Patent Application
20220112671
This invention relates to concrete forms for materials such as concrete, polymer concrete or the like and, in particular, to a prefabricated pier top form for creating a shape for the top of a structural pier in a shape different from a typical cylindrical shape of the structural pier itself while maintaining the intended structural integrity of the structural pier.
The use of structural piers made from a concrete material is well known and widely practiced in the construction industry. These piers are typically formed by pouring concrete into a prefabricated tubular form made of spirally wrapped cardboard, plastic, or other materials. A common tubular pier form is a product with a tradename Sonotube®. Filling a Sonotube® form or other tubular form with concrete creates a cylindrical pier. Further, according to most building codes, structural piers are supported by a footing. The footing, which is normally also made of concrete material, provides support for the pier and its load. Traditionally, builders used in construction wooden footing forms built on-site. Today, various types of prefabricated footing forms exist, most of which are somewhat tapered towards the top where the tubular pier form and the footing form are joined. Prefabricated pier building is quick and is generally done in one pour of concrete, which increases cost savings. The method often consists of fitting a Sonotube® form or other prefabricated tubular pier form to a prefabricated footer form thus creating a pier form assembly. Next, rebar or steel reinforcing rods are placed inside the assembly. The form assembly is then often backfilled with dirt. Finally, the structural pier is created by filling the form assembly with one pour of concrete.
The typical structural pier arrangement leaves a portion of the cylindrical concrete pier protruding from the ground. International Building Code states that the finished structural pier be at least 6″ above finished grade when finished so the wood beam or post that attaches to it will be above any potential moisture. This, however, leaves a cylinder shaped unfinished structural pier look. Importantly, a homeowner or building owner may desire the pier to have a different shape other than a cylinder. This desire maybe driven by mere esthetics or the want to cover the pier with another material such as a stone material. To avoid this cylindrical look, many architects specify the entire pier be rectangle shaped to create a rectangle shaped upper portion of the pier protruding from the ground instead of a cylindrical upper portion of the pier so that either the pier could have rock or tile placed on it or the pier can be left rectangle to achieve a clean finish. Another reason for desiring a rectangle shaped upper portion of the pier protruding from the ground may be to match the pier with the same shape as a post attached above the pier, such as a rectangle 10″ upper pier portion matching with an 8″ rectangle wooden post.
Today, to build a rectangle pier instead of a cylindrical pier takes many more hours of on-site form work and generally two separate concrete pours, one to form a footer and then a second pour to form the rectangle pier. What is needed is a prefabricated pier top form that mates with a tubular pier form to create a desired shape for the final pier top different from the cylindrical pier itself while still allowing for the footer, the pier, and the pier top to be created with one concrete pour.
One embodiment of the present invention is a prefabricated pier top form for finishing the top of a prefabricated cylindrical pier in a shape such as a rectangle that is different from the cylindrical pier or pier created by a Sonotube® form. The pier top form allows the use of a prefabricated footer, a prefabricated tubular pier form or Sonotube® form, and the prefabricated pier top form to be filled with rebar and then with concrete in one pour to create a typical cylindrical pier but with a rectangle top or other desired shape that can be cleanly finished or finished with other materials such as stone to create an architect's desired look while maintaining the intended structural integrity of the pier.
The pier top form in one embodiment is a prefabricated form that mates with a tubular pier form, or Sonotube® form or another prefabricated concrete form such as prefabricated footer form. The footer form, tubular form, and pier top form create a structural pier form assembly into which rebar is placed as per local code and or International Building codes. The entire assembly can be backfilled as normal and filled with concrete in one pour.
The concrete pier top form does not have to be filled to the top. The pier top form could be partially filled to any desired level, typically 6″ above finished grade. The pier top form can also be directly fitted to the footer if a shorter height structural pier is needed.
Once the concrete has cured, the pier top form can be removed to expose the clean concrete shape of the pier top form. Typically, the pier top form will have a rectangle shape to create a structural pier with a rectangle shape top or upper portion, but the pier top form may have a pyramid shape, another quadrilateral shape, rock shape, or other custom shape to meet architectural specifications.
The prefabricated pier top form could be either a single-use form manufactured from material like cardboard or plastic, or the pier top form could be manufactured from a metal material to be reused. The pier top form may be made to any height or width with a lower portion sized to mate a typical 8, 10, or 12 inch diameter tubular form such as a form manufactured by Sonotube®. The pier top form may be fixed to the tubular pier form using any common method such as using screws to secure the two forms together.
The embodiments of the present invention will be described with reference to the drawings
Embodiments of the present invention are illustrated by way of examples and are not limited to the accompanying drawings:
Referring now to the figures,
Referring to
The pier top form 20 can be fully or partially filled with concrete to achieve the desired finished height. The pier top form 20 could be partially filled to any desired level. Typically, the pier top form 20 will be filled to a resulting height of six inches above finished grade. In some applications where a shorter overall structural pier is desired, the pier top form 20 can also be directly fitted to the footer form 14 as shown in
The tapered mid-section 40 transitions between the lower section 30 that mates to the pier form 12 and the upper section 50 that forms the desired shape of the pier top. The taper section 40 in one embodiment smoothly transitions between the two other sections permitting concrete to flow through the pier top form 20 to the pier form 12. In another embodiment, the pier top form 20 transition section 40 comprises a step or other shape as required to maintain flow of concrete through the pier top form 20 as it is being filled. The transition section 40 may also have securing portions for securing rebar or other structural members inside the pier top form 30.
The upper section 50 of the pier top form 20 forms the desired shape of the top of the structural pier.
The prefabricated pier top form 20 may be made from various materials including cardboard, plastic, or metal. In an embodiment of the invention, the pier top form 20 is made from cardboard. Following pouring concrete to create the pier and the setting of the concrete, the cardboard pier top form 20 may be cut away from the concrete exposing a clean pier top.
In another embodiment of the invention, the prefabricated the pier top form 20 is divided into first and second sections couple by a hinge. The first and second sections are held shut by a closure. The hinge permits easy removal of the pier top form 20 after concrete has been poured to form a structural pier. One or more, clasps or other structures may be used to hold the pier top form 20 closed as part of the structural pier form assembly 10 prior to pouring concrete.
It will be appreciated by those skilled in the art that the present invention is not limited to any particular the arrangement described above or below.
