U.S. patent application number 13/590118 was filed with the patent office on 2013-10-17 for stay-in-place concrete form.
The applicant listed for this patent is Kevin P. Ryan. Invention is credited to Kevin P. Ryan.
Application Number | 20130269275 13/590118 |
Document ID | / |
Family ID | 49323810 |
Filed Date | 2013-10-17 |
United States Patent
Application |
20130269275 |
Kind Code |
A1 |
Ryan; Kevin P. |
October 17, 2013 |
STAY-IN-PLACE CONCRETE FORM
Abstract
A stay-in-place concrete form includes masonry shells layered
with lightweight concrete and rigid insulation tied with plastic
ladders. The masonry shells can be capped with plastic shims that
compensate for the variation in height of the shells. This allows
for the shells, together with the shims, to be a consistent height
and allows for dry stacking. The masonry shells are bonded together
with a layer of lightweight concrete poured in a cavity behind the
masonry shells instead of being bonded together by mortar joints.
This dry stacking method can result in labor time and training
savings over conventional masonry mortar construction.
Inventors: |
Ryan; Kevin P.; (Zionsville,
PA) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Ryan; Kevin P. |
Zionsville |
PA |
US |
|
|
Family ID: |
49323810 |
Appl. No.: |
13/590118 |
Filed: |
August 20, 2012 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
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61625447 |
Apr 17, 2012 |
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Current U.S.
Class: |
52/426 ;
52/742.14 |
Current CPC
Class: |
E04G 21/02 20130101;
E04B 2/8641 20130101 |
Class at
Publication: |
52/426 ;
52/742.14 |
International
Class: |
E04B 2/86 20060101
E04B002/86; E04G 21/02 20060101 E04G021/02 |
Claims
1. A stay-in-place concrete wall system comprising: a masonry shell
forming an exterior of a concrete wall; masonry shell channels
formed along a height of the masonry shell, the masonry shell
channels spaced apart by a spacing; a concrete shell forming an
interior of the concrete wall; concrete shell channels formed along
a height of the concrete shell, the concrete shell channels spaced
apart by the spacing; a form tie ladder having a first protrusion
on a first end of the form tie ladder and a second protrusion on a
second, opposite end of the form tie ladder, the first protrusion
operable to fit into the masonry shell channels and the second
protrusion operable to fit into the concrete shell channels; and
first and second rigid insulation form liners operable to disposed
on each end of the form tie ladder with a space formed between the
rigid insulation form liners and the masonry shell and the concrete
shell, the space adapted to receive lightweight concrete.
2. The stay-in-place concrete wall system of claim 1, further
comprising an I-strut disposed on the form tie ladder to retain the
first and second rigid insulation form liners.
3. The stay-in-place concrete wall system of claim 1, wherein the
masonry shell channels and the concrete shell channels are dovetail
shaped channels.
4. The stay-in-place concrete wall system of claim 1, further
comprising a plastic cap shim adapted to fit on the masonry shell
to adjust a height of the masonry shell.
5. The stay-in-place concrete wall system of claim 1, further
comprising concrete poured in a central region, between the first
and second rigid insulation form liners.
6. A method for forming a stay-in-place concrete wall system
comprising: disposing form tie ladder where a concrete wall is
desired, the form tie ladder having a first protrusion on a first
end of the form tie ladder and a second protrusion on a second,
opposite end of the form tie ladder; sliding a masonry shell onto
an exterior side of the form tie ladder, the masonry shell having
masonry shell channels formed along a height of the masonry shell,
the masonry shell channels spaced apart by a spacing and adapted to
receive the first protrusion; sliding a concrete shell onto an
interior side of the form tie ladder, the concrete shell having
concrete shell channels formed along a height of the concrete
shell, the concrete shell channels spaced apart by the spacing and
adapted to receive the second protrusion; and securing first and
second rigid insulation form liners on each end of the form tie
ladder with a space formed between the rigid insulation form liners
and the masonry shell and the concrete shell, the space adapted to
receive lightweight concrete.
7. The method of claim 6, further comprising pouring the
lightweight concrete into the space to a height approximately
one-half the way up a top course during wall construction.
8. The method of claim 6, further comprising securing the first and
second rigid insulation form liners with an I-strut formed on the
form tie ladder.
9. The method of claim 6, wherein the masonry shell channels and
the concrete shell channels are dovetail shaped channels.
10. The method of claim 6, further comprising adjusting a height of
the masonry shell by securing a plastic shim cap on the masonry
shell.
11. The method of claim 6, further comprising pouring concrete in a
central region, between the first and second rigid insulation form
liners.
