Patent Application
20220412106
In construction, concrete curbs are constructed using a form construction arrangement, usually made of wood or metal or a combination of wood and metal components. The form arrangement sets the general boundaries of the curb, much like a mold. The pourable concrete, which can be in liquid mixture or a semi-solid state or be a slurry, is poured into the form arrangement. Once the pourable concrete has reached a sufficiently solid state, the form arrangement is removed and the curb is finished.
This section is for informational purposes only and does not necessarily admit that any publications discussed or referred to herein, if any, are prior art. In traditional or standard curb construction, wood guides are usually used. Some modern systems do not use wood, but instead use metal forms. However, metal forms are expensive, usually have one set design, and are very heavy to move around. Wood forms are often favored by most concrete contractors due to their lower cost, flexibility in design, and ease of transportation.
In concrete curb construction using wood form arrangements, the first step is to define the location and shape of the concrete curb. This first step involves placing metal rods, known as pins or stakes, into the ground at the corners or ends of the concrete curb or sections thereof. String is usually tied between pins to determine general concrete curb orientation and location.
The next step is to set up the wood form that will define the dimensions of the concrete curb. The use of wood allows for an unlimited number of configurations, but the general design is two parallel wood panel structures placed vertically or on edge to define an elongated trough or mold or channel between them, into which the concrete will ultimately be poured. Usually the wood panels are “two-inch” boards or “two-by” material, that is, wood boards or similar having a thickness of two inches. It is possible to use boards of a greater or lesser thickness. The width and length of such boards can be selected to whatever is suitable for the job. The most common widths for the boards are in the range of 12 inches to 18 inches, such as a 2″×12″ or 2″×18″. However, virtually any width outside of that range could be used, such as, for example, 2″×10″ or 2″×24″. The length of each individual board can be purchased or cut to a desired length. These wood panel structures define the back face and the front face of the concrete curb. The front face of the curb is the side facing an adjacent road or parking area, and the back face is the opposite side further away from the road or parking area, such as an adjacent sidewalk or building. Concrete curbs can often easily be quite long, such as, for example, 2000 to 3000 feet in total length, so many wooden boards are lined up along the length of the form, including curved and straight wooden pieces. While the entire curb can technically be framed before concrete is poured, it is often more common to frame out sections. For example, for a 3000-foot curb installation, 400- to 600-foot sections may be framed out and poured in steps.
In addition, while some curbs only consist of what is visible after construction, it is more common for the visible part to only be a portion of the concrete curb. For example, when installing a curb next to a roadway, the foundation of the curb is the ground underneath the roadway. The height of the curb therefore must extend from the ground, across the thickness of the roadway, and then a distance above the roadway surface to form the visible portion, also known as the reveal. The height of the concrete curb during construction therefore varies, though a common range is anywhere from 12 to 18 inches, or possibly more or less, wherein approximately six inches form the visible reveal and anywhere from six to 12 inches, or possibly more or less, are covered or obscured by the roadway. Such concrete curbs require front and back faces of equivalent height.
Since the panels are positioned on their edges, such as, for example, the two-inch side edge, they are much taller than they are wide, and thus they can easily be knocked over. Furthermore, since the panels are being used to temporarily hold and shape the pourable concrete, they need to be able to withstand the lateral pressure forces exerted by the concrete on the panels. The wood panels therefore obviously require some sort of holding mechanism or reinforcement to minimize and/or prevent displacement of the panels after set up and during pouring and setting of concrete. To achieve this reinforcement, usually metal rods known as pins or stakes are used. These pins are usually two to four feet in length, made of iron or steel, and have multiple holes therein. The holes are to allow nails or screws to be inserted through the pins to temporarily affix the pins and wood boards together. During installation, the pins are driven into the material next to the boards on the outside of both the front and back faces. The material can either be the ground or existing concrete or asphalt, as the case may be. Depending on the height and length of the concrete curb, many, many pins will have to be installed. For example, for taller concrete curbs, pins should be inserted no less than every three to five feet, +/−12 inches, along the length of the concrete curb. Curved sections may require pins every 12 inches, +/−6 inches. Therefore, for a 400-foot long straight concrete curb, for example, a total of approximately 200 pins-100 on the front face and 100 on the back face—could be required, or possibly even more, depending on the shape and design of the curb. These pins can often be installed by driving them into the ground using a sledge hammer or similar. However, if the surrounding material is very hard, such as rock or concrete, holes will have to be drilled to permit insertion of the pins. By installing the pins, the lateral pressure generated by the pourable concrete, which concrete is very heavy, i.e., approximately 150 pounds per square foot, will be resisted to prevent what are known as blowouts, that is, when a section of the front face or back face is knocked over or laterally displaced by the incoming concrete. Blowouts are very problematic because there could be substantial losses of concrete materials and work time to correct the problem.
