U.S. patent application number 13/888582 was filed with the patent office on 2013-11-28 for plastic stay-in-place concrete forming system.
The applicant listed for this patent is Kenneth Robert Kreizinger. Invention is credited to Kenneth Robert Kreizinger.
Application Number | 20130312350 13/888582 |
Document ID | / |
Family ID | 49620481 |
Filed Date | 2013-11-28 |
United States Patent
Application |
20130312350 |
Kind Code |
A1 |
Kreizinger; Kenneth Robert |
November 28, 2013 |
Plastic Stay-In-Place Concrete Forming System
Abstract
A plastic stay-in-place concrete forming system used for one or
more sides of a multi-sided form and is based upon a form panel
comprised of a thin plastic sheet reinforced on its interior side
and capable of bonding to the concrete cast inside the form to
create a solid composite structure. In one configuration the form
panels are connected to internal bracing that connects to a second
form side. The internal bracing is comprised of plastic connecting
frames, lateral supports or individual connectors that may further
reinforce the form panels or may be used solely for connecting
purposes. The second side form may be any type of form including
the form panel or a stud supporting foam board. The form panel may
also be shaped to form two or more sides of an internally braced,
multi-sided form. It may also be externally braced on one or more
sides of a form.
Inventors: |
Kreizinger; Kenneth Robert;
(Fort Lauderdale, FL) |
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Applicant: |
Name |
City |
State |
Country |
Type |
Kreizinger; Kenneth Robert |
Fort Lauderdale |
FL |
US |
|
|
Family ID: |
49620481 |
Appl. No.: |
13/888582 |
Filed: |
May 7, 2013 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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12927379 |
Nov 12, 2010 |
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13888582 |
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13374839 |
Jan 17, 2012 |
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12927379 |
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Current U.S.
Class: |
52/426 ;
52/745.21 |
Current CPC
Class: |
E04B 1/161 20130101;
E04C 5/168 20130101; E04C 5/20 20130101; E04B 2/8641 20130101; E04B
2/8647 20130101; E04B 5/32 20130101; E04G 11/00 20130101; E04G
17/00 20130101; E04C 3/34 20130101 |
Class at
Publication: |
52/426 ;
52/745.21 |
International
Class: |
E04G 11/00 20060101
E04G011/00; E04G 17/00 20060101 E04G017/00 |
Claims
1. A stay-in-place, plastic concrete form comprising: a. a form
panel on one or more sides of a multi-sided concrete form and said
form panel comprised of a pliable plastic sheet with reinforcement
means and connecting means arranged across the interior side of
said plastic sheet and said form panel mechanically bonds to the
concrete, b. one or more internal bracing having a means for
connecting to said form panel and extending inward with a means for
connecting to at least a second side of said concrete form.
2. A concrete form of claim 1 further including a means for shaping
a single said form panel to form at least two sides of said
concrete form.
3. A concrete form of claim 1 wherein said form panel on at least
one side of said concrete form further includes foam bonded to at
least a portion of said interior side.
4. A concrete form of claim 1 wherein said second side comprises at
least one foam board secured in a predetermined position by
elongated rigid studs adjoining said foam board on two or more
sides and said stud having one or more flange and means for
connecting to said internal bracing.
5. A concrete form of claim 1 wherein said reinforcement comprises
a multitude of ribs fabricated onto said interior side.
6. A concrete form of claim 1 wherein said internal bracing
comprises a connecting frame with a means for connecting
perpendicular to said form panel.
7. A concrete form of claim 1 wherein said internal bracing
comprises individual connectors.
8. A concrete form of claim 1 wherein said internal bracing
comprises rebar tie connectors.
9. A concrete form of claim 1 wherein said reinforcement means
comprises protrusions.
10. A concrete form of claim 1 further including a means for
reducing the hydrostatic pressure in said concrete form.
11. A concrete form of claim 1 wherein said internal bracing has a
means for connecting to other internal bracing.
12. A concrete form of claim 1 wherein one or more said form panels
includes a filler and/or backing material.
13. A concrete form of claim 1 wherein said second side comprises
one or more foam boards supported by one or more studs.
14. A concrete form of claim 1 wherein said second side comprises
said form panel.
15. A concrete form of claim 1 further including a means for
finishing the exterior side of said form panel.
16. A stay-in-place concrete form panel comprising a plastic sheet
reinforced by protrusions arranged across the interior side of said
plastic sheet and said protrusions mechanically bond to the
concrete placed against said interior side and said form panel is
externally braced.
17. A concrete form of claim 16 further including a means for
reducing the hydrostatic pressure from said concrete placed.
18. A concrete form of claim 16 further including a means for
finishing the exterior side of said form panel.
19. A method of constructing a multi-sided concrete form with a
stay-in-place form panel on one or more sides, said method
comprising: a. fabricating said form panel by reinforcing a plastic
sheet across its interior side with protrusions capable of bonding
to concrete and connecting to internal bracing, b. arranging said
form panel to form one or more sides of said concrete form, c.
attaching internal bracing to said form panel, d. connecting said
internal bracing to at least a second side of said concrete form,
whereby a multi-sided concrete form is constructed with a
stay-in-place form panel on one or more sides.
Description
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation-in-part of application
Ser. No. 12/927,379 filed Nov. 12, 2010 which claims the benefit of
the filing date of provisional application Nos. 41/281,166 and
41/281.121 both filed Nov. 13, 2009. This application claims the
benefit of copending application Ser. No. 13/374,839 filed Jan. 17,
2012 claiming the benefit of the filing date of provisional
application Nos. 61/461,437 filed Jan. 18, 2011 and 61/462,463
filed Feb. 3, 2011. All the above cited applications are
incorporated herein by reference.
BACKGROUND OF THE INVENTION
Prior Art
[0002] The following is a tabulation of some prior art that
presently appears relevant:
U.S. Patents
TABLE-US-00001 [0003] Patent Number Kind Code Issue Date Patentee
7,146,773 B2 2006 Dec. 12 Wilson 6,247,280 B1 2001 Jun. 19
Grinshpun et al. 6,167,669 B1 2001 Jan. 2 Lane 5,974,751 1999 Nov.
