entitled “Masonry Form System and Method Comprising Plastic Reusable Masonry Form Members,” filed on Jul. 13, 2018, the disclosure of which is incorporated herein by reference in its entirety.
| Number | Date | Country | |
|---|---|---|---|
| 62697604 | Jul 2018 | US |