In addition to setting up the front face, back face, and the pins, wood cross pieces or braces are usually installed. These wood braces are formed by cutting off sections of wood from a wood beam, usually a two by four, i.e., a wood board having dimensions of two inches by four inches. The wood braces are cut to match either the inner distance between the front and back face panels, or the outer distance from the outer edge of the front face to the outer edge of the back face. The wood braces are usually about 8-12 inches, +/−two inches or more, in length, depending on the width of the concrete curb. During installation, the wood braces are either inserted in between the panels near the top edge or across the top of the trough lying on the top side of the panels. In either case, the wood braces are nailed or screwed to the wood panels to provide additional securing or bracing of the wood panels of the front and back faces. Wood braces are usually cut on site using a visual estimate of length, and thus are of varied and different lengths.
In some concrete curb installations, the front face and back face are oriented perpendicular or essentially perpendicular to the ground or the horizontal and parallel or essentially parallel to each other. In other concrete curb installations, the front face may be oriented at an angle, such as a 60-70 degree angle, or possibly more or less, with respect to the ground or the horizontal, but the back face is oriented perpendicular or essentially perpendicular to the ground or the horizontal. When the front face is sloped in this manner, such that the thickness of the curb at the top is less than the thickness of the curb at the bottom, the distance between the top edge and the bottom edge of this sloped face is known as the batter. In such a situation, the reinforcement pins are inserted into the ground at the same angle to reinforce the sloped front face. In other concrete curb installations, the front face has more than one face surface in a stepped design, commonly used in a concrete curb and gutter installation. In this installation, the front face is essentially split into an upper portion and a lower portion, wherein the upper portion is closer to the back face and forms the curb with the back face, and the lower portion of the front face is further from the back face and forms the wider gutter with the back face. Before the concrete is poured, the upper portion of the front face is essentially suspended in mid-air, such that when concrete is poured into the form, the concrete can flow under the upper portion to form the gutter. Pins are also used to reinforce this upper portion, and must therefore be removed from the concrete that flows around the portions of the pins disposed below the upper portion of the front face.
Once all this extensive framing has been installed and the curb form defined, the pourable concrete is poured into the wood form arrangement. As the concrete sets in the form, the top surface of the concrete curb is scraped using a trowel or similar edged tool to remove any excess concrete sitting above or on top of the wood form arrangement to create a smooth upper surface even with or essentially parallel to the top edge surface of the wood panels. Another tool known as an edger is then used to form a contoured edge at the transition between the top surface and the side surfaces of the concrete curb.
After the scraping and edging is done, as well as any other desired finishing steps, the wood panel arrangement is removed from the concrete curb in a process known as stripping. The stripping process involves disconnecting the wood braces or cross pieces and the pins from the wood panels or boards by either unscrewing the screws or pulling out the nails connecting the wood panels to the metal pins and wood braces. As pieces are disconnected, the wood panels and cross pieces are removed and the pins or stakes are pulled up from the ground. Much of the wood is thrown away at substantial expense, especially if it was customized for a particular type of installation, though the metal pins are collected for use on future projects. Any gaps in the concrete curb, which can be formed when the concrete flows around the pins (in curb and gutter installations) or when the cross pieces are removed, must be filled in with concrete and/or smoothed over.
While the preceding process is effective for concrete curb installation, it does present some deficiencies. The installation of the metal pins is time-consuming and can be very difficult, especially when installing in hard surfaces such as rock or concrete. The removal of such pins can be as equally difficult as the installation, especially if the pins get stuck. All this effort results in increased labor costs. The metal pins are relatively heavy and somewhat expensive, which weight and expense is multiplied over dozens or hundreds of metal pins that may be necessary for a particular concrete curb. The wood cross pieces or braces are often cut at the work site by inexperienced workers, which results in often inaccurately cut cross pieces. Since these cross pieces help determine the shape of the wood form arrangement, the resulting curb can be jagged or crooked along its length, which can be unsightly for the consumer, if not unacceptable. In addition, these wood pieces are usually discarded at the end of the job. While this may not be an immense expense for a single job, the expense increases over multiple jobs, especially if lumber prices are increased for contractors in a particular area. Finally, the gaps in the concrete mentioned above are quite troublesome for the installers because they must be filled in with additional concrete. To further explain, any structure that is in the concrete at the time of pouring or setting must be quickly removed and the gap filled in before the concrete sets. In addition, the wood cross pieces on the top of the frame, though not in the concrete itself, create gaps or divots. As concrete fills into the frame, air gets trapped under the wood cross pieces as the concrete fills the area around it. When the wood cross pieces are removed, those gaps must be addressed almost immediately. Since concrete starts to harden or set relatively quickly after pouring, a team of multiple workers must work together all at the same time in a sort of organized chaos to try to address these gaps as quickly as possible, while at the same time managing the pouring of concrete, removal of framing components, etc. Not only does this approach necessitate additional labor costs, the risk of error increases because it is challenging to coordinate all persons involved, especially if the persons have different skill levels and experience in the field.
It therefore would be advantageous to eliminate the use of pins and wood braces in wood form arrangements. Elaborate metal form arrangements can eliminate the need for wood cross pieces and reduce the need for pins, but pins are often and still needed, and any labor or cost-savings resulting from elimination of wood cross pieces are matched or exceeded by the increased expense of very large metal forms and the relative difficulty of transporting and setting them up. In addition, metal forms usually are extremely limiting as they usually only allow one shape of curb, whereas wood forms allow much greater flexibility in curb design. Unfortunately, because of the weight of the concrete and the risk of blowouts, installations with wood forms have always been performed with metal reinforcement pins or similar reinforcing structures, and it is not generally believed in the industry that the use of such pins could be eliminated.