Description
CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application claims the benefit of priority of U.S.
provisional application No. 61/625,447, filed Apr. 17, 2012, the
contents of which are herein incorporated by reference.
BACKGROUND OF THE INVENTION
[0002] The present invention relates to concrete forms and, more
particularly, to a stay-in-place concrete form including masonry
shells layered with lightweight concrete and rigid insulation tied
with plastic ladders.
[0003] Formed concrete walls do not have a desirable appearance and
require additional steps to insulate and finish when used as a
structural wall in buildings.
[0004] Blocks mortared in place require skilled laborers with
extensive training. Mortared blocks must come assembled and
therefore must be lifted over reinforcement or other vertical
obstacles that are required to be embedded in concrete wall
construction.
[0005] Dry stacking the shells could save labor, time and training.
However, masonry block is manufactured in a process that results in
variations in the height of the block of plus or minus about 1/8
inch. This makes it unfeasible to dry stack masonry as the wall
would not stay straight and plumb due to the variations of heights
in the blocks.
[0006] Conventional stay-in-place masonry forms come in the form of
blocks that needed to be mortared into place, the same as normal
masonry construction.
[0007] As can be seen, there is a need for an improved
stay-in-place concrete form that can be assembled around obstacles,
can be dry stacked with consistent heights, and can provide
insulation within the wall construction.
SUMMARY OF THE INVENTION
[0008] In one aspect of the present invention, a stay-in-place
concrete wall system comprises a masonry shell forming an exterior
of a concrete wall; masonry shell channels formed along a height of
the masonry shell, the masonry shell channels spaced apart by a
spacing; a concrete shell forming an interior of the concrete wall;
concrete shell channels formed along a height of the concrete
shell, the concrete shell channels spaced apart by the spacing; a
form tie ladder having a first protrusion on a first end of the
form tie ladder and a second protrusion on a second, opposite end
of the form tie ladder, the first protrusion operable to fit into
the masonry shell channels and the second protrusion operable to
fit into the concrete shell channels; and first and second rigid
insulation form liners operable to disposed on each end of the form
tie ladder with a space formed between the rigid insulation form
liners and the masonry shell and the concrete shell, the space
adapted to receive lightweight concrete.
[0009] In another aspect of the present invention, a method for
forming a stay-in-place concrete wall system comprises disposing
form tie ladder where a concrete wall is desired, the form tie
ladder having a first protrusion on a first end of the form tie
ladder and a second protrusion on a second, opposite end of the
form tie ladder; sliding a masonry shell onto an exterior side of
the form tie ladder, the masonry shell having masonry shell
channels formed along a height of the masonry shell, the masonry
shell channels spaced apart by a spacing and adapted to receive the
first protrusion; sliding a concrete shell onto an interior side of
the form tie ladder, the concrete shell having concrete shell
channels formed along a height of the concrete shell, the concrete
shell channels spaced apart by the spacing and adapted to receive
the second protrusion; and securing first and second rigid
insulation form liners on each end of the form tie ladder with a
space formed between the rigid insulation form liners and the
masonry shell and the concrete shell, the space adapted to receive
lightweight concrete.
[0010] These and other features, aspects and advantages of the
present invention will become better understood with reference to
the following drawings, description and claims.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] FIG. 1A is an exploded plan view of a concrete form
according to an exemplary embodiment of the present invention;
[0012] FIG. 1B is a side sectional view of the concrete form of
FIG. 1A;
[0013] FIG. 2A is a plan view of the concrete form of FIG. 1A
filled with both lightweight concrete and its concrete wall;
[0014] FIG. 2B is a sectional view showing a step-wise dry-stack
construction of the concrete form of the present invention;
[0015] FIG. 3A is a plan view showing plastic cap shims disposed on
masonry shells to create a level dry-stack of the concrete form of
the present invention;
[0016] FIG. 3B is a sectional view showing the plastic cap shims
being disposed on the masonry shells of the concrete form of the
present invention;
[0017] FIG. 4 is a sectional view showing assembly of the
components of the concrete form of the present invention;
[0018] FIG. 5A is a plan view showing installation of the rigid
insulation form liner of the concrete form of the present
invention;
[0019] FIG. 5B is a sectional view of an assembled masonry form
according to an exemplary embodiment of the present invention;
[0020] FIG. 5C side view of a rigid insulation form liner used in
the concrete form of the present invention; and
[0021] FIG. 6 is a sectional view showing the step-wise
construction of the concrete form of the present invention as the
lightweight concrete insulation is added as each row is added.