2 De Zen 5,729,944 1998 Mar. 24 De Zen 5,706,620 1998 Jan. 13 De
Zen 5,092,093 1992 Mar. 3 Lu 4,876,054 1989 Oct. 24 Goodwin
3,238,684 1963 Jan. 17 Wood
U.S. Patent Application Publications
TABLE-US-00002 [0004] Publication No. Kind Code Publ. Date
Applicant 2004/0244321 A1 2004 Dec. 9 Dincel 2004/0010994 A1 2004
Jan. 22 Piccone
Non-published U.S. Patent Applications
TABLE-US-00003 [0005] Application No. Filing Date Applicant
13/373,816 2011 Dec. 1 Kreizinger
Nonpatent Literature Documents
[0006] Octaform Systems, Inc. brochure. [0007] P2Forms internet
downloads. [0008] Conform internet download.
[0009] The invention is a plastic stay-in-place formwork system for
cast-in-situ cementicious members such as columns, beams, walls and
raised floor/ceilings. Concrete forms have historically been made
of wood, metal or fiberglass and are typically removed after the
concrete has hardened and reused. Recently foam forms (insulated
concrete forms) and plastic stay-in-place forms have been developed
which provide insulation and/or a concrete covering, labor savings
and faster construction. These features have enabled single use,
stay-in-place foam or plastic forms to be competitive with multiple
use wood, metal or fiberglass forms.
[0010] The foam or insulated concrete forms have a foam exterior
that must be covered to protect the foam from deterioration and as
a fire safety precaution. The foam forms must also be covered to
provide an aesthetically pleasing finished appearance and the foam
provides an inadequate base for structural connections between
concrete members or to facilitate cladding materials.
[0011] Plastic stay-in-place forms have been developed that use
plastic sheets as the form panels and thereby provide a solid
stay-in-place concrete covering that needs no protection, is fire
safe and has a finished appearance. However, these plastic sheets
that comprise the forms do not attach or otherwise bond to the
concrete cast inside the form. The plastic forms only enclose the
concrete and since all concrete shrinks as it cures the concrete
pulls away from the plastic form which results in a loose and
flimsy plastic covering. Such a loose or flimsy covering is not
only unsightly; it also inhibits the attachment of cladding
materials to the exterior of the plastic form.
[0012] As a concrete form, plastic forms are subjected to high
levels of hydrostatic pressure and since plastic has a low modulus
of elasticity the form walls must be strengthened to prevent
deflection and deformation. To strengthen the form wall and
compensate for the plastic material's relative weakness the plastic
forms are made of thick plastic sheets and/or have closely spaced
lateral connectors/webs which shortens the distance the plastic
sheets span. These thicker forms and large number of lateral
connectors/webs substantially increases the amount of plastic
material needed for a sufficiently strong concrete form.
[0013] All of the prior art uses closed connectors/webs to connect
the two sides of the form which makes it difficult to place steel
reinforcement bars and impractical to use less expensive welded
wire fabric sheets as a concrete reinforcement. As such, the
horizontal rebars must be laterally fished through the openings of
the connectors/webs which is difficult and time consuming,
especially for the standard 20' sections of rebar. Moreover, it is
difficult to tie the lapped rebar inside these plastic forms as
required by some building codes. Additionally, the closed
connectors/webs prevent the use of less expensive welded wire
fabric.
[0014] Plastic stay-in-place forms are also inflexible is
controlling the deflection and deformation of the form that
significantly varies from the top to the bottom. The hydrostatic
pressure caused by the wet concrete is several times greater at the
bottom of a form than at the top. None of the prior art provides
any flexibility to strengthen the bottom with additional support or
use less support near the top of the form. The support is uniform
throughout the form which results in an inefficient and costly use
of materials.
SUMMARY OF INVENTION
[0015] The invention relates to the construction and the formwork
of cast-in-situ concrete members such as columns, beams, walls and
floor/ceilings. The concrete forms herein disclosed are
stay-in-place forms that are made primarily of plastic materials
and intended to remain attached to the concrete for the life of the
concrete member.
[0016] According to the invention, a unique lightweight plastic
stay-in-place form is provided that attaches or otherwise
permanently bonds to the wet concrete cast inside. When the
concrete cures, the plastic form and the concrete become a solid,
composite structure with the plastic covering firmly attached to
the concrete.
[0017] In accordance with another configuration of the invention,
the plastic forms are reinforced to enable the form to be covered
by a thin plastic sheet and still withstand the weight and the
hydrostatic pressure of the wet concrete cast within. The invention
further provides a method by which the connectors used to connect
the forms are spaced further apart so that fewer connectors are
needed. The invention also provides for separate supports to
stiffen and strengthen the form and the plastic sheet covering.
These separate supports provide substantial flexibility in their
placement so as to vary the relative strength of the form according
to the hydrostatic pressures present from the bottom to the top of
the form.
[0018] In accordance with another configuration of the invention,
individual connectors are used to connect the forms for a more
efficient use of materials. This also provides greater flexibility
in locating the individual connectors throughout the forms. The
individual connectors also create an open access to the inside of
the form so as to simplify the placement of horizontal and vertical
rebar and facilitate the use of welded wire fabric.
[0019] The invention also provides a plastic form with a finished
exterior texture and appearance so that no other coating or
cladding is necessary.
[0020] In accordance with another configuration a plastic form
panel on the first side of a multi-sided form is connected to a
second side form through internal bracing and the second side form
may be different from the form panel.
[0021] In accordance with another configuration a second side form
is comprised of a stud supporting foam board. The stud is connected
to internal bracing extending from the form panel on first side and
its flanges provide support to a stay-in-place form board.
[0022] In accordance with another configuration the plastic form
panel is used as a stay-in-place form on one side of a multi-sided
form.
