Wall Forming Apparatus

Abstract

A barrier forming system is described that includes a plurality of studs, rails and barrier reinforcement members interconnected between top and bottom plates. The interconnected studs, rails, reinforcement members, top plate and bottom plate may be precisely bent or curved in either or both the vertical and horizontal directions. The interconnected studs, rails, barrier reinforcement members, top plate, and bottom plate may be embedded in a filler material to form a curved concrete barrier having a complex geometry.

Description

FEDERAL SPONSORSHIP

Not Applicable

JOINT RESEARCH AGREEMENT

Not Applicable

TECHNICAL FIELD

The present invention relates generally to structural multi-dimensional interior or exterior curved barriers such as walls and/or ceilings, and more particularly relates to a form that utilizes a plurality of curved studs, rails, plates and sheathing suitable for constructing structural load bearing barriers or walls made from pneumatically projected or applied concrete.

BACKGROUND

In the past, construction of concrete walls has required presetting temporary wall forms or formworks in a location where the concrete wall is desired. Concrete is then poured into the formwork and allowed to stabilize or cure before removing the form. A formwork may typically include sidewalls and steel or wood shoring to create the desired shape of the wall. Straight concrete structures that contain planar faces, either plumb or leaning, are created using straight sidewalls and shoring. Concrete structures requiring a more unique shape have required many pieces to be mitered or curved and then pieced together to create the desired shape of the sidewalls of the formwork. Wood beams for the shoring can be cut into curved shapes with a saw, and plywood for the sidewalls can be curved easily using multiple thin layers, but cutting and shaping the wood beams and plywood are only economical when the shape is a continuous two dimensional surface like a drum or a cone. Creating a formwork for a simple dome requires many compound shapes and further requires complex cutting of the plywood into an orange-peel type of shape and then installing on formwork in a faceted manner.

Other multi-dimensional complex surfaces or curved surfaces have been created utilizing a custom formwork that utilizes a single sidewall and shotcrete that is sprayed onto the sidewall until a desired thickness of the concrete wall is established. The shape of the form work has been defined by creating a grid work of rebar and then bending the rebar to create the desired shape of the wall. Additionally the sidewall may be created to define the desired shape and then the sidewall is attached to the rebar. A single sidewall formwork typically includes a plastic sheathing overlying the more rigid material such as plywood or foam board. The plastic sheathing layer is utilized so that the foam board or plywood is easily removed once the concrete has cured. Once the concrete cures the formwork is removed and disposed. The present invention utilizes stud profiles and rails to define and hold the shape of the screens or sheathing. The studs and rails of the present invention are embedded in the concrete, are not intended to be removed, and do not require removal or disposal. Utilizing the present invention to form curved concrete walls further eliminates the time required to remove and dispose of the shaped plywood or foam board mold used for one side of the wall.

SUMMARY

Embodiments according to aspects of the invention provide a barrier forming system or apparatus that reduces the total amount of time required to construct a curved concrete surface or wall formed from a spray on filler material such as shotcrete. According to other aspects, the framework of steel profiles or studs, rails and wall reinforcement remain embedded in the barrier having a complex geometry. These and other embodiments according to aspects of the invention include spaced apart corrugated studs, a top plate, bottom plate, and corresponding rails. Depending upon the orientation of the invention the top and bottom plates could be construed as side to side plates. The corrugated studs are spaced apart and are curved to define a curvature of the barrier or concrete wall. Similarly the corresponding rails are shaped to correspond with the curvature of the studs and further to define the curvature of the barrier or concrete wall. The top plate is coupled to top ends of the studs and the bottom plate is coupled to bottom ends of the studs. The rails include a first set of rails that correspond with the studs, wherein the set of first rails are coupled to first edges of the corresponding studs. Likewise the rails include a second set of rails that correspond with the studs, wherein the set of second rails are coupled to second edges of the corresponding studs. The inner side of the curvature of the barrier or concrete wall is defined by the first set of rails and first edges of the studs. Also, the outer side of the curvature of the barrier concrete wall is defined by the set of second rails and the second edges of the studs. After the studs, top plate, bottom plate and rails are assembled, a filler material such as concrete embeds the studs and rails to create a barrier or concrete wall capable of having a curved complex geometry.