An object of the present application is to describe a method of constructing a concrete curb using a wood form, but without the use of reinforcing pins or wooden cross pieces or braces, or at least with the use of a minimal number of reinforcing pins. This method is performed using a bracket device made of metal or similarly strong material to hold and brace the wood forms against both vertical and lateral or horizontal displacement. The bracket device is designed such that the front and back faces can be held in place in essentially parallel alignment with one another, or at a predetermined angle if a batter is desired, throughout the entire curb construction process, including before, during, and after pouring of the concrete. The bracket device permits fast setup and removal of the wood form and promotes optimal construction of very straight concrete curbs, while also eliminating the substantial costs in materials and labor of the current construction methods using pins and braces.
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In at least one possible exemplary embodiment, the double-reinforced bracket device 1 has a fixed design, wherein the sections or components are all connected by a permanent connection, such as by welding or similar connection, or the sections or components are made in a unitary manner, such as by injection molding or similar forming in a mold. In at least one other possible exemplary embodiment, the double-reinforced bracket device 1 has an adjustable design, wherein the central portion 3 is made of at least two adjustable sections that can be moved with respect to one another to widen or shorten the gap or space between the bracket structures 5 and between the flanges 9.
The bracket structures 5 include a first or top portion 11 and a second or side portion 13 disposed at a right angle, or essentially a right angle, or substantially a right angle to the top portion 11. Upon installation on two wood panels or boards, the top portion 11 will lie on and be in contact with the top edge surface of a corresponding wood panel, whereas the side portion 13 will lie against and be in contact with a portion of the outer side surface of a corresponding wood panel. Two holes or openings 15 are located in each of the top portions 11, though more or fewer holes could be included. Screws can be inserted through these holes 15 and into the corresponding wood boards through their top edge surfaces to secure and temporarily fasten the double-reinforced bracket device 1 and the wood boards together. Nails or other affixing items could possibly be used, but screws will draw the pieces together to form a more secure connection. The flanges 9 also have two holes 17 therein, but could likewise have more or fewer holes as desired. These holes 17 permit the insertion of screws or other affixing structures into the wood boards through their side surfaces to further secure and temporarily fasten the double-reinforced bracket device 1 and the wood boards together. In at least one possible exemplary embodiment, the bracket structures 5 have holes 15, but the flanges 9 do not have any holes. In at least one other possible exemplary embodiment, the flanges have holes 17, but the bracket structures 5 do not have any holes. In at least one further possible exemplary embodiment, neither the bracket structures 5 nor the flanges 9 have any holes therein. In the exemplary embodiment shown in
The double-reinforced bracket device 1 does something that, to the knowledge of the inventor, was not before thought possible and was a surprise to the inventor and others in concrete curb construction, and that is the use of a wood form arrangement in concrete curb construction without the use of metal pins or stakes, and without the need for wood cross pieces, braces, or spacers. The bracket structures 5 first accurately space the front face and back face, such that the concrete curb has a consistent width or thickness along the length thereof. The bracket structure 5 also provide a securing force to prevent or minimize lateral or horizontal movement or displacement of the wood boards by the concrete as it is poured into the wood form arrangement. The bracket structures 5 further provide a securing force to prevent or minimize perpendicular or vertical movement or displacement of the wood boards, especially in curb and gutter or similar installations in which concrete will be flowing underneath one of the wood boards. Therefore, the bracket structures 5 and central portion 3 alone provide a very strong securing force that can resist the lateral forces exerted by the concrete on the wood panels as it is poured into the wood form arrangement, thereby minimizing the need for metal pins for lateral reinforcement.
When the double-reinforced bracket devices 1 are affixed at intervals to the wood panels, the resulting wood form arrangement will essentially stand on its own, ready for pouring of concrete. The double-reinforced bracket device 1 advantageously aligns the wood panels in a plumb manner and at precise, consistent, spacing, much like a metal form system would do, but without the expense and difficult handling and installation of a metal form system. Wood spacer blocks and guide strings are no longer needed. Metal pins can also be omitted, or at least used very sparingly. For example, 400 feet of concrete curb would likely require the installation of at least 200 metal pins, at least 75 wood spacers, and other guide strings and supplementary reinforcing structures, all of which then need to be removed in the stripping process. The double-reinforced bracket device 1 can eliminate all of these additional components, or minimize these components to much fewer metal pins for extra reinforcement, or at the very least cut the number of metal pins used by 50-80%. For example, for the 400-foot curb, the number of metal pins used could be reduced to a maximum of 100 rather than 200, and optionally even less, such as 50 or fewer metal pins. It is possible that even no metal pins could be used. The use of metal pins is dependent on the comfort level, preference, and experience of the installer, as some installers may prefer to still use metal pins as a backup support or out of habit. Again, this substantial reduction to complete elimination of metal pins was a very surprising result and not thought possible to the knowledge of the inventor, as further evidenced by the ubiquitous use of metal pins in all wood form concrete curb construction.