DETAILED DESCRIPTION OF THE INVENTION
[0022] The following detailed description is of the best currently
contemplated modes of carrying out exemplary embodiments of the
invention. The description is not to be taken in a limiting sense,
but is made merely for the purpose of illustrating the general
principles of the invention, since the scope of the invention is
best defined by the appended claims.
[0023] Broadly, an embodiment of the present invention provides a
stay-in-place concrete form including masonry shells layered with
lightweight concrete and rigid insulation tied with plastic
ladders. The masonry shells can be capped with plastic shims that
compensate for the variation in height of the shells. This allows
for the shells, together with the shims, to be a consistent height
and allows for dry stacking. The masonry shells are bonded together
with a layer of lightweight concrete poured in a cavity behind the
masonry shells instead of being bonded together by mortar joints.
This dry stacking method can result in labor time and training
savings over conventional masonry mortar construction.
[0024] Conventional formed concrete walls do not have a desirable
appearance and require additional steps to insulate and finish when
used as a structural wall in buildings. The present invention
solves this problem.
[0025] Stay-in-place forms eliminate the need to strip off
temporary forms for concrete wall construction. Adding insulation
to the concrete wall in a later step is not required as insulation
is integrated into the stay-in-place form of the present invention.
The stay-in-place form can act as an exterior and/or interior wall
finish that is desirable to the end user.
[0026] Prior to the present invention, stay-in-place block forms
came in the form of blocks that needed to be mortared into place,
the same as normal masonry construction. The present invention
eliminates the need for mortar joints, provides two layers of
lightweight concrete adding to the insulation value of the assembly
while also improving fire resistance, moisture resistance, and
sound deadening characteristics. The present invention can be
assembled in the field which allows for this assembly to be
constructed around construction obstacles such as vertical rebar
reinforcement in concrete and/or embedded utility piping.
[0027] With the concrete forms present invention, the masonry
shells can be capped with plastic shims of various thicknesses that
compensate for the variation in height of the shells. This allows
for the shells with the shims together to be a consistent height
and allows for dry stacking. The masonry shells are bonded together
with a layer of lightweight concrete poured in a cavity behind the
masonry shells instead of being bonded together by mortar joints.
This dry stacking design of the present invention can result in
labor time and training savings over conventional block mortar
construction.
[0028] Concrete wall forms consist of two vertical surfaces
connected by ties spaced at close intervals so that when concrete
is poured between the two surfaces they are held in place by equal
and opposite forces induced by the wet concrete.
[0029] Referring now to the Figures, a form tie ladder 10,
typically made of plastic such as polypropylene, can act as a tie
to prevent the vertical surfaces of the concrete form of the
present invention from separating under the pressure of wet
concrete. The form tie ladder 10 also can act as a spacer to attach
and position the other components into one stay-in-place concrete
form unit. The form tie ladder 10 can attach to the same item in
the course below and has a height that matches a set standardized
height, such as eight inches, has a spacing at the 1/4 points, such
as four inches, and has a set standardized width, such as 16
inches.
[0030] The form tie ladder 10 can include a dovetail channel 12 on
both sides to accept attachment of interior and exterior shell
items (masonry shells 20 and concrete shells 30, described
below).
[0031] The form tie ladder 10 can include I-struts 14 running
horizontally across the center core to accept the insertion and
placement of pre-cut rigid insulation inserts 50. The I-struts 14
also act as tension ties to resist the pressure exerted when
pouring the concrete core 70 against the exterior and interior
walls acting as concrete forms. The exterior concrete form can
include an assembly of the masonry shells 20, the lightweight
concrete 60 and the rigid insulation form liner 50. The interior
concrete form wall can include the concrete shells 30 or the
masonry shells 20, the lightweight concrete 60 and the rigid
insulation form liner 50.
[0032] The form tie ladder 10 can come in various standardized
widths so the designer of the concrete core 70 can decide on the
width required to meet the configuration and load resistance
requirements for the intended application.
[0033] Masonry exterior shells 20 can attach to the plastic form
tie ladder 10 directly through a plastic dovetail channel connector
22 to form the finished exterior outside surfaces of the
stay-in-place concrete form unit. (see FIG. 4) The masonry shells
20 in combination with the rigid insulation form liner 50 can form
a confined space for the lightweight concrete insulation 60 to be
poured in place in small lifts matching the height of 1/2 of the
masonry shells 20 (see FIG. 6).