In accordance with certain aspects of the invention, the barrier forming apparatus may further include a first barrier or wall reinforcement network coupled to the first edges of the studs and coupled to the first rails. A second barrier or wall reinforcement network may be coupled to the second rails and second edges of the studs. Both the first and second barrier or wall reinforcement networks may be comprised of a mesh or grid network of rebar that are coupled together. The barrier or wall reinforcement networks are set or sandwiched between the rails and studs. When a complex geometry of curves is desired, the top plate and the bottom plate may be constructed from a corrugated plate or stud, for example and without limitation intended, to facilitate the shaping of the top and bottom plate to match a desired curve. Sheathing is attached to the first rails and retains the filler or concrete when the filler or concrete is sprayed to embed the rails and studs.

In use, the wall forming apparatus may be used to construct a cast surface having complex geometries and curves in both the horizontal and vertical directions. The cast surface may, for example, include concrete, fiberglass, foam or plaster. Further, by way of example, a concrete wall structure may be formed by determining a desired horizontal curvature of the concrete wall; determining a desired vertical curvature of the concrete wall; bending a top plate and bending a bottom plate to match the desired horizontal or vertical curvature of the concrete wall; bending studs and bending rails to match a desired vertical curvature of the concrete wall; aligning the bent studs with the top plate and bottom plate; fastening the bent studs to the top plate and the bottom plate; fastening rails to the studs; setting wall reinforcement members between the studs and rails; attaching sheathing to the first rails; and embedding the studs and rails in concrete.

This new methodology bypasses the traditional methods of casting concrete or other materials in temporary forms. A structure of the present invention is created by assembling curved studs or profiles to create and maintain the geometry of the required barrier or wall regardless of the degree of simplicity or complexity. An example of the methodology uses curved studs or profile members which are attached to top and bottom tracks. The studs or profiles have attached to them a series of universal clips which act as an attachment point for both the rebar or other reinforcement and the outer shaped channel or rail (in this case a hat channel but an angle or other shape can work as well). The clip size and location is designed to carry the total loads to support the re-bar and furring member sheathing assemblies until the form or volume is filled in with the filler material. The shapes of the studs and rails illustrated in the drawings can be replaced by other embodiments and materials and still create the same affect.

The accompanying drawings, which are incorporated in and constitute a portion of this specification, illustrate embodiments of the invention and, together with the detailed description, serve to further explain the invention. The embodiments illustrated herein are presently preferred; however, it should be understood, that the invention is not limited to the precise arrangements and instrumentalities shown. For a fuller understanding of the nature and advantages of the invention, reference should be made to the detailed description in conjunction with the accompanying drawings.

DESCRIPTION OF THE DRAWINGS

In the various figures, which are not necessarily drawn to scale, like numerals throughout the figures identify substantially similar components.

FIG. 1 is an inner perspective view of a barrier forming apparatus of the present invention shown with one attached sheathing member;

FIG. 2 is an outer perspective view of a barrier forming apparatus of the present invention;

FIG. 3 is an inner perspective view of a barrier forming apparatus of the present invention shown with one attached sheathing member;

FIG. 4 is an inner perspective view of the barrier forming apparatus of the type illustrated in FIG. 3;

FIG. 5 is an inner perspective view of the barrier forming apparatus of the type illustrated in FIG. 3;

FIG. 6 is an inner perspective view of the barrier forming apparatus of the type illustrated in FIG. 3;

FIG. 7 is a left perspective view of a profiled stud of the present invention;

FIG. 8 is a right perspective view of a profiled stud of the type illustrated in

FIG. 7;

FIG. 9 is a left perspective view of a profiled rail of the present invention;

FIG. 10 is a right perspective view of a profiled rail of the type illustrated in FIG. 9;

FIG. 11 is a left perspective view of an alternative profiled rail of the present invention;

FIG. 12 is a perspective view of an attachment clip of the present invention;

FIG. 13 is a left side view of the barrier forming apparatus of the type illustrated in FIG. 1;

FIG. 14 is a partial sectional perspective view of the barrier forming apparatus of the present invention;

FIG. 15 is a partial sectional left side view of a bottom portion of the barrier forming apparatus of the present invention;

FIG. 16 is a bottom left partial sectional perspective view of a portion of the barrier forming apparatus of the present invention; and

FIG. 17 is a flowchart illustrating the process of forming a curved concrete wall utilizing the barrier forming apparatus of the present invention.