Such a design of the double-reinforced bracket device 1 produces substantial cost savings in materials and labor by the elimination or minimization of wood spacers and metal pins and the related time and effort spent in installation and removal of these structures. In addition, the double-reinforced bracket device 1 is very easy to install because there is no need to measure the spacing of the wood boards due to the guidance provided, which allows a construction crew to utilize even relatively inexperienced, lower-pay workers, thereby resulting in cost savings as more experienced, higher-pay workers can devote their time to higher skill tasks.
In accordance with at least one other possible embodiment, the thickness of the bracket structures 5 and flanges 9 can be minimized, such as to one-quarter or one-eighth of inch, or possibly thicker or thinner. The small thickness allows for the use of smaller screws to connect the bracket device 1 to the wood panels. To further explain, the thicker the bracket 5 or flange 9, the longer the screw needs to be to pass through the hole and into the wood. While long screws, i.e., screws in excess of two inches in length, can be useful as a securing structure, they do present some disadvantages. First, the cost of a longer screw is more than that of a shorter screw. Second, it takes more time, effort, and force to screw in and/or unscrew a longer screw. Third, the forces exerted on the longer screw during the lengthier screwing in process can cause the screw to sometimes break. Fourth, shorter screws can usually be screwed in without the need to drill pilot holes, whereas longer screws can cause splits or cracks in a board if pilot holes are not used. Therefore, if it is possible to use shorter screws in an application, they can be preferable. However, the bracket device, because the holes 15 for the screws can be located in the top portion 11 of the bracket structures 5, longer screws can be used if desired. If the screws are inserted into the top edge of the wood panel, then screws longer than two inches, such as three-inch or four-inch screws, can be used. As is well known, the longer the screw is, the more secure the connection is and retaining force.
By using a minimal thickness, such as one-eighth of an inch, the screws used can be quite small, such as in the range of one inch to one and five-eighths of an inch. Such smaller screws achieve all of the advantages listed above. In concrete construction, this is very important because of the massive number of screws used in an installation. Consequently, even minimal savings in time and material costs per screw are multiplied by the hundreds or thousands. In addition, as discussed above, the concrete curb process requires multiple jobs to be done at the same time. For example, as the concrete is being poured into the form by at least one person, another person is conducting the stripping process by removing screws and wood blocks, while yet another person is following soon after to do edging and/or finishing. Depending on the size and complexity of the job, it is common to have five or six persons working simultaneously. If any portion of the job takes longer than the others, then more people are needed to do that job. By using smaller screws, the person tasked with removing those screws in the stripping process can get the job done much more quickly and easily without additional help. In addition, it is important that the edger and finisher have access to the concrete while it is still workable and not set or hardened. If the screws can be removed quickly, then any components of the form in the way of the edger or finisher can also be quickly moved or removed right after the concrete has been poured. Finally, the design of the bracket device 1 allows for the use of such small screws without any sacrifice of securing force. For example, bracket structures 5 and flanges 9 act essentially like reinforcing washers for the screws, thereby maximizing the securing forces provided by the screw head.
That being said, concrete is very heavy and produces substantial liquid pressure on the wood panels as it is being poured, even for relatively short curbs. This pressure increases as the height of the curb increases, so the bracket structures 5 and central portion 3 alone may not provide a sufficient or desired amount of securing force. However, the angle portions 7 and the flanges 9 can generate an additional securing force that meets or exceeds any lateral forces exerted by the concrete as it is poured into the wood form arrangement for essentially any concrete curb construction. The angle portions 7 act as gussets and take advantage of the strength of triangular or angular reinforcements, with the flanges 9 providing a greater contact surface and displacement of forces. The flanges 9 also allow for the use of additional securing screws, although the double-reinforced bracket device 1 could provide sufficient securing forces without the screws.
One of the interesting and surprising effects of the design of the double-reinforced bracket devices 1 is that this pressure exerted by the concrete can advantageously be used to supply the securing or bracing force. To further explain, when the double-reinforced bracket devices 1 are first attached to the wood panels, they are exclusively held in place by the screws. However, as the concrete is poured and it starts to expand and press against the wood panels, the concrete presses the wood panels against the double-reinforced bracket device 1 itself. As the double-reinforced bracket devices 1 resist this expansion, a clamping effect is produced such that the double-reinforced bracket devices 1 are held tightly in place. In essence, the forces generated by the expanding concrete are now holding the double-reinforced bracket devices 1 in place on the wood panels more so than the screws, if not completely without any assistance from the screws. In prior art designs, the metal pins are held in place against this pressing force by being sunk into the ground. The double-reinforced bracket device 1, instead of simply fighting against this pressing force, takes advantage of it to create an extremely stable and secure form that is not dependent on how well-installed or secure or numerous the metal pins are. Since the concrete is now supplying all or essentially all or substantially all of the holding forces, the screws can immediately or essentially immediately be removed after pouring with little to possibly no risk that the wood panels will become displaced or moved by the concrete, or at least not displaced or moved to any noticeable degree or amount. Not only does this provide a secure form that will maintain the shape of the curb, it also provides enormous advantage during installation because it results in maximized time for the edgers and finishers to perform their work sooner while the concrete is workable, thereby minimizing overall work time and pressure to work faster than would be preferable to avoid mistakes. Again, the workers are usually working nearly simultaneously, so the sooner one worker can finish his job or stage in the process, the sooner the next job can be done. Therefore, the quicker the stripping process can be completed, the quicker the edgers and finishers can do their part.