[0034] The concrete interior shells 30 can attach to the plastic
form tie ladder 10 directly through plastic dovetail channel
connectors 32 to form the finished interior surfaces of the
stay-in-place concrete form unit (see FIG. 4). The concrete shells
30 in combination with the rigid insulation form liner 50 can form
a confined space for the lightweight concrete insulation 60 to be
poured in place in small lifts matching the height of 1/2 of the
concrete shells 30 (see FIG. 6).
[0035] The concrete shells 30 can be a cementitious (autoclaved
aerated concrete in one iteration) shell that forms the final
interior finish of the wall assembly. The concrete shells 30 can
have a consistency and appearance similar to drywall. The joints
can be taped and spackled to give the appearance of a finished
drywall system.
[0036] Plastic cap shims 40 can snap on top of the masonry shells
20 and can be held in place (see FIG. 3) by forcing a tongue 42 of
the plastic cap shims 40 into a slot 22 in the masonry shells 20.
Force can be applied to the plastic cap shims 40 and the plastic
cap shims 40 can be joined with the masonry shells 20 in a manner
that results in a consistent height of the two components combined
(see FIG. 3).
[0037] The tongue 42 can be sized slightly larger than the slot 22
in the masonry shell 20 such that force is required to insert the
tongue 42 into the slot 22. Force is applied, pushing the tongue 42
into the slot 22 until the shim is positioned at the desired
location, at which time the force is no longer applied.
[0038] When properly inserted, the height of the concrete masonry
shell 20 plus the plastic shim 40 would exactly match a
standardized dimension, such as an eight-inch height. Dry stacking
of the conventional masonry would result in walls that would be out
of plumb and level.
[0039] The rigid insulation form liner 50 engages I-Struts 14
formed in the plastic form tie ladder 10 at various locations (see
FIG. 5). The rigid insulation form liner 50 and the masonry shells
20 form a confined space 62 for the forming of the lightweight
concrete insulation and wall form 60.
[0040] The lightweight concrete insulation and wall form 50 can be
poured into confined spaces 62 formed by the rigid insulation form
liner 50 and the masonry shells 20 and the concrete shells 30 in
lifts that match the height of 1/2 of the shells 20, 30 (see FIG.
6). The lightweight concrete 60 bonds to the shells 20, 30 to
permanently lock the shells 20, 30 in place. The lightweight
concrete 60 also cures to create the two vertical surfaces required
in a concrete forms to resist the equal and opposite forces created
by pouring the concrete wall 70. The lightweight concrete 60 can
engage the plastic form tie ladder 10 acting as a tension member to
resist the equal and opposite forces created by the concrete wall
70.
[0041] The lightweight concrete 60 bonds the layers of shells 20,
30 together from behind the shells 20, 30 instead of between the
shells as is traditionally the case in masonry construction. The
method of the present invention is easier than mortared joints and
results in labor savings over traditional mortared joint
methods.
[0042] The concrete wall 70 is a reserved space for the concrete
wall designer (see FIG. 2). The designer will determine the
reinforcement and compression strength and thickness of this
element. Vertical reinforcing rods, such as concrete rebar, can be
placed before assembling the block wall.
[0043] The elements of the present invention can be stacked
similarly to masonry block construction one course at a time.
However, unlike masonry block construction, the elements of the
present invention create a stay-in-place concrete wall form. The
concrete wall inside becomes the structural element. The
stay-in-place form adds an exterior and interior finish. The
lightweight concrete insulation 60 provides insulation value, fire
resistance, sound deadening characteristics, and moisture
resistance along with bonding to the shells 20, 30. The rigid
insulation 50 provides additional insulation value to the completed
assembly.
[0044] The exterior masonry shell 20 can act as the exterior
finish, eliminating a step in the construction process. The
assembly eliminates the need to strip and remove concrete forms as
the forms stay-in-place. Masonry walls create thermal bridges and
the plastic form tie ladder 10 with rigid insulation 50 reduces the
thermal bridge and saves on heating and cooling costs. The rigid
insulation 50 and lightweight concrete insulation 60 combined can
provide the code required insulation values and eliminate another
step in the construction process.
[0045] The lightweight concrete insulation 60 forms two vertical
enclosed surfaces tied together by plastic form tie ladders 10 at
close spacing to facilitate concrete wall construction.
[0046] In one embodiment, the plastic members can be made from
polypropylene. Molds conforming to the configurations shown in the
attached figures are constructed. Each plastic piece is then
reproduced repeatedly using an injection molding process.
[0047] The masonry shells 20 are configured to be compatible with
standard concrete masonry unit manufacturing methods. Required
amounts of sand, gravel, and cement are transferred to a weigh
batcher that measures the proper amounts of each material. In the
block machine, the concrete is forced downward into molds. The
molds consist of an outer mold box containing several mold liners.