DETAILED DESCRIPTION

The following description provides detail of various embodiments of the invention, one or more examples of which are set forth below. Each of these embodiments are provided by way of explanation of the invention, and not intended to be a limitation of the invention. Further, those skilled in the art will appreciate that various modifications and variations may be made in the present invention without departing from the scope or spirit of the invention. By way of example, those skilled in the art will recognize that features illustrated or described as part of one embodiment, may be used in another embodiment to yield a still further embodiment. Thus, it is intended that the present invention also cover such modifications and variations that come within the scope of the appended claims and their equivalents.

The barrier forming apparatus 10 of the present invention is particularly well suited for creating a curved concrete wall having complex geometries. Those skilled in the art will appreciate that the barrier forming apparatus may also be utilized to form a barrier or partition such as ceilings or domes without departing from the scope of the invention. Thus, references to a curved concrete wall is not intended to be limiting to a vertically extending wall but also includes other barriers and partitions including a curved dome or ceiling. The present invention is further particularly well suited to reduce the time needed to create and construct an accurate barrier having a complex geometry. With reference to FIGS. 1 and 2 the barrier forming apparatus 10 is shown assembled with a plurality of rails 40, studs 20, and opposing grid works 92 of rebar, wherein the plurality of rails and studs are aligned and spaced apart with top and bottom plates 60 and 70. The grid work 92 of rebar is comprised of spaced apart horizontally oriented rebar 94 and spaced apart vertically oriented rebar 96. The assembly of studs 20, rails 40, top plate 60, bottom plate 70 and grid works 92 are held in place with clips 80 and fasteners. The curvature and complex geometry of the barrier forming apparatus 10 is defined by the curvature of the spaced apart studs 20 and rails 40. The inner curvature of the barrier forming apparatus includes sheathing attached to the inner rails. Although the Figures illustrate only one panel of sheathing 100 those skilled in the art will appreciate that the entire inner side may be covered with sheathing 100. Once the sheathing 100 is attached to the rails 40, pneumatically applied or sprayed filler such as concrete 14 is applied to the structure 10 to embed the studs 20, rails 40 and rebar 90.

FIGS. 3-6 further illustrates the barrier forming assembly 10, the position of the sheathing 100, and the suitability of the form 10 for pneumatic applied filler applications. Those skilled in the art will appreciate that the grid work or wall reinforcement 92 may comprise a series of space apart rebar 90 or other suitable network of rods, wire mesh, or fibers. The rods are preferably tied together with wire so that the wall reinforcement network may be placed between the studs and rails in a secure manner to allow the spraying of the filler material. After the filler is applied, the outer surface of the wall may covered with a plaster, gypsum, sheathing or other barrier finishing product. The clips 80 include holes or apertures 86 that are well suited for wire, screws or other fasteners to extend there through. The wires or screws fasten the clips to the wall reinforcement network, the rails 40 and the studs 20. The length of the clip 80 determines the thickness of the filler into which the barrier reinforcement network is embedded. The top plate 60 includes a main body 62 and sides 64. The bottom plate 70 similarly includes a main body 72 and sides 74.

FIGS. 7 and 8 further illustrate the construction of a preferred corrugated stud 20 suitable for the present invention. The stud 20 includes a main body or channel member 22, substantially opposed sides 24 extending upward from the main body, and inwardly extending flanges 30 extending inwards from the opposing sides 24. Preformed creases 26 are formed in the main body 22 and preformed crease 28 is formed in a side of the stud. The method of forming the preformed creases is further described in U.S. Pat. Nos. 7,458,188 and 6,138,359 the entire disclosures of which are incorporated herein by reference. The preformed creases allow the stud to be bent to have a desired curvature. The studs may also be twisted to provide a still further geometric complexity to the barrier or wall. Of course bendable studs having different structure may be utilized without departing from the scope of the invention.

FIGS. 9-11 illustrate a suitable rail 40, however, those skilled in the art will appreciate that other known hat channel or DIN rail may be utilized without departing from the scope of the invention. The rail 40 includes a base 42, flange 44 and channel 46. The rail 40 may be bent either towards or away from the channel 46. In this manner, the flange 44 may be placed against the wall reinforcement network or grid work 92 and while matching the curvature of the outer barrier 48 or matching the curvature of the inner barrier 50. Numeral 48 identifies the curvature that corresponds with an outer barrier while numeral 50 identifies the curvature that corresponds with an inner barrier. Further, by way of example and without limitation intended, the rail may be constructed in accordance with the teachings of U.S. Pat. No. 8,621,823 the entire disclosure of which is incorporated herein by reference.