[0023] The invention also discloses plastic forms used in
conjunction with a method of reducing the concrete's hydrostatic
pressure in forms. The reduced pressure enables the use of weaker
and less expensive plastic forms.
BRIEF DESCRIPTION OF THE DRAWINGS
[0024] FIG. 1 is an exploded view of two form panels to be
connected by a connecting frame.
[0025] FIG. 2 is a plan view of a closed form with two sides
connected by a connecting frame.
[0026] FIG. 3 is a plan view of one form panel connected to a
connecting frame and an exploded view of a second form panel to be
connected to the connecting frame in accordance with another
embodiment.
[0027] FIG. 4 is a perspective view of a form panel comprised of a
plastic sheet reinforced with T ribs in accordance with another
embodiment.
[0028] FIG. 5 is a perspective view of a form panel comprised of a
plastic sheet reinforced with a grate in accordance with another
embodiment.
[0029] FIG. 6 is a perspective view of a form panel comprised of a
plastic sheet reinforced with a lattice in accordance with another
embodiment.
[0030] FIG. 7A is a perspective view of a form panel comprised of a
plastic sheet reinforced with T ribs and a lateral support
positioned to be attached to the form panel in accordance with
another embodiment.
[0031] FIG. 7B is a perspective view of FIG. 7A with the lateral
support and a stud attached to the T ribs of the form panel in
accordance with another embodiment.
[0032] FIG. 8A is a section view of a lateral support with a track
on top in accordance with another embodiment.
[0033] FIG. 8B is a section view of an alternative lateral support
with holes in accordance with another embodiment.
[0034] FIG. 9A is a section of a double insert, individual
connector ready to be snapped into a grate attached to a form panel
in accordance with another embodiment.
[0035] FIG. 9B is a section of an individual connector with a
slider positioned to be attached to a track on a form panel in
accordance with another embodiment.
[0036] FIG. 10A is an exploded view of a beam form in accordance
with another embodiment.
[0037] FIG. 10B is an assembled beam form ready for rebar and
connectors in accordance with another embodiment.
[0038] FIG. 10C is a plan and section view of a corner brace in
accordance with another embodiment.
[0039] FIG. 10D is a section view of a fully assembled beam form
with connectors, rebar and stirrups in accordance with another
embodiment.
[0040] FIG. 11A is a section view of an inside corner brace with
inserts in accordance with another embodiment.
[0041] FIG. 11B is a section view of an outside corner brace with
inserts in accordance with another embodiment.
[0042] FIG. 12 is a section view of a beam form with rebar and
stirrups in accordance with another embodiment.
[0043] FIG. 13A is a section view of a rebar tie connector
positioned to be attached to a grated form panel in accordance with
another embodiment.
[0044] FIG. 13B is a section view of a rebar tie connector with a
slider positioned to be attached to a track on a form panel in
accordance with another embodiment.
[0045] FIG. 14 is a perspective of a block wall being built with
reinforced form panels, connecting frame and foam boards in
accordance with another embodiment.
[0046] FIG. 15 is a perspective view of a column form being
assembled with reinforced form panels and individual connectors
with rebar and stirrups positioned inside the form in accordance
with another embodiment.
[0047] FIG. 16 is a section view of an exterior wall and
ceiling/floor comprised of the various components disclosed in the
invention in accordance with another embodiment.
[0048] FIG. 17 is a plan view of a column form being assembled in
accordance with another embodiment.
[0049] FIG. 18A is a section view of a T rib reinforced form panel
being rolled into a circular shape to create a column form in
accordance with another embodiment.
[0050] FIG. 18B is a section view of a circular column form with a
connecting frame inserted over the T ribs in accordance with
another embodiment.
[0051] FIG. 18C is a section view of a circular column form with a
connecting frame used to position the stirrups in accordance with
another embodiment.
[0052] FIG. 18D is a plan view of connecting frame used in FIG.
18C.
[0053] FIG. 19A is an exploded section view of a wall form being
prepared for final assembly in accordance with another
embodiment.
[0054] FIG. 19B is a plan view of FIG. 19A.
[0055] FIG. 20A is a section view of the assembled wall form of
FIG. 19A.
[0056] FIG. 20B is a plan view of the assembled wall form of FIG.
19B.
[0057] FIG. 21 is an exploded plan view of a form ready for
assembly in accordance with another embodiment.
[0058] FIG. 22 is a plan view of the assembled form of FIG. 21.
[0059] FIG. 23 is a section view of a stud in accordance with
another embodiment.
[0060] FIG. 24A is a plan view of a stud with a track and a
connector being positioned to attach to the stud in accordance with
another embodiment.
[0061] FIG. 24B is a section view of FIG. 24A.
[0062] FIG. 25 is a plan view of an alternative design of the stud
and a connector being readied to attach to the stud in accordance
with another embodiment.
[0063] FIG. 26 is a plan view of an alternative design of the stud
and a connector being readied to attach to the stud in accordance
with another embodiment.
[0064] FIG. 27A is a section view of an open wall form into which
vertical and horizontal rebar has been placed in accordance with
another embodiment.
[0065] FIG. 27B is a section view of FIG. 27A showing the stud
being slid over the individual connectors to lock them in position
in accordance with another embodiment.
[0066] FIG. 28 is a plan view of FIG. 27B.
[0067] FIG. 29A is a section view of a closed wall form with foam
board in accordance with another embodiment.
[0068] FIG. 29B is a plan view of FIG. 29A.
DETAILED DESCRIPTION ACCORDING TO THE EMBODIMENTS OF THE PRESENT
INVENTION
[0069] This invention concerns the use of plastic form panels as
stay-in-place forms that may be used to form at least one side of a
multi-sided concrete form. The plastic form panels are made from a
thin plastic sheet that may be pliable and is reinforced on one or
both sides. The term pliable shall mean the plastic sheet can be at
least partially rolled up to form at least a quarter circle. As
such, the form panels referred to in the invention include the
plastic sheet that is at least partially stiffened by reinforcement
permanently fabricated onto one or both sides of the plastic sheet.