Another advantage is that the double-reinforced bracket device 1 can be installed at the joints or abutments between two coplanar, abutting or adjoining wood panels. By placing the bracket structure 5 and flange 9 over the seam or abutment, such that half the bracket structure 5 is in contact with one wood board and half with the other wood board, and such that half of the flange 9 is in contact with the one wood board and half with the other wood board, the double-reinforced bracket device 1 simultaneously reinforces against vertical and lateral displacement, as discussed above, and secures the two wood boards together at their ends to produce a continuous front face or back face. In this situation, the double-reinforced bracket device 1 by itself eliminates a metal pin, a wood spacer block, and a wood joining or connecting piece needed to join or connect the ends of the abutting wood panels or boards.
One other advantage of said double-reinforced bracket device 1 is that the double-reinforced bracket device 1 is not positioned in any of the concrete when it is poured into the wood form arrangement. The central portion 3 is disposed above the trough that forms the concrete curb, and all other parts of the double-reinforced bracket device 1 are disposed outside of the trough, as opposed to the wood blocks or braces (see
In addition, as discussed above, even if frame pieces are outside of the concrete, this can still create problems, such as when air gaps form under the wood pieces that are flush with the top of the curb. The central portion 3 solves this problem by positioning and/or design. If the central portion 3 has a rod design, such as is shown in
Another advantage of the quick removal of the screws is quicker displacement or removal of the double-reinforced bracket device 1 to allow for prompt and efficient edging and finishing. To further explain, once the concrete is poured into the form, the excess concrete is scraped off of the top to form a top curb surface that is essentially parallel to the top edge surfaces of the wood boards of the front face and back face. The top curb surface is then further shaped or edged using an edger device. The edger device is run along the top of the concrete and creates a rounded or angled edge along the point where the concrete meets each of the wood boards, such that the corners of the concrete curb are rounded or angled rather than being at essentially right angles. In the prior art methods, the spacer blocks have to be removed and the gaps or divots filled before the scraping and edge work can be done. However, with the double-reinforced bracket device 1, the gaps and divots are first minimized or eliminated, saving that time and work. Next, it is possible to slightly displace the double-reinforced bracket devices 1 upwardly while the concrete is very workable. To further explain, after the concrete is poured and pressing against the wood panels and the bracket structures 5 and flanges 9, the screws can be removed. Since the flanges 9 are located a substantial distance from the top of the wood panel, such as near the middle of the wood panel, the double-reinforced bracket device 1, and thus the flanges 9, can be moved upwardly, such as a distance of about one to two inches, yet the flanges 9 will still be engaged and clamped to the wood panels with substantial holding force sufficient to resist the pressing forces of the concrete and maintain the wood panels in the desired position. Due to this upward movement, the central portion 3 can possibly be moved a distance above the top surface of the concrete to allow for scraping, edging, and/or finishing while the double-reinforced bracket device 1 is still connected to or installed on the wood panels. The edging and finishing work can therefore be started and/or completed very quickly after pouring. Instead of displacing the double-reinforced bracket device 1 a short distance, a worker could substantially displace or completely remove an individual double-reinforced bracket device 1 because the other bracket devices used along the wood panels provide sufficient holding force to prevent blowouts or the wood form losing shape. Alternatively, a combination of some metal pins and other bracket devices. In at least one possible embodiment, the double-reinforced bracket device 1 could be designed such that the central portion 3 is raised some distance above the bracket structure 5 sufficient to allow scraping or edging even without displacing the double-reinforced bracket device 1. Regardless of the exact procedure or combination of procedures and devices, the design and use of the double-reinforced bracket device 1 allows for substantial time-saving and increased efficiency.
In addition, the required workers for a curb construction project can be substantially reduced. Because the bracket devices according to at least one possible exemplary embodiment are easily installed, automatically-centering and forming, self-securing under pressure, and easily removed, a normal six-man team could be reduced to three or even two workers. For example, a 400-foot curb job might take anywhere from four to eight hours, depending on the skill and experience of the workers. This time and manpower could easily be reduced by 50% to 75%. Skilled workers with experience using the double-reinforced bracket device 1 could possibly complete such a job in as little as one hour. Therefore, instead of a 2000- or 3000-foot curb job taking many hours over several days, the job could theoretically be completed in as little as one day, representing massive savings for both workers and customers.