FIG. 12 illustrates a clip suitable to couple the studs, rails and sheathing while retaining a grid work of rebar in a fixed position until the filler such as concrete is applied and cured. Clip 80 may be attached to either the main body 62 and 72 or the sides 64 and 74 corresponding to the respective top plate 60 and bottom plate 70. Clip 80 may be further attached to the base 42 or flange 44 of the rail 40. Fasteners, weld, wires, screws or other known suitable fastener may be utilized to attach the clip to the corresponding parts in the desired location.

FIGS. 13-16 illustrates the barrier components and how they interrelate and attach together. The corrugated, spaced apart plurality of studs 20 define a curvature of the barrier such as a concrete wall. The studs 20 may extend in a vertical direction and curve in only the vertical direction or alternatively the studs may curve in the vertical direction and twist in the horizontal direction. The top plate 60 and bottom plate 70 are straight when the barrier only curves in the vertical direction. When the formed barrier includes a curve in both the vertical direction and the horizontal direction (in the case of a dome, for example), the studs are at least curved vertically and the top plate 60 and bottom plate 70 are curved and aligned in the approximately horizontal direction. The curved top and bottom plates may be corrugated to aid in the bending of the plates.

Those skilled in the art will appreciate that many complex barrier or wall geometries may be precisely formed utilizing the barrier forming apparatus 10 of the present invention. When the barrier forming apparatus 10 is assembled, the top plate 60 couples to top ends of the plurality of studs 20. Similarly, when the barrier forming apparatus 10 is assembled, the bottom plate 70 couples to bottom ends of the plurality of studs 20. The curved studs 20 of the assembly further include curved rails that correspond with the studs, attached to opposing edges of each stud. The inner side of the curvature of the barrier is defined by the curvature of a first plurality of rails 40 attached to corresponding first edges of the studs 20. Likewise, the outer side of the curvature of the barrier is defined by the curvature of a second plurality of rails 40 attached to corresponding second edges of the studs 20. A first barrier reinforcement network 92 may be sandwiched or set between and coupled to the first edges of the studs and the first rails. Further, a second barrier reinforcement network 92 may be coupled to the second edges of the studs and coupled to the second rails. The sheathing 100 may be held in place and attached to the first plurality of rails forming the inner curve of the barrier. Clips 80 may be utilized to couple the studs 20 and rails 40. Once the barrier forming apparatus 10 is assembled a filler material such as concrete is pneumatically applied to the sheathing from the outer side of the barrier. The concrete may be of a shotcrete type and the plates, studs, rails and network of reinforcement are all embedded in the concrete.

FIG. 17 is a representative flowchart that illustrates a process 110 suitable for forming a curved concrete wall having a complex geometry. Although the process is described in terms of forming a curved concrete wall, those skilled in the art will appreciate that a similar process may be utilized to form other barriers such as a curved ceiling or fiberglass filled walls without departing from the scope of the inventive process. Referring to FIG. 17, a user determines a desired horizontal curvature of the concrete wall 120 and a desired vertical curvature of the wall 122. The top plate and bottom plate are bent to match the desired horizontal curvature of the concrete wall 124. Likewise, the studs and rails are bent to match a desired vertical curvature of the concrete wall 126. The bent studs are spaced apart and aligned with the top plate and bottom plate. Once aligned, the bent studs may be fastened or otherwise attached to the top plate and the bottom plate 128. A desired network of reinforcement or rebar grid is determined 130 the grid work is set between the studs and rails 132. The rails and studs are then fastened or otherwise attached or coupled together 134. An inner side of the curvature of the concrete wall is defined by first rails and first edges of the studs. The sheathing 100 is attached to the inside wall portion or the first plurality of rails 40 as described above in greater detail 136. A user may then embed the studs and rails and grid 92 in concrete 138. After the concrete is pneumatically applied the concrete may be troweled or otherwise smoothed and then allowed to cure 140.