The form panels may have a single sheet of plastic material of any
thickness or it may have composite or layered sheets or strips,
with or without filler and/or backing materials on the interior
and/or the exterior side of the plastic sheet. Such a filler and/or
backing material may be for insulation, to achieve fire ratings, to
provide a finished appearance or for other reasons that make the
form panel more functional in any respect. The form panels may also
be of any size and shape and have a smooth or textured finish as
well as having either a flat or shaped surface.
[0070] In one configuration a multi-sided form is comprised of a
form panel on one or more sides of the form and the form panel has
a means of connecting to internal bracing that has a means for
connecting to a second side of the form. The means for connecting
used throughout this disclosure is by any fastener, compound, shape
or method that may be used to connect to plastic or connect two or
more plastic parts together including snaps, inserts, sliders,
tracks, slots, hangers, hooks, hitch, latch, lodge, ties, threads,
embed, pressure, prongs, plug, couple, twisting, pins, rivets,
clasp, locks, interlocking, molding, adhering, cohering, coatings,
adhesives, fusing and welding to name a few. FIG. 1 shows form
panels 1A and 1B connected together by a connecting frame 4, which
is a horizontally oriented frame used to connect two vertically
oriented form panels together. The means for connecting the
connecting frame 4 to the form panels 1A and 1B is by inserting the
snap inserts 6 into the grate 3 which is a protrusion 15 that
reinforces the plastic sheet 2 and is fabricated onto the interior
side of the plastic sheet 2 to comprise form panels 1A and 1B
respectively in this configuration. FIG. 2 shows the first form
panel 1A, as the first side of form 10, and a second form panel 1B,
as the second side of form 10, and connected by the connecting
frame 4 to create a form 10 into which a cementicious material is
cast.
[0071] FIG. 3 shows an alternative means for connecting the
connecting frame 4 to the form panel 1A and 1B by either snapping
or sliding the connecting frame 4 into position on a rib 7 that is
a protrusion 15 used to reinforce the plastic sheet 2 and has a
round lip 5 attached that functions as a track 8 in this
configuration. The lips 5 may be of any size and shape including
circular or rectangular. The connecting frame 4 has a slider 9 that
snaps or slides onto the track 8 created by the lip 5 that is
attached to the rib 7 that is attached to the plastic sheet 2 to
create form panels 1A and 1B in FIG. 3. Since the connecting frame
4 attaches perpendicularly to the ribs the combination of the ribs
7 and the connecting frame 4 provide the form panels 1A and 1B with
a means for reinforcement in two directions. As such, FIGS. 1 to 3
all show a form panel with protrusions providing both reinforcement
means and connecting means across the interior side of the plastic
sheet.
[0072] Another embodiment of the plastic form is its ability to
mechanically bond to the concrete and remain attached for the life
of the concrete member. This is accomplished by fabricating
protrusions 15 onto the interior side of the plastic sheet 2 and
when concrete is placed against the interior side of the plastic
sheet 2 it flows around or through the protrusions and bonds to
them, and thereby to the form panel, during and/or after the
concrete hardens. Such a bond may be achieved by becoming lodged,
confined, embedded, develop friction or adhesion or otherwise be
fastened together. For example, FIG. 4 shows a form panel 1
comprised of a plastic sheet 2 onto which T shaped ribs 12 have
been extruded or otherwise fabricated and are protruding from the
face of said plastic sheet 2 a distance that enables wet concrete
to flow in and around the T ribs 12. When the concrete cures it
will be lodged around the shape of the T rib 12 which will prevent
the concrete from being pulled away from the T rib 12 and the
plastic sheet 2. The shorter the span between the individual
protrusions 15, the tighter the bond of the concrete to the form
panel 1 and the plastic sheet 2. The protrusions and/or internal
bracing may also be fabricated with opening 16 near the interior
side of the plastic sheet to enable the concrete to fully surround
at least a portion of the protrusion or internal bracing and
thereby increase the concrete's effective depth.
[0073] FIG. 5 shows another example with a form panel 1 having a
grate 3 that has a lip 5 on the end of some protruding members and
the grated lip creates the mechanical bond between the plastic
sheet 2 and the concrete that is cast inside the grate 3. The lip 5
may be attached to one or both of the cross members used to create
the grate 3. As such, only some or part of the protrusion(s) must
be capable of bonding to the concrete as may be necessary to obtain
the desired bond. In FIG. 6 the form panel 1 is comprised of a
lattice 14 fabricated onto the plastic sheet 2 as a means for
reinforcement and to bond the form panel to the concrete. The grate
3 has cross members and therefore when either the grate 3 or the
lattice 14 are fabricated onto the plastic sheet 2, they provide
the form panel 1 with a means for reinforcement in two
directions.
[0074] The protrusions 15 attached to the plastic sheet may be in
any height, shape or design including rectangular, circular,
irregular, indented, scratched, under cut or roughened as long as
at least some or part of the protrusions have the ability to
directly or indirectly bond to the concrete as or after it hardens.
The protrusions 15 may also be solid or hollow and of a single or
composite material and be relatively large in size such as foam
boards. Another embodiment of the invention is for the plastic
sheets 2 to provide a means for finishing the exterior side of the
form panel and thereby provide a finished appearance to the
concrete member. The means for finishing the exterior side of the
form panel includes extruding the plastic sheet with a finished
appearance, laminating a finished appearance onto the plastic sheet
or fabricating a finished material onto the plastic sheet. In
addition, the plastic sheet may be all or partially thickened to
enable fasteners such as screws to attach to the plastic sheet so
that wallboards or panels may be attached. The thickened area may
be solid plastic or other material such as rubber, a hollowed area
or filled with a filler material. Both the fabrication of a
finished material onto the plastic sheet and the thickening of only
part of the plastic sheet, such as parallel strips, may also
reinforce the plastic sheet which in turn reinforces the form
panel.