The double-reinforced bracket device 1 and the other devices disclosed herein may be used in forming all sorts of concrete structures, and possibly even other structures where a frame is required. For example, wall caps are concrete structures formed on the top of walls or similar structures, such as those made of brick or cinder blocks or similar. The wall caps protect the wall and create a smooth, aesthetic appearance. Unfortunately, wall caps are located a few to several feet off the ground, so framing methods like the metal pins and wood frames of the prior art for curb construction are unsuitable. Usually elaborate frame structures need to be built and heavily reinforced and supported to prevent the concrete from flowing out or breaking the frame. The bracket devices according to at least one possible exemplary embodiment can eliminate the need for extensive framing. Similarly to how the double-reinforced bracket device 1, for example, can eliminate or minimize the use of metal pins for curbs, it can do the same for elevated concrete structures, such as wall caps, by eliminating or minimizing the elaborate framing and supports required for installation, primarily because the pouring of the concrete actually strengthens the frame, rather than straining the frame.
At least one possible exemplary embodiment of the present application relates to a method of constructing a concrete curb or other shaped concrete structure using a wood form construction arrangement, said method comprising the steps of: positioning a first wood board and a second wood board opposite and essentially parallel to one another, such that said first wood board and said second wood board are oriented with their length dimension and height or thickness dimension running essentially parallel to the ground and their width dimension running essentially perpendicular to the ground to define a front face and a back face of a trough or mold for receiving concrete; spacing said first wood board a distance from said second wood board, wherein said distance corresponds to a width of a concrete curb or other shaped concrete structure; positioning and securing a double-reinforced bracket device on both said first wood board and said second wood board, such that a central portion of said double-reinforced bracket device spans said distance between said first wood board and said second wood board, said steps of positioning and securing comprising: aligning a first right-angle bracket, attached to the underside of said central portion, with an upper portion of said first wood board, such that a top portion of said first right-angle bracket is in contact with a top edge surface of said first wood board, and a side portion of said first right-angle bracket is in contact with an outer side surface of said first wood board; aligning a second right-angle bracket, attached to the underside of said central portion, with an upper portion of said second wood board, such that a top portion of said second right-angle bracket is in contact with a top edge surface of said second wood board, and a side portion of said second right-angle bracket is in contact with an outer side surface of said second wood board; inserting screws through at least one of: holes in said top portion of said first right-angle bracket and into said first wood board through and essentially perpendicular to said top edge surface of said first wood board, and holes in said side portion of said first right-angle bracket and into said first wood board through and essentially perpendicular to said outer side surface of said first wood board; inserting screws through at least one of: holes in said top portion of said second right-angle bracket and into said second wood board through and essentially perpendicular to said top edge surface of said second wood board, and holes in said side portion of said second right-angle bracket and into said second wood board through and essentially perpendicular to said outer side surface of said second wood board; aligning a first reinforcing flange, attached to the end of a first angled portion extending toward said outer surface of said first wood board at an approximately forty to fifty degree angle from a first end of said central portion projecting beyond said outer side surface of said first wood board, such that said first reinforcing flange is in contact with and essentially parallel to a portion of said outer side surface of said first wood board at a substantial distance from said right angle bracket; aligning a second reinforcing flange, attached to the end of a second angled portion extending toward said outer side surface of said second wood board at an approximately forty to fifty degree angle from a second end of said central portion projecting beyond said outer side surface of said second wood board, such that said second reinforcing flange is in contact with and essentially parallel to a portion of said outer side surface of said second wood board at a substantial distance from said right angle bracket; inserting screws through holes in said first reinforcing flange and into said first wood board through and essentially perpendicular to said outer side surface of said first wood board; and inserting screws through holes in said first reinforcing flange and into said first wood board through and essentially perpendicular to said outer side surface of said first wood board; repeating said steps of positioning wood boards and positioning and securing double-reinforced bracket devices for additional wood boards until said trough or mold comprises a shape and dimensions corresponding to a concrete curb or other shaped concrete structure to be poured; pouring pourable concrete into said trough or mold and permitting said double-reinforced bracket devices to secure and hold said wood boards in position and provide sufficient counter force against liquid pressure forces generated by the concrete on said wood boards, using either very few or no metal pins or stakes driven into the adjacent ground for reinforcement of said wood boards against lateral displacement.
At least one other possible exemplary embodiment of the present application relates to the method, wherein said method further comprises: unscrewing said screws for each of said double-reinforced bracket devices, which step of unscrewing is performed either immediately or shortly after pouring concrete to a level at or near a top portion of the portion of said trough or mold adjacent the screws of the double-reinforced bracket device to be unscrewed, and wherein said double-reinforced bracket devices can be unscrewed sequentially while concrete is being poured along the length of said trough or mold; and upon unscrewing of said screws, holding said first and second wood boards in position using an adjacent one of said double-reinforced bracket devices by permitting the liquid pressure forces generated by said concrete to press said first and second wood boards laterally against said first and second reinforcing flanges in a secure, clamping manner.
At least one other possible exemplary embodiment of the present application relates to the method, wherein said method further comprises at least partially displacing at least one of said double-reinforced bracket devices upwardly a distance, which distance is sufficient to permit scraping and/or edging of concrete under said central portion yet still permits said first and second reinforcing flanges to be in contact with said first and second wood boards, such that said first and second wood boards are still held in position by said at least one of said double-reinforced bracket devices.