The liners determine the shape of the block. The concrete is
compacted by the weight of the upper mold head coming down on the
mold cavities.
[0048] The interior concrete shells 30 can be made from autoclaved
aerated concrete. This product is a baked concrete product that can
be produced in slab form and can be cut and routed similar to wood.
Slabs of AAC are cut to configurations compatible to standard
concrete masonry units. Dovetail slots as required for connection
to the plastic dovetail channels are routed onto the AAC
shells.
[0049] Rigid insulation 50 can be procured in precut heights and
width with the desired thicknesses.
[0050] In one embodiment, the lightweight insulating concrete 60
includes Perlite concrete. Perlite concrete can be mixed in a
concrete mixer. The required amounts of water, air entraining
admixture and Portland cement can be placed in the mixer and can be
mixed until slurry is formed. The proper quantity of perlite
concrete aggregate can then he added to the slurry and all
materials mixed until design wet density is reached.
[0051] The masonry shells 20 and the plastic cap shims 40 can be
assembled in the plant or at the site. The plastic cap shim 40 can
be driven into the masonry shell 20 to achieve a predetermined
standard assembly height. The plastic cap shim 40 has a tongue 42
that fits into the top of the dovetail slot 22 in the masonry shell
20.
[0052] In warm exterior climate conditions, it might be possible to
have a mass wall where high thermal mass, such as a concrete wall,
is exposed to the interior of a building. The high thermal mass can
absorb heat from occupants making them feel cooler.
[0053] In the present invention, there is an exterior insulation
barrier and an interior insulation barrier including lightweight
insulating concrete 60 and rigid insulation 50. The interior
insulating barrier can have non-insulating materials substituted in
warm exterior climate conditions when high thermal mass
construction is desired. The interior precut rigid insulation 50
can be replaced by cement board with the same dimensions. The
lightweight insulating concrete 60 can be replaced with
non-insulating concrete. This would create thermal bridging from
the interior to the center concrete core 70 while maintaining the
thermal break from the exterior to the center concrete core 70.
[0054] The present invention would be used to form vertical
concrete walls. In one embodiment, the forms would rest on
continuous spread concrete footings. The mason would first position
the vertical reinforcement bars required for the concrete wall to
be constructed. The present invention would be laid up in courses
similar to cmu block construction. In one embodiment, the course
would match 8 inch heights similar to typical masonry block
construction.
[0055] The first course of masonry shells and plastic form tie
ladders would be joined together around the rebar and would rest in
a bed of mason's mortar. The mortar would allow for adjustments in
plumb and level in this first course. Future courses after the
first course would be dry stacked. The bottom of the plastic form
tie ladders in this first course must be trimmed as required to
prevent any interference with the spread footing base.
[0056] Rigid insulation one coarse high can be inserted into the
plastic form tie ladders on both sides to create the confined space
for the lightweight insulating concrete. The insulating concrete is
not used until the second course is in place.
[0057] In subsequent courses the first step is to snap plastic form
tie ladders onto matching form tie ladders from the course below.
In one embodiment the form tie ladders would be spaced at 4 inch
centers. The masonry shell assemblies with the plastic cap shims
already installed would be snapped onto the tabs of the plastic
form tie ladders and dry stacked onto the masonry shells from the
course below. This would occur on both the interior and exterior
sides of the wall.
[0058] Precut rigid insulation would be slide down from the top
into the form tie ladders on both sides to create a confined space
for pouring the two lightweight insulating concrete layers. The
lightweight insulating concrete would be mixed on site and poured
into each of the confined spaces so as to fill 1/2 of the block
height from the course below and 1/2 of the block height of the
current course being installed. When cured this will result in the
two courses of shells to be bonded together with the lightweight
insulating concrete. The second half of the confined spaces of the
current course will be filled when the lightweight concrete for the
course above is poured.
[0059] Any horizontal rebar required for the center core concrete
wall can be placed and secured before proceeding to the next
course.
[0060] The above steps can be repeated, coarse by coarse, until the
stay-in-place concrete form reaches the desired height.
[0061] Once the lightweight insulating concrete layer has cured,
the center concrete wall can be poured in one lift up to the
designed height. This process creates an insulated concrete wall
with an interior and exterior hard shell finish.
[0062] It should be understood, of course, that the foregoing
relates to exemplary embodiments of the invention and that
modifications may be made without departing from the spirit and
scope of the invention as set forth in the following claims.
* * * * *