These and various other aspects and features of the invention are described with the intent to be illustrative, and not restrictive. This invention has been described herein with detail in order to comply with the patent statutes and to provide those skilled in the art with information needed to apply the novel principles and to construct and use such specialized components as are required. It is to be understood, however, that the invention can be carried out by specifically different constructions, and that various modifications, both as to the construction and operating procedures, can be accomplished without departing from the scope of the invention. Further, in the appended claims, the transitional terms comprising and including are used in the open ended sense in that elements in addition to those enumerated may also be present. Other examples will be apparent to those of skill in the art upon reviewing this document.

Claims

1. A barrier forming apparatus for load bearing surface structures, the barrier forming apparatus comprising: corrugated spaced apart studs defining a curvature of the barrier;a top plate coupled to top ends of the studs;a bottom plate coupled to bottom ends of the studs;first rails that correspond with the studs, the first rails being coupled to first edges of the corresponding studs;second rails that correspond with the studs, the seconds rails being coupled to second edges of the corresponding studs;wherein an inner side of the curvature of the barrier is defined by the first rails and first edges of the studs;wherein an outer side of the curvature of the barrier is defined by the second rails and the second edges of the studs; anda filler material that embeds the studs and rails.

2. The barrier forming apparatus as recited in claim 1, further including a first barrier reinforcement network coupled to the first edges of the studs and coupled to the first rails.

3. The barrier forming apparatus as recited in claim 1, further including a second barrier reinforcement network coupled to the second edges of the studs and coupled to the second rails.

4. The barrier forming apparatus as recited in claim 1, wherein the top plate and the bottom plate are constructed from a corrugated plate.

5. The barrier forming apparatus as recited in claim 1, further including a sheathing attached to the first rails.

6. The barrier forming apparatus as recited in claim 1, further including clips that couple the studs and first rails together.

7. The barrier forming apparatus as recited in claim 1, further including clips that couple the studs and second rails together.

8. The barrier forming apparatus as recited in claim 1, wherein the filler material is of the shotcrete type.

9. The wall forming apparatus as recited in claim 1, wherein the inner side and outer side of the barrier are exposed above ground level.

10. A barrier forming apparatus for concrete wall structures, the barrier forming apparatus comprising: corrugated spaced apart studs defining a curvature of the concrete wall;a top plate coupled to top ends of the studs;a bottom plate coupled to bottom ends of the studs;first rails that correspond with the studs, the first rails being coupled to first edges of the corresponding studs;a first wall reinforcement network coupled to the first edges of the studs and coupled to the first rails;second rails that correspond with the studs, the seconds rails being coupled to second edges of the corresponding studs;a second wall reinforcement network coupled to the second edges of the studs and coupled to the second rails;wherein an inner side of the curvature of the concrete wall is defined by the first rails and first edges of the studs;wherein an outer side of the curvature of the concrete wall is defined by the second rails and the second edges of the studs; andconcrete that embeds the studs and rails.

11. The barrier forming apparatus as recited in claim 10, wherein the first wall reinforcement network is comprised of a mesh of rebar.

12. The barrier forming apparatus as recited in claim 10, wherein the second wall reinforcement network is comprised of a mesh of rebar.

13. The barrier forming apparatus as recited in claim 10, wherein the top plate and the bottom plate are constructed from a corrugated plate.

14. The barrier forming apparatus as recited in claim 10, further including a sheathing attached to the first rails.

15. The barrier forming apparatus as recited in claim 10, further including clips that couple the studs and first rails together.

16. The barrier forming apparatus as recited in claim 10, further including clips that couple the studs and second rails together.

17. The barrier forming apparatus as recited in claim 10, wherein the concrete is of the shotcrete type.

18. The barrier forming apparatus as recited in claim 10, wherein the inner side and outer side of the concrete wall are exposed above ground level.

19. A method of forming a barrier, the method comprising the steps of: determining a desired horizontal curvature of the barrier;determining a desired vertical curvature of the barrier;bending a top plate and bending a bottom plate to match the desired horizontal curvature of the barrier;bending studs and bending rails to match a desired vertical curvature of the barrier;aligning bent studs with the top plate and bottom plate;fastening the bent studs to the top plate and the bottom plate;fastening rails to the studs;wherein an inner side of the curvature of the barrier is defined by first rails and first edges of the studs;setting barrier reinforcement members between the studs and rails;attaching sheathing to the first rails; andembedding the studs and rails in a filler material.

20. The method as recited in claim 19, further including the steps of smoothing the filler material and curing the filler material.