Patent Application
20110271620
1. Field of the Invention
The present invention concerns a method and apparatus for forming cast-in-place concrete window wells as part of construction of a building. More particularly, it is concerned with a window well form which is adaptable for forming window wells which may be selectively varied in height, width or wall thickness.
2. Description of the Prior Art
In the construction of buildings, many homebuilders desire, or building codes require, the provision of windows in poured concrete foundation walls. Such windows admit light and ventilation, and provide a point of egress directly to the exterior. Where the windows are below the grade of the earth proximate the foundation, it is necessary to provide a clear area around the exterior of the window which extends below the grade to at or above the grade. In order to retain the earth from entering this open area, window wells are commonly used.
Heretofore, window wells have most commonly been provided of galvanized steel which are placed near or attached to the structure around the window opening before backfilling of the earth. These galvanized steel window wells are of common sizes and retained in inventory by the concrete contractor until needed for use. While relatively lightweight and thus portable, they present numerous disadvantages. For example, they are not particularly attractive, the galvanizing layer may be penetrated resulting in rusting, are limited in strength, and require a great deal of space for storage and tie up considerable inventory costs for the contractor.
Another alternative for providing a window well for a building has been to provide precast concrete window wells. These window wells are precast at a location remote from the job site and then placed around the window to create the well. While generally more corrosion resistant and somewhat more able to blend into the environment of the structure than the galvanized steel window wells, they present other problems. Their precast concrete construction makes them heavy to transport and set, and typically require off-road equipment to move and set in place. This may result in damage to the precast concrete window well during transport and placement by such equipment. They also occupy a significant amount of storage space for inventory as well as associated inventory costs. Like galvanized steel window wells, they also are typically available only in a limited number of sizes, with the result that customizing a window well for height, depth, or width requires preplanning and/or additional cost as compared to the wells of standard dimensions.
A yet further alternative which has been previously adopted to a limited extent is to cast full-length wall extensions from the foundation wall which extends down to a footing which is in a common horizontal plane with the footing of the foundation wall. This alternative in some instances of construction involves a full-length wall to be cast from the concrete opposite the window to form a window well using 90° corners and full-length forming panels, and essentially is the same process as for forming a separate, enclosed foundation wall structure extending from the foundation wall of the building, rather than a window well wall. Principal disadvantages to this type of construction include appearance, the excess weight of the wall, attendant cost of excavation, the cost of the footing necessarily extending under the forms and the resultant wall, depth of wall, and consequent material cost and labor, and the resultant waste arising from excess material and excavation.
As a result, there has developed a significant need for a more advanced window well system.
These and other advantages have largely been achieved by the apparatus and method for forming cast-in-place window wells of the present invention. While forming systems of wood or metal forms are well known, the present invention provides an easy and economical approach to the problems associated with window well construction not previously contemplated nor developed in the prior art. As a result, a window well forming system has been developed which provides not only an economical way of forming window wells at the job site which integrates in structure and appearance with the foundation walls, reduces the inventory issues of the contractor, and provides enhanced flexibility in the size of the window well and consequently the window opening, but also results in enhanced strength to the foundation wall as compared to existing window well approaches.
Broadly speaking, the present invention achieves these objects by providing forming panel modules which integrate with existing forming panels to provide a channel for forming a window well. The forming panel modules are configured to provide an attractive and correctly sized window well and to mount with conventional metal forms as a part of a forming wall system. The concrete window well forming panel systems utilizes the forming panel modules which are positioned opposite a portion of the forming wall system for the foundation wall and which provides the window opening so that concrete poured between the forms flows into the window well apparatus and integrates with the existing wall. The forming panel modules are preferably provided as pairs of module sections, typically configured as inner and outer sections, whereby a bottom rail of the modules is elevated relative to the bottom rail of the foundation wall forming panel modules. Most preferably, each section is a separate forming member which may be connected directly or indirectly to forming panels for the foundation wall, and preferably have an inboard leg which extends outwardly from the forming panels for the exterior of the foundation wall, and outboard legs which are angled with respect to the inboard leg to extend toward the outboard legs of the other module and provide a continuous concrete-receiving channel for defining the window well wall. Because the modules for forming the window well walls are in pairs, and thus separate module pairs are provided for the right and left side of the window well wall with a rail which permits them to be connected or separate, the modules permit selective adjustment of the width of the window well from a minimum width to a wider width, the minimum width being defined by the size and configuration of the inner and outer sections of the modules. In order to increase the width of the window well to be formed from a minimum width, and to provide a pier for the window well, one or several inner and outer filler forms may be positioned between the angular forming members. Preferably, the outboard legs of the module are oriented substantially parallel to the forming panels for the foundation wall, while the inboard legs are oriented at an oblique angle relative to the outboard leg and to the adjacent feet which are aligned with the forming panels of the foundation wall. An arcuate, rounded corner preferably connects the inboard leg to the outboard leg to minimize stress concentrations in the concrete window well wall formed thereby.