At least one other possible exemplary embodiment of the present application relates to the method, wherein said method further comprises: removing all of said double-reinforced bracket devices upon said concrete being hardened or set sufficient to hold its shape without said double-reinforced bracket devices; or removing a portion of said double-reinforced bracket devices upon a section of said concrete being hardened or set sufficient to hold its shape without said portion of said double-reinforced bracket devices.
At least one other possible exemplary embodiment of the present application relates to the method, wherein said wood boards are held in position using solely said double-reinforced bracket devices and no metal pins or stakes.
At least one other possible exemplary embodiment of the present application relates to the method, wherein said wood boards are held in position using solely said double-reinforced bracket devices and no metal pins or stakes.
At least one other possible exemplary embodiment of the present application relates to the method, wherein: said wood form construction arrangement comprises at least one single-reinforced bracket device, which comprises: a central portion configured to span said distance between said first wood board and said second wood board; a first right-angle bracket and a second right-angle bracket attached to the underside of said central portion and at opposite ends; and a reinforcing flange attached to an end of an angled portion extending toward said outer side surface of one of said first and second wood boards at an approximately forty to fifty degree angle from one end of said central portion projecting beyond said outer side surface of said first wood board; and said first and second wood boards are held in position by a combination of said at least one single-reinforced bracket device and said double-reinforced bracket devices.
At least one other possible exemplary embodiment of the present application relates to the method, wherein: said wood form construction arrangement comprises at least one unreinforced bracket device, which comprises: a central portion configured to span said distance between said first wood board and said second wood board; and a first right-angle bracket and a second right-angle bracket attached to the underside of said central portion and at opposite ends; and said first and second wood boards are held in position by a combination of said at least one unreinforced bracket device and said double-reinforced bracket devices.
At least one other possible exemplary embodiment of the present application relates to the method, wherein: said wood form construction arrangement comprises at least one single-reinforced bracket device, which comprises: a central portion configured to span said distance between said first wood board and said second wood board; a first right-angle bracket and a second right-angle bracket attached to the underside of said central portion and at opposite ends; and a reinforcing flange attached to an end of an angled portion extending toward said outer side surface of one of said first and second wood boards at an approximately forty to fifty degree angle from one end of said central portion projecting beyond said outer side surface of said first wood board; said wood form construction arrangement comprises at least one unreinforced bracket device, which comprises: a central portion configured to span said distance between said first wood board and said second wood board; and a first right-angle bracket and a second right-angle bracket attached to the underside of said central portion and at opposite ends; and said first and second wood boards are held in position by a combination of said at least one unreinforced bracket device, said at least one single-reinforced bracket device, and said double-reinforced bracket devices.
At least one other possible exemplary embodiment of the present application relates to the method, wherein said method further comprises inserting screws into all holes in said first and second right-angle brackets.
At least one other possible exemplary embodiment of the present application relates to the method, wherein: at least one of said double-reinforced bracket devices comprises an adjustable double-reinforced bracket device configured to be adjustable in width; and said method further comprises adjusting the width of said at least one adjustable double-reinforced bracket device according to a desired width of said trough or mold.
At least one other possible exemplary embodiment of the present application relates to the method, wherein: said central portion of said at least one adjustable double-reinforced bracket device comprises a rod portion, a first tubular portion, and a second tubular portion, wherein said rod portion is configured and disposed to be inserted into said first and second tubular portions such that said first and second tubular portions can slide along said rod portion in a telescoping manner; said first right-angle bracket, said first reinforcing flange, and said first angled portion are attached to said first tubular portion, and said second right-angle bracket, said second reinforcing flange, and said second angled portion are attached to said second tubular portion, to permit adjustment of the distance between said first and second right-angle brackets and said first and second reinforcing flanges; said first and second tubular portions each comprise at least one locking screw being configured and disposed to be screwed in to lock said first and second tubular portions in a desired position on said rod portion, and to be unscrewed to release said first and second tubular portions to permit sliding adjustment thereof; and said step of adjusting the width of said at least one adjustable double-reinforced bracket device according to a desired width of said trough or mold comprises: sliding said first and second tubular portions along said rod portion to a desired position on said rod portion; and screwing in said locking screws and thereby locking said first and second tubular portions in said desired position on said rod portion.
At least one other possible exemplary embodiment of the present application relates to the method, wherein: at least one of said at least one single-reinforced bracket device comprises an adjustable single-reinforced bracket device configured to be adjustable in width; and said method further comprises adjusting the width of said at least one adjustable single-reinforced bracket device according to a desired width of said trough or mold.
At least one other possible exemplary embodiment of the present application relates to the method, wherein: said central portion of said at least one adjustable single-reinforced bracket device comprises a rod portion and a tubular portion, wherein said rod portion is configured and disposed to be inserted into said tubular portion such that said tubular portion can slide along said rod portion in a telescoping manner; said first right-angle bracket, said first reinforcing flange, and said angled portion are attached to said tubular portion to permit adjustment of the distance between said first and second right-angle brackets; said tubular portion comprises at least one locking screw being configured and disposed to be screwed in to lock said tubular portion in a desired position on said rod portion, and to be unscrewed to release said tubular portion to permit sliding adjustment thereof; and said step of adjusting the width of said at least one adjustable single-reinforced bracket device according to a desired width of said trough or mold comprises: sliding said tubular portion along said rod portion to a desired position on said rod portion; and screwing in said at least one locking screw and thereby locking said tubular portions in said desired position on said rod portion.
At least one other possible exemplary embodiment of the present application relates to the wood form construction arrangement according to the method, wherein said wood form construction arrangement comprising said wood boards, said double-reinforced bracket devices, and said screws.
At least one other possible exemplary embodiment of the present application relates to the wood form construction arrangement according to the method, wherein said wood form construction arrangement comprising said wood boards, said at least one single-reinforced bracket device, said double-reinforced bracket devices, and said screws.
At least one other possible exemplary embodiment of the present application relates to the wood form construction arrangement according to the method, wherein said wood form construction arrangement comprising said wood boards, said at least one unreinforced bracket device, said double-reinforced bracket devices, and said screws.
At least one other possible exemplary embodiment of the present application relates to the wood form construction arrangement according to the method, wherein said wood form construction arrangement comprising said wood boards, said at least one unreinforced bracket device, said at least one single-reinforced bracket device, said double-reinforced bracket devices, and said screws.
At least one other possible exemplary embodiment of the present application relates to the wood form construction arrangement according to the method, wherein at least one of said double-reinforced bracket devices comprises an adjustable double-reinforced bracket device configured to be adjustable in width.
At least one other possible exemplary embodiment of the present application relates to the wood form construction arrangement according to the method, wherein: said central portion of said at least one adjustable double-reinforced bracket device comprises a rod portion, a first tubular portion, and a second tubular portion, wherein said rod portion is configured and disposed to be inserted into said first and second tubular portions such that said first and second tubular portions can slide along said rod portion in a telescoping manner; said first right-angle bracket, said first reinforcing flange, and said first angled portion are attached to said first tubular portion, and said second right-angle bracket, said second reinforcing flange, and said second angled portion are attached to said second tubular portion, to permit adjustment of the distance between said first and second right-angle brackets and said first and second reinforcing flanges; and said first and second tubular portions each comprise at least one locking screw being configured and disposed to be screwed in to lock said first and second tubular portions in a desired position on said rod portion, and to be unscrewed to release said first and second tubular portions to permit sliding adjustment thereof.
Any numerical values disclosed herein, if any, should be understood as disclosing all approximate values within plus or minus ten percent of the numerical value. Any ranges of numerical values disclosed herein, if any, should be understood as disclosing all individual values within the range of values, including whole numbers, tenths of numbers, or hundredths of numbers.
The entirety of the appended drawings, including all dimensions, proportions, and/or shapes disclosed thereby or reasonably understood therefrom, are hereby incorporated by reference.
All of the patents, patent applications, patent publications, and other documents cited herein, are hereby incorporated by reference as if set forth in their entirety herein.
Some examples of concrete pouring structures and methods, components of which may possibly be incorporated into or adapted for use in at least one possible exemplary embodiment of the present application, may possibly be found in the following documents, as follows: “Product Book 2016” published by dee® Concrete Accessories II, Division of Tesko Enterprises, 7350 W. Montrose Ave., Norridge, Ill. 60706, www.deeconcrete.com and International PCT publication WO 2009010889.
Some examples of concrete pouring structures and methods, components of which may possibly be incorporated into or adapted for use in at least one possible exemplary embodiment of the present application, may possibly be found in the following U.S. patents and published U.S. patent applications, which are hereby incorporated by reference as if set forth in their entirety herein, as follows: U.S. Pat. Nos. 458,915; 657,802; 729,852; 1,067,420; 1,739,254; 1,922,584; 2,260,447; 2,678,482; 2,688,174; 2,793,416; 2,795,836; 2,809,414; 2,835,017; 2,894,307; 2,894,310; 2,965,950; 3,395,884; 3,785,606; 4,635,895; 4,836,487; 5,562,272; 6,629,681; 6,752,370; 7,182,309; 7,632,042; 9,243,374; 9,822,496; 10,106,993; and 20190010715.
Although the invention has been described in detail for the purpose of illustration of any embodiments disclosed herein, including the most practical or preferred embodiments at the time of filing of this application, it is to be understood that such detail is solely for that purpose and that the invention is not limited to such embodiments, but, on the contrary, is intended to cover modifications and equivalent arrangements that are within the spirit and scope of the present application, including the specification and the claims as originally filed, as amended, or as issued. For example, it is to be understood that the present invention contemplates that, to the extent possible, one or more features or components of any disclosed embodiment can be combined with one or more features or components of any other disclosed embodiment.
The present application claims the benefit of U.S. Provisional Patent Application No. 62/215,058, filed Jun. 25, 2021, which is incorporated by reference herein in its entirety.
| Number | Date | Country | |
|---|---|---|---|
| 63215058 | Jun 2021 | US |