[0075] In another embodiment, the protrusions 15 fabricated onto
the interior side of the plastic sheet may also provide a means for
reinforcing the plastic sheet, and thereby the form panel, to
withstand the hydrostatic and/or other pressures from the wet
concrete or otherwise applied against the form. The protrusions 15,
from the plastic sheet 2, (the ribs, grate and lattice, etc., in
FIGS. 4, 5 and 6 respectively) or other reinforcement such as foam
board act to stiffen the plastic sheet in one or more directions
across the plastic sheet.
[0076] In some applications reinforcement in a single direction is
necessary such as when a form panel is rolled and may be provided
by parallel ribs or thickened strips. In other applications
reinforcement in two or more directions is needed and the means for
reinforcement may be by a crossed grate, lattice, a combination of
protrusions and internal bracing or by other means as discussed
below.
[0077] In those instances where the protrusions fabricated onto the
plastic sheet provide reinforcement in a single direction, the form
panel may be further reinforced by lateral supports perpendicular
to the protrusions. FIGS. 7A and 7B shows a lateral support 30 that
is slid onto T ribs 12 fabricated onto the plastic sheet 2. FIG. 7A
shows the form panel 1 and the lateral support 30 separately. FIG.
7B shows the lateral supports 30 after they have been slid into the
form panel 1 to stiffen the form panel 1 in the direction
perpendicular to the T ribs 12 and thereby provides the form panel
1 with the means for reinforcement in two direction. The lateral
supports 30 may totally enclose the T ribs 12 or only the rib's lip
5.
[0078] The lateral supports 30 may also have a means for connecting
to a junction bar 31. In FIG. 7B, the lateral supports 30 have a
slider 9 that is fabricated onto the lateral supports 30. The
sliders 9 facilitate the placement of a junction bar 31 with tracks
8 that allow the junction bar 31 to slide through the sliders 9. In
this configuration the junction bar 31 internally braces the form
panel 1 and also provides an alternative means for connecting the
form panel to other internal bracing. The junction bar 31 in FIG.
7B shows a double track, the first track 8A attaches to the lateral
support 30 and the second track 8B attaches to a lateral support of
a second form.
[0079] The lateral support 30 may be made with a track 8, as shown
in FIG. 8A as a means for connecting to other internal bracing. Or
the lateral support 30 may also be made with holes 32, as shown in
FIG. 8B, to which an individual connector can snap into the holes
as another means for connecting to other internal bracing. FIG. 8B
also shows how the lateral support 30 may be used to connect to
only the lip 5 and a small section of the supporting T rib 12.
[0080] The form panels 1 may be frameless around their perimeter,
i.e. the plastic sheet perimeter, to enable various internal
bracing to be slid onto tracks 8 or T ribs 12 that reinforce the
plastic sheet 2. The frameless perimeter also allows the form panel
to be folded, rolled or otherwise shaped and further facilitates
joining form panels at angles to each other.
[0081] In another embodiment the form panels may be connected and
held together by internal bracing. Internal bracing is used to
build the form by connecting the sides and/or bottom of the form
panels and by holding the form together during placement of the
form and casting concrete inside the form. Internal bracing may
also be used to facilitate and/or provide mechanical bonding the
form panels to the concrete. Moreover, internal bracing may also
provide lateral rigidity to the protrusions so that the form panel
has a means for reinforcement in two or more direction, Internal
bracing includes all bracing that supports the form panel from its
interior side such as connecting frames, webs, rebar tie
connectors, ties, braces, junction bars, lateral supports, prongs,
inserts or individual connectors. Some internal bracing may connect
directly to the form panel by attaching to the grate, ribs, lattice
or other protrusion fabricated onto the plastic sheet. Other
internal bracing may indirectly connect to the form panel by
connecting to another internal brace that in turn connects to the
form panel. Both the connecting means and the internal bracing
shall be sufficiently rigid and/or secured and/or positioned to
withstand the hydrostatic, vibratory and other pressures exerted
inside the form during concrete placement. The internal braces may
be individual pieces or may be fabricated onto other internal
braces, the form panel or the studs.
[0082] The forms of this invention may be cast with any slump of
concrete that have different amounts of hydrostatic pressure or
they may be cast using a special technique that reduces the
concrete's hydrostatic pressure. Applicant has copending
applications No. 13/374,839 filed 17 Jan. 2012 entitled the
Thixotropic Building System, incorporated by reference, wherein a
method of reducing the hydrostatic pressure in concrete forms is
described by using the thixotropic properties of low or no-slump
concrete.
[0083] Thixotropy is a material property that describes a material
as being in a solid or semi-solid state when at rest and becoming
liquefied when agitated (vibrated). Thixotropy is a property of
freshly mixed no-slump or low-slump concrete in that this type of
concrete is in a semi-solid state, similar to moist, clumpy dirt,
when at rest and becomes liquefied when vibrated. Since hydrostatic
pressure is only present when a liquid state exists, limiting the
amount of a liquid or semi-liquid concrete present at any one time
in a form will limit the amount of hydrostatic pressure present in
that form. Moreover, the liquefaction is temporary in that as soon
as the vibration ceases, the concrete immediately reverts to its
semi-solid state and stops exerting hydrostatic pressure. It is
well known in the art that vibration causes the concrete to be
consolidated and that concrete can be vibrated several times prior
to setting up.
[0084] Therefore, the means for reducing hydrostatic pressure in
forms is by using low or no-slump concrete and minimizing the
amount of concrete being vibrated, and thereby liquefied, at any
one time. Specifically, this is accomplished in column and wall
forms and deep beam forms by casting one level (lift) of low or
no-slump concrete at a time and then vibrating each level before
the next level is cast. In those instances were cold joints are to
be avoided, it is important to vibrate each subsequent level with
the level immediately below. In order to ensure the concrete is
sufficiently vibrated to acceptable consolidation, it may be
necessary to set at least one side of the forms one level at a time
and setting that level of forms after the preceding level has been
cast. This enables the vibrator operator to visually observe from
close range the vibration of each level, to ensure proper
consolidation, before the next level of forms is fully set. Such
observance is not possible into fully erected, tall and narrow
forms several feet high and containing steel reinforcement.