Advantageously, the forming panel modules are configured to accept like-configured modules atop one another, to increase the height of the window well formed thereby. Furthermore, filler panels may be inserted between the modules and the panels which form the structure wall to increase the thickness of the wall as constructed. Where desired, the forming panel modules may be constructed so as to form or receive steps to aid in ingress or egress from the window well.
Because the forming panel modules are configured to couple to and integrate with existing flat foaming panels, and provide the flexibility to expand in depth, height, length and wall thickness, the inventory of the contractor is greatly reduced. In especially preferred embodiments, the modules are configured with identically shaped inner and outer sections, whereby inversion of an inner section of one module, e.g. an inner section or an outer section of a left module, will then serve as a corresponding inner or outer section of the other module, e.g. the right module. Because the resulting window well wall is integrated into the foundation wall because it is poured in place therewith, the window well wall adds dimensional strength and reinforces the wall of the foundation surrounding the window. Similarly, because in the preferred embodiments, the window well wall does not extend downwardly as far as the adjacent foundation wall and its bottom edge is elevated above the bottom of the foundation wall which is adjacent to the window well, the aforementioned problems and additional costs including those attendant to excavation, labor, and excess material are avoided. When needed, the ability to pour a pier contemporaneously with the window well avoids a cantilevered stress on the foundation wall.
The present invention also includes the ability to cast or receive steps as a part of the window well construction. In one embodiment, the inner section of a module may be configured to include a plurality of aligned boxes. The boxes are sized and configured to provide recesses in the poured concrete window well for receiving human hands and/or feet. Thus, upon removal of the window well forming system, the recesses in the formed window well permit egress or facilitate entry by emergency personnel. Alternatively, the inner sections can be configured with the boxes extending into the window well area such that instead of recesses, steps are formed which project interiorly into the window well area. Such steps also provide footing and handholds for ingress and egress, and maybe positioned as site conditions dictate. Another alternative for providing steps in the window well wall contemplates the formation of hollows in the window well wall. This may be accomplished by providing the inner section of a module with bushings which are sized to receive insertable tools, preferably tapered tools. When the tools are removed from the bushing after curing of the poured concrete, the resulting hollows formed thereby may receive steps, such as U-shaped steps. The U-shaped steps may be driven into the hollows and held by gripping members to provide steps for ingress and egress.
In another alternative embodiment, the inboard leg of one or both of the inner sections and the outboard sections may be pivotally coupled to an adjacent foot which is configured for coupling and mounting to an adjacent forming panel by hinges. The use of a hinge coupling between the feet and the inboard legs facilitates installation of forming panels to the window well forming system, and provides an ability to adjust for variations in form placement or site conditions.
The present invention thus provides for an improved method of constructing structures having window openings and utilizing window wells. By providing complementally configured inner and outer sections and coupling the inner and outer sections which are coupled to fanning panels proximate a window buck, a window well may be cast in place by depositing flowable concrete between the inner and outer sections. Upon removal of the window well forming system, the resulting window well is of monolithic construction as a part of the wall, such as a foundation wall, of the structure. As used herein, “monolithic” construction means that the resulting window well wall and the building wall, typically a foundation wall of a building structure, is formed by concrete which is continuous and unbroken therebetween when cured. Most preferably, the monolithic construction of the present invention includes the provision of reinforcing steel in the form of bars, mesh or the like which extends outwardly from the building wall and extends into the window well wall, such that the concrete is poured to flow from the channel between the opposing forming panels of the wall and into the channel between the opposing panels of the window well module such that the poured concrete of the building wall and the window well wall cures at the same time and is continuous. Most preferably, at least that part of the window well wall formed by the angular inner and outer sections does not extend downwardly to be on substantially a common horizontal plane with the bottom of the foundation wall reducing waste. This can be accomplished by grading below the window well forming system hereof, or more preferably, by utilizing base plates which prevent the flow of concrete downwardly out from the channel between the forming panels. When additional support is needed for a window well, the present invention also provides for a pier to be poured as a part of the window well wall and on the outboard portion of the window well wall.