[0085] FIGS. 9A and 9B are examples of means for connecting
individual connectors 40 directly to the form panel's ribs, grate
or track that are fabricated onto the interior side of the plastic
sheet 2 to comprise the form panel 1 as shown in FIGS. 4 through 6.
In FIG. 9A an individual connector 40 is fabricated with a double
insert 41 that snaps into the lip 5 of a grate 3 that is fabricated
onto the plastic sheet 2. Once the double insert 41 is attached to
the grate 3, it is connected to the form panel 1 in sufficient
strength to prevent pullout.
[0086] Also shown in FIG. 9A is a rebar bracket 42 and a gusset 48.
The gusset 48 can be fabricated or otherwise attached to secure the
individual connector 40 in a perpendicular position to the first
form panel 1. By maintaining the individual connector 40 in a
perpendicular position, it facilitates and simplifies the
attachment of the connector to other internal braces or to the
second form panel. The gusset 48 also strengthens the individual
connector 40 from the pressure of the concrete being cast into the
form.
[0087] FIG. 9B shows another means for connecting the individual
connector 40 to the form panel 1 whereby a T shaped track 8 is
fabricated onto or otherwise attached to the plastic sheet 2 and a
slider 9 is attached to the end of the individual connector 40.
When the tracks 8 are arranged in close proximity to one another,
they act similar to the T ribs shown in FIG. 4 and provide a means
of reinforcing the plastic sheet 2. In FIG. 9B the slider 9 simply
slides onto one of the tracks 8 and the other tracks serve to
reinforce the plastic sheet 2. One alternative embodiment enables
the slider 9 to twist or snap onto or otherwise attach to the track
8.
[0088] The individual connectors 40 may have both ends the same or
may be fabricated with different ends. Both the individual
connectors 40 and the respective ends may be designed in a variety
of ways through which a means for connecting to the form panel is
accomplished. For example, the individual connectors may also have
a means for connecting to other internal bracing such as lateral
supports, connecting frames, ties, studs, junction bars or braces
inside the form which are in turn connected to the form panels.
Therefore the means for connecting the internal bracing to the form
panels may be directly or indirectly through other internal
bracing.
[0089] In one embodiment connecting frames 4 are used to connect
two form panels together to construct a two sided form as shown in
FIGS. 1 through 3. However, a connecting frame 4 may have more
functions than to simply connect the form panels. A connecting
frame 4 may also be used as a truss to stiffen and thereby provide
a means for reinforcing the form panel. In FIG. 3, the connecting
frame 4, as attached to the form panels 1A and 1B, substantially
stiffens the form panels 1A and 1B in the direction parallel to the
frame 4 and perpendicular to the ribs 7 that are fabricated onto
the plastic sheet 2. Thereby when a connecting frame 4 is attached
to the ribs 7, it provides the form panels 1A and 1B with the means
for reinforcement in two directions. Connecting frames 4 may be of
different sizes and shapes and may be used parallel or
perpendicular or even diagonally to one another.
[0090] A multi-sided form can have two sides to form a wall, three
sides to form a beam or four or more sides to form a column (to
include an infinite number of sides to form a circular column).
FIGS. 10A, 10B and 10C demonstrate the assembly of a three sided
beam form using three individual form panels. In FIG. 10A the three
sides of the beam form 20 are disassembled and the form panels 1A,
1B and 1C, are reinforced in one direction by ribs 7 with a round
lip 5. The lateral supports 30 have holes 32 as a means for
connecting to the individual connectors 40. The means for
connecting the lateral supports 30 to the form panels 1A, 1B and 1C
is with the slide 9 that fits over the lip 5. The means for
connecting the corner braces 44 is by snapping them into the holes
32 in the lateral supports 30. As such form panels 1A, 1B and 1C
each are comprised of a pliable plastic sheet with reinforcement
means and connecting means arranged across the interior side of the
plastic sheet 2 and each of the form panels is able to mechanically
bond to concrete.
[0091] In FIG. 10B, the three sides of the beam form 20 have been
assembled with the lateral supports 30 bracing each form panel on
its interior side which reinforces them in a second direction,
perpendicular to the ribs 7. Interlocking corners 47 provide
additional internal bracing on the interior side of each form panel
and a means for connecting to the interior side of the adjacent
form panel. Corner braces 44 are additional internal bracing that
connect to the interior side of two adjacent and perpendicular form
sides and provide a means for connecting by snapping into the holes
32 of the lateral supports 30. As shown in FIG. 10C, the corner
braces have a protruding knob 46 that snaps and locks into the
holes 32 of the lateral supports 30.
[0092] Of course the three individual lateral supports in FIGS.
10A, 10B and 10D may alternatively have been combined into a single
"U" shaped structure (not shown) as internal bracing to which the
three form panels each attach.
[0093] The beam form 20 is now ready for the steel reinforcement
which is placed inside the form 10. After the rebar 45 and stirrups
43 have been placed, the individual connectors 40 are snapped into
the lateral supports 30 as the means for connecting the two form
panels 1A and 1B together. FIG. 10D shows the form 10 ready for
concrete with the rebar 45, stirrups 43 and the individual
connectors 40 all in place. In this configuration each of the form
panels 1A, 1B and 1C are connected to a second and a third side of
the form 10.
[0094] When a grate is used to reinforce the plastic sheet and
create a form panel, the cross members of the grate provide the
form panel with a means for reinforcement in two directions and
thereby a lateral support may not be needed. As such the individual
connectors and corner braces attach directly to the grate. FIGS.
11A and 11B show the means for connecting inside and outside corner
braces to a form panel with a grate and snap inserts 6.