As noted above, the method provides for adjusting the size and configuration of the window well to be provided on-site, and without maintaining a large inventory of window wells. That is, by adding filler panels, or by stacking modules, the window well size can be readily increased, and piering provided as a part of the construction process so that the window well thereby formed is well supported at a distance from the wall formed contemporaneously with the window well. Also, as a part of the forming process, a textured or patterned surface may be provided on the window well to complement the surface of the walls of the structure by utilizing textured or patterned at least inner, concrete receiving surfaces on the face plates of the inner, or more preferably outer sections. The method also includes the provision of steps into the inner, window-well facing surfaces of the formed window well as discussed herein.
These and other advantages will be readily appreciated by those skilled in the art with reference to the drawings and the description which follow.
Referring now to the drawings, a window well forming panel system 100 in accordance with the present invention is adapted for use with conventional interior forming wall panels 102 and exterior forming wall panels 170 (which may be the same or similar panels) to permit the construction of a poured-in-place window well wall 106 (
In greater detail, the forming panel modules 108 and 110 include pairs of angular sections provided as preferably metal forms, and most preferably of a lightweight relatively inexpensive but relatively rigid material such as aluminum. The forming panel module 108 is comprised of angular sections 112 and 116, and the optional base plate 126, while the forming panel module 110 is comprised of angular sections 114 and 118 and a corresponding optional base plate 126. The optional base plate 126 may also be attached to the top rail of the angular sections by pins and wedges to limit overflow of concrete when design conditions dictate. The angular sections 112 and 116 are configured as inner sections, and thus are shorter in total length than their respective outer sections 114 and 118, so that while the inner sections parallel the outer sections, they are not congruent therewith. The inner sections 112 and 116 are complementally configured to their respective outer sections 114 and 118, so that with the exception of the formation of steps as described hereinafter, the distance therebetween remains substantially constant. Each of the angular sections 112, 114, 116 and 118 has a frame 136 to which a face plate 138 is attached by welding or the like. The face plate 138 has an inner (that is, facing toward the channel 174) concrete receiving surface 140 and an outer surface 142. The concrete-receiving surface 140 may be either substantially smooth, or provided with relief such as a textured relief to present a stucco appearance, a brick-face pattern as shown in
The rails 144, 146, 148 and 158 of each section 112, 114, 116 and 118 extend rearwardly from the face plate 138 of each section. The face plate is preferably a continuous sheet of metal and thus bends at a corner 156 of each section. In order to provide the necessary depth of an outboard wall portion 158 of the window well wall 106 away from the foundation wall 134 and to have the outboard wall portion 158 relatively parallel to the portion of the foundation wall 134 opposite, each section 112, 114, 116 and 118 preferably includes an inboard leg 162 which is preferably, though not necessarily straight, and an outboard leg 164 which is preferably, though again not necessarily straight, with the corner 156 therebetween. The corner 156 is most preferably arcuate to minimize stress concentrations and to provide a pleasing appearance to the resulting window well 106.
A first foot 166 is provided in each of the inner sections 112 and 116 which extends toward the window opening to be formed, and thus is angled at an angle of 90 degrees or less relative to the inboard leg 162 from which it extends. More preferably, the inner angle between the first foot 166 and the inboard leg 162 of the inner sections 112 and 116 is between about 85 and 40 degrees, and most preferably about 92 1/2 degrees. Because the rails are preferably constructed approximately perpendicular to the face plate, the inboard side rail 148 preferably is about parallel to the end rail 168 of the exterior wall surface forming panel 170 to which it connects, and as a result, the inboard leg 162 of each of the inner sections 112 and 116 extends outwardly from the forming panels 170 for the foundation wall and converge towards each other and the window opening 172. So that the outboard leg 164 may be approximately parallel to the face plate of the exterior wall surface forming panels 170, as a consequence the preferred angle between the inboard leg 162 and the first foot is the remainder after the inner angle of the corner 156 is subtracted from 180. Thus, in the most preferred embodiment, the angle between the first foot 166 and the inboard leg 162 is 92 1/2 degrees.
The outer sections 114 and 118 also have an inboard leg 162 and an outboard leg 164, and are configured with a corner 156. The outer sections 114 and 118 are constructed to have their corners and inboard and outboard legs substantially parallel but spaced apart from the respective opposing inboard sections 112 and 116. The nominal spacing, and thus the channel 174 between the inboard and outboard sections, is about 3 inches, but may be increased as described hereinafter. In order that the inboard leg 162 of the sections 114 and 118 may connect with adjacent forming panels 170 which are in parallel alignment along the forming wall, a second foot 176 extends from the inboard leg 162 of the outer sections 114 and 118 at least perpendicular or greater, or more preferably at an obtuse angle. Thus, the angle between the inboard leg 162 and the second foot 176 is preferably about 95 to 130 degrees, and most preferably about 102 1/2 degrees. The corners 156 of the outer sections 114 and 118 are arcuate and the angle between the inboard and outboard legs is the same as corners 156 of the inner sections 112 and 116, although the radius of curvature is greater to accommodate the channel 174 into which concrete flows during pouring.
Outboard side rail 150 of each of the inner sections 112 and 116 may be coupled to the spacer panel 120 and outer sections 114 and 118 may be coupled to spacer panel 122. The spacer panels 120 and 122 are opposed to one another and connected by pins and wedges or other fasteners known to those in the art to filler panels 124 on the lower part of the spacer panels 120 and 122 to constrain the flow of concrete poured therein. The filler panels 124 may be, for example, bulkhead forms or wooden boards used to span the space between the spacer panels 120 and 122 below the forming panel modules 108 and 110 The spacer panels 120 and 122 are opposed to one another and provide several functions and benefits. These include the ability to increase the width of the window well 184 to accommodate windows of various sizes or simply to provide the ability to adjust the width of the window well wall as desired. In this regard, the spacer panels 120 and 122 may be conventional flat forming panels of any desired width having top, bottom and side rails and reinforcing members typically known in the art as “hats” on the rearward, non-concrete-receiving side of a face plate as is conventional. Furthermore, the invention hereof facilitates the use of several such spacer panels 120 and 122 in side-by side relationship to further increase the width of the window well wall 106. Another function and benefit is that spacer panels 120 and 122 may be of different sizes or the same size. For example, the thickness of the concrete in at least a part of the window well wall 106 may be increased by the use of a spacer panel 122 connected to the outer sections 114 and 118 which is wider than spacer panel 120 which is connected to the inner sections 112 and 116. A further function and benefit when needed is to provide a support for the window well wall 106 by providing a space for receipt of concrete to form a pier 160 which supports the window well wall 106 so that the wall 106 is not cantilevered from the foundation wall but without the necessity of extending the modules 108 and 110 downwardly so that the entire window well wall 106 extends downwardly as far as the lower edge of the adjacent foundation wall. As shown in
As may be seen from the drawing
In order to enclose the bottom of the modules 108 and 110, base plates 126 are provided which conform in shape to the forming panel modules and include holes 180 for alignment with the holes 154 in the upper or lower rails of the modules. Fasteners such as pins and wedges or clamps may be used to couple the base plates to the respective sections of the modules 108 and 110 and to thereby inhibit the escape of flowable concrete through the bottom of the window well forming panel system 100. Typically, if the upper rails of the modules 108 and 110 are no lower than about a foot below the top of the pour into the forming panels 170 or further cap forms or other forms coupled thereabove, the hydraulic effect is insufficient to cause the concrete to flow up and over the upper rail 144 of the forming modules 108 and 110 and thus it is not necessary to cover the forming modules. However, where the height of the top of the foundation wall 134 is greater than about one foot above the top of the upper rail 144 of the forming modules 108 and 110, then additional base plates 126 may be attached to the upper rails using fasteners or clamps as described above to inhibit the overflow of concrete.