[0095] In addition to being used to connect the form panels, the
connectors may be used to position the concrete's reinforcement
members such as the rebar and the stirrups. FIG. 12 shows a form 10
for a concrete beam wherein the individual connectors 40 connect to
the form panel 1 and also connect to the steel stirrups 43 by
snapping onto them. When the steel stirrups 43 are attached to the
individual connectors 40, they become internal braces comprising a
connecting frame that supports the form panels 1 from the pressure
of the wet concrete cast inside the form 10. In essence the
stirrups are used as a connecting frame to brace the form from the
inside.
[0096] FIGS. 13A and 13B show two different types of rebar tie
connectors 49 being attached to the form panels 1 and used as an
internal bracing. Both rebar tie connectors 49 have a plastic or
wire tie 33 on one end as a means for connecting to the rebar 45
while the second end of the rebar tie connector 49 has a means for
connecting to the form panel 1. In this way the rebar 45 can be
used as another type of internal bracing to support the form panel
1 from the concrete's pressure. The means for connecting the rebar
tie connector 49 to the form panel 1 is by snapping, clipping or
sliding onto one end to the form panel 1 while the second end is
tied 33 or uses some type of fastening device to attach to the
rebar 45 or stirrup.
[0097] The invention may be used in larger sizes such as
4'.times.8' or larger form panels or for smaller form panels such
as blocks or similar applications. FIG. 14 shows the invention used
to build a wall using individual blocks made from the components
disclosed herein.
[0098] A multi-sided form is shown in FIGS. 14 and 15 comprised of
a block. In FIG. 14, the block 70 is two sided with form panels 1A
and 1B each providing one side, although not in any particular
order. In this configuration both form panels 1A and 1B are
comprised of a thin, pliable plastic sheet 2 that has both
reinforcement means and connecting means arranged across their
respective interior sides. Form panel 1A is reinforced with ribs 7
that have a lip 5 to which the connecting frame 4 is attached. The
connecting frame 4, in this configuration, provides both the
lateral support (reinforcement means in a second direction) for the
form panel 1A and the means for connection to form panel 1B. Form
panel 1B is comprised of a thin plastic sheet 2 to which a foam
board 65 is bonded to provide both reinforcement in multiple
directions and insulation. (The foam used throughout this
disclosure may be in board or panel form or may be sprayed or
otherwise fabricated onto the plastic sheet.) In addition, form
panel 1B has a track 8 fabricated onto its interior side that
provides both reinforcement and a means for connecting to the
connecting frame 4.
[0099] As a result form panels 1A and 1B are on two sides of form
10 and each has reinforcement and connection means arranged across
their respective interior sides and are connected to internal
bracing that connects to a second side of form 10, which in this
configuration can be either form panel 1A or 1B.
[0100] The individual blocks 70 may be stacked with one block
partially overlapping the other so as to provide some stability and
to prevent leakage when the concrete is cast. The blocks slide over
the vertical rebar 45 while the horizontal rebar is set in place as
the blocks are laid. A wire raceway 60 may be attached to the
inside of the form panel for each block in such a location that the
raceway from block to block is continuous and extends the entire
height or width of the wall.
[0101] FIG. 15 is another configuration that shows four sided
individual blocks 70 that are stacked to construct a column. In
FIG. 15, the blocks 70 are four individual form panels 1 for each
of the four sides of the multi-sided form 10 and are locked
together at their corners and reinforced with lateral supports 30.
The form panels 1 are reinforced on their interior side in one
direction with ribs fabricated onto the plastic sheet 2 and in a
second direction with lateral supports attached to the ribs 7 and
lips 5. Corner braces 44 further connect the form panels 1 together
and create a precise 90 degree corner.
[0102] The blocks 70 may be set in place before, after or
simultaneous with the rebars. In FIG. 15, the blocks 70 are set in
place after the rebar 45 and stirrups 43 have been set. The block
70, absent the individual connectors, simply slides over the rebar
cage and the bottom section slips into the top of the block 70
immediately below it.
[0103] After the block 70 has been placed, the individual
connectors 40 are snapped into or otherwise attached to the lateral
supports 30 to brace and connect the four sides of the form
together from the interior sides of the forms so as to withstand
the concrete pressure. The blocks 70 permanently remain in place
after the concrete cures. In this configuration the form panel 1 is
on four sides of the form 10 and each of the individual form panels
1 are connected by both corner braces 44 and individual connectors
40, as internal bracing, to a second side of the form 10.
[0104] The invention may also be used to create moldings, reveals,
indentations and other design features to a building's interior or
exterior. FIG. 16 shows a section of an exterior wall with window
molding and foam board insulation as well as a section of the
interior ceiling. From FIG. 16, form panel 1A is the exterior form
which has a laminated finish 71 that was fabricated onto the thin
plastic sheet 2. The attractive exterior window molding 72 is also
made of plastic forms as herein disclosed. The window molding 72 is
snapped into or otherwise attached to the form panel 1 and concrete
will flow into the inside of the molding so as to make it
solid.
[0105] In this configuration the form 10 is comprised of form
panels 1A and 1B. The exterior form panel 1A reinforced on the
interior side by a grate 3 to which individual connectors 40 are
attached. Both vertical and horizontal rebar 45 are set in place
inside the form panel before the inside form panel 1B is set in
position.
[0106] The inside form panel 1B has a finished or unfinished
interior face 73 and is reinforced and insulated by a foam board 65
bonded to the interior side of the form panel 1B. The form panel 1B
also has tracks 8 to which the individual connectors 40 attach. The
form panel 1B is attached to the individual connectors 40 by
sliding the form panel 1B vertically down the lines of individual
connectors 40 from the top connector to the bottom connector. The
individual connectors 40 are maintained in their horizontal
position by a gusset (not shown) against the interior side of form
panel 1A. Not shown is the wire raceway that is concealed by the
foam board 65.
[0107] In FIG. 16 the exterior form panel 1A extends a distance
above the height of the interior wall 74 so as to provide formwork
for the floor/ceiling concrete 11. A molded ceiling form panel 51
is used to form the bottom of the floor/ceiling slab and is
comprised of a frameless, pliable plastic sheet with ribs (not
shown) on the interior side that bonds to the concrete. The ceiling
form panels 51 simply interlock to one another and are supported by
shoring (not shown) prior to the concrete curing. After the
concrete cures and the shoring is removed, the ceiling form panels
51 remain in place to expose an aesthetically pleasing and fully
finished ceiling.
[0108] FIG. 17 shows another configuration comprising a connecting
frame 4 used to connect the four sides of the form 10 to construct
a rectangular column form. In this configuration a single form
panel 1 is used to form all four sides of the form 10 and the
connecting frame 4 acts as to secure the rebar 45 as well as
provide the framework for the form 10. The form panel 1 is composed
of a pliable plastic sheet 2 to which a grate 3 is fabricated to
provide reinforcement means and the connection means on the plastic
sheet's 2 interior side. The form panel 1 is creased to allow it to
be folded as a means for shaping a single form panel to form more
than one side of a multi-sided form. The connecting frame 4
provides the internal bracing with the attached pronged inserts 41
providing the means for connecting to the other three sides of the
form 10, which in this configuration are all provided by the folded
form panel 1.
[0109] FIG. 18A is another configuration that shows a circular form
75 comprised of a single form panel 1 with ribs 7 and lips 5 as
reinforcement and connection means fabricated onto and across the
interior side of the pliable plastic sheet 2 to create the form
panel 1. The form panel 1 may be rolled, extruded, or otherwise
molded into said circular shape, or into any other shape as
additional means for shaping the form panel to form more than one
side of a multi-sided form. Several circular connecting frames 4
with sliders 9 as a means for connecting are slid into the circular
form 75, attaching to the ribs 7 and lips 5 as shown in FIG. 18B to
provide the form panel 1 with a means for reinforcement in a second
direction. After all of the connecting frames 4 are in place, the
circular form 75 is then slid down over the rebar to its final
position. In this configuration a single form panel 1 is on an
infinite number of sides of the form 10 to shape a circular form.
The circular connecting frame 4 provides the internal bracing and
has a means connecting to some of the infinite number of sides of
circular form 10.
[0110] In an alternative configuration, FIG. 18C shows circular
form 75 reinforced with a connecting frame 4 that has a rebar
support area 76 that secures the rebar 45 and stirrups 43 in their
respective positions. In this configuration the stirrups 43 are
attached to the connecting frame 4 which is then slid into position
on the inside of the circular form 75. After this, the vertical
rebar 45 is slid through the rebar support area 76 which secures
the rebar in place next to the stirrups 43. In another
configuration, FIGS. 19A through 20B are side or top views of the
form panel on two sides of form 10 that is used to build a wall.
FIG. 19A is a section view with form panel 1A comprising a plastic
sheet 2 to which a grate 3 is fabricated onto as the reinforcement
and connections means. The individual connectors 40, rebar tie
connectors 49 and lateral supports 30 all of which are internal
bracing, have been snapped into the grate 3 as a means for
connecting to form panel 1A.
[0111] Also shown in FIG. 19A is the second form panel 1B comprised
of a plastic sheet 2 reinforced with a foam board 65 across the
interior side of the plastic sheet 2. In addition a "T" shaped
slider 9B may be either individual or a spaced apart means for
connecting or it may be a continuous, track-like slider extending
the full height of the plastic sheet 2 and providing both
reinforcement and connections means across the interior side of the
plastic sheet 2 to comprise form panel 1B. For purposes of this
disclosure the term "across" shall mean from side to side in at
least one direction, but not necessarily continuously from side to
side nor extending all the way to a side. It shall also mean more
than the perimeter. For example in FIG. 19B the foam board 65 is
not continuous across the plastic sheet 2 because it is interrupted
in several places by the slider 9B. In those interrupted areas, the
slider 9B is connected to internal bracing which supports and
thereby reinforces the plastic sheet 2 in that immediate area.
Likewise a reinforcing means may end near a side of the plastic
sheet that has other reinforcement such as in FIG. 25 wherein the
stud's flange supports the edge of a plastic sheet/form panel.
[0112] In FIG. 19B both the slider 9B and the foam board are
protrusions and both provide a means for reinforcing the plastic
sheet 2 and thereby the form panel 1B. In addition both the slider
9B and the foam board 65 will also bond to the concrete when it is
hardened. In the slider's 9B case the concrete will lodge under the
"T" shape whereas in the foam board's 65 case the concrete on the
side of the foam board 65 where it is interrupted by the slider 9B
will develop friction with the foam board 65. In addition, the
concrete may also adhere to the foam board 65 as the concrete cures
and/or it may partially embed into the foam board during placement.
Moreover, the foam board may be undercut on its side and/or have
dove tails into which the concrete will flow and thereby enabling
it to bond to the foam board 65.
[0113] After form panel 1A with the internal bracing is set in
place, the horizontal and vertical rebar 45 are positioned with the
horizontal rebar 45 placed in the rebar bracket 42. One function of
the rebar bracket 42 is to secure the rebar 45 a set distance from
the form panel 1A. Rebar tie connectors 49 are then tied to the
rebar 45 and snapped into the grate 3 so as to provide additional
internal bracing to the form panel 1A by the rebar 45 and to
stabilize the form panel 1A in the upright position.
[0114] As the rebar tie connector 49 is tightened, it pulls the
form panel 1A toward the rebar while the rebar bracket 42 holds the
form panel a set distance. In this way the rebar 45 is used as an
internal bracing to support the form panel 1A from the pressure of
the wet concrete.
[0115] After the steel rebars 45 have been placed, a junction bar
31 is slid down the sliders 9A attached to the individual
connectors 40 as a means for connecting, and as can be better
understood by FIG. 19B, which is a plan view of FIG. 19A. The
junction bars 31 in FIG. 19B has a double track 8 as a means for
connecting with