Alternatively, the inner sections 112 or 116, or the spacer panel 120, maybe configured with a box extending in the opposite direction, that is, forwardly into the channel where the concrete is received between the inner sections and outer sections of the forming modules. As shown in
A further approach to the provision of steps in a cast-in-place window well wall 106 is illustrated in
The outside window well forming panels 210 and 222 are of well-known construction including frames of aluminum include rails having holes for receiving coupling pins, and reinforcing members to which a face plate is welded as is known in the art, and are sized to be of a desired height and width. If provided with holes in the face plate thereof, plugs of synthetic rubber may be inserted therein to prevent concrete from flowing therethrough. The inside window well forming panels 208 and 220 are similarly constructed, but additionally include metal, typically steel or alternatively aluminum, bushings 228 welded to reinforcing bars 230 which are on the outer face 142 of the face plate 138 thereof so that the inside window well forming panels serve as step riser forms. The bushings 228 have a central bore 232 which is aligned with holes 234 in the face plate 138 of the panels 208 and 220. The bushings 228 and their corresponding holes 234 are arranged in vertical and horizontal alignment as seen in
Concrete received in the channel 174 flows around the projection to provide a cone-shaped hollow 244. When the concrete in the channel 174 is sufficiently cured to be self-sustaining, thereby forming the window well wall 106, the tools 236 are removed from their respective bushings 228 to leave the corresponding, frustoconically shaped hollows 244. The hollows 244 may also be provided by a drill using a masonry bit. U-shaped steps 246 having spaced apart substantially parallel extending fingers 248 and 250 may then be mounted to the inside (that is, the window well facing side) of the window well wall 106 to provide ingress and egress. The U-shaped steps 246 are preferably of synthetic resin or the like and may be adhesively bonded or more preferably provided with elastomeric ribs 252, nubs or other gripping members to hold fast to the window well wall 106 when pushed or driven into the hollows 244, as seen in
In the modified window well forming panel system 100A, it may be also be seen that the feet 212, 214, 226 and 228 are provided as separate members rather than unitary with the inner and outer sections as shown with regard to the forming system 100. The feet 212, 214, 226 and 228 can be of any desired width of vertical length, but in the embodiment illustrated herein, the feet are all of the same length and feet 212 and 226 are of one width while feet 214 and 228 are of a different width. It is simply to be understood that the length of the feet will require corresponding filler panel sections in the forming panel wall 132 above and below the feet, as illustrated in
As illustrated in
In accordance with the preferred method of the present invention, a foundation wall forming panel system 104 includes the use of conventional aluminum forming panels 102 placed side by side and opposed to one another using forming ties as is well known to those in the art. Such a forming panel system 104 is typically placed atop footings located below any frost line so that the resulting foundation wall 160 will not be damaged by heaving in the earth due to a cycle of freezing and thawing. Where a window is to be placed in the foundation wall 160, the forming panels 102 are configured to accept a window buck 272 therebetween, as illustrated in
In the present invention, the window well wall forming system 100 is provided so that the window well wall 106 maybe cast in place and provide added structural reinforcement. Footings are provided in the usual manner for the foundation wall 134, and in addition, a footing 178 is placed or poured at a desired depth and distance from the foundation wall 160 corresponding to the displacement or depth of the window well wall 106 from the foundation wall 160. While several conventional forming panels 102 may be employed along what will be the interior side of the foundation wall 160, forming panels 170 are coupled in combination with the forming panel modules 108 and 110 of the present invention so that concrete may flow from the volume 128 between the forming panels 102 and 170 and also into the continuous channel 174 located between the inner and outer sections of the modules 108 and 110 and between the spacers 120 and 122. Pins 276 and wedges 278 are typically employed as couplers for connecting the various modules, panels, spacers, fillers, feet and the like, as is well known in the art, and thus for clarity, only a small sampling of the number of such pins 276 are shown in the drawing. In addition, other couplers such as the latching bolt mechanism shown in U.S. Pat. No. 5,058,855, the entire disclosure of which is incorporated herein by reference, may be used in many instances instead of pins and wedges to couple adjacent panels and like forming members. The modules 108 and 110 are configured and operatively connected to preferably have the upper rails in substantially the same horizontal plane to one another, although it is to be understood that the depth of the concrete pour in the channel is largely determined by the contractor on site depending on how much concrete is poured into the volume between the forms 102 and 170 and then flows into the channel. The first and second feet of the respective inner and outer sections are designed to couple directly using pins and wedges or other coupler, or indirectly by including additional filler panels or the like as described above, to the adjacent forming panels 170 using pins and wedges or other couplers. Where the modules 108 and 110 are located lower than the upper rails of the forming panels 170, cap forms 212 are added atop the modules as shown in
Alternatives for forming steps in the window well wall 106 are described as above, including the use of step riser forms, flexible or other insets to form inset steps as in
It may also be appreciated that the window well forming panel system 100 may be readily stripped from the cured concrete window well wall 106 by the construction hereof. After removal of the base plates 126 and after the filler panels 124 are removed, the spacer panels may be pulled in a direction generally perpendicular to their plane. The forming panels 170 are disconnected from the inner and outer sections, and pulled away from the foundation wall 160. The outer sections 114 and 118 do not form any acute angles with the concrete, and thus are readily removed. The inner sections 112 and 116, once any forming panels 170 therebetween are removed, may be pulled toward one another to shear away from the concrete window well wall 106. Thus, the resulting window well is open at the bottom for drainage, and supported at its outboard extreme opposite the window opening by the pier 160 to avoid the necessity for additional support if cantilevered from the foundation wall 134. In this regard, it may be appreciated that the window well wall 106 in fact contributes strength to the foundation wall, in that it is unitary with and poured contemporaneously with the foundation wall. It provides additional strength in the manner of an outrigger to brace the foundation wall 134 against loads applied in a direction perpendicular to the plane in which it lies. It further bridges across the window opening in the foundation to provide a further structural member where there is reduced material in the foundation wall.
For reasons of aesthetics, the integrated system 104 of the present invention also contemplates the use of components such as inner or outer sections of the forming panel modules 108, 110 and the exterior forming wall panels 170 to be provided with a patterned or textured concrete-receiving surface of the face plate 138. By way of example,
In this manner, upon removal of the various modules and forming panels, the foundation wall 134 and the window well wall 106 may be provided with a surface with a brickface, stucco, or other appearance, with the appearance of the window well wall 106 being visually similar and compatible with the appearance of the foundation wall 134. Such an appearance may be more aesthetically pleasing to one viewing the inside of the window well wall 106 through the window placed in the window opening 134. The patterned or textured concrete-receiving surface may be provided in various manners, such as by stamping or forming the aluminum of the face plate 138A with the desired appearance, or alternatively by the use of a flexible member, made of material such as synthetic rubber, which has the desired pattern and which may be fitted over the face plate 138 of the desired sections prior to pouring of the concrete.
A further alternative method of providing a poured-in-place cementatious window well wall 300 is illustrated in
Although preferred forms of the invention have been described above, it is to be recognized that such disclosure is by way of illustration only, and should not be utilized in a limiting sense in interpreting the scope of the present invention. Obvious modifications to the exemplary embodiments, as hereinabove set forth, could be readily made by those skilled in the art after reviewing the disclosure herein without departing from the spirit of the present invention. For example, while arcuate corners are preferred, the corners could be angled instead of arcuate and provide a defined intersection between the inboard and outboard legs of the sections of the modules. Also, the modules can be provided as sections which are continuously arcuate of the same or changing radii of curvature, rather than configured with legs which are straight and connected at a corner.
The inventors hereby state their intent to rely on the Doctrine of Equivalents to determine and assess the reasonably fair scope of his invention as pertains to any apparatus not materially departing from but outside the literal scope of the invention as set out in the following claims.
This application is a divisional of application Ser. No. 12/016,142 filed Jan. 17, 2008, which claims the benefit of U.S. Provisional Application No. 60/885,355 filed Jan. 17, 2007, the entire disclosures of which are incorporated herein by reference.
| Number | Date | Country | |
|---|---|---|---|
| 60885355 | Jan 2007 | US |
| Number | Date | Country | |
|---|---|---|---|
| Parent | 12016142 | Jan 2008 | US |
| Child | 13184888 | US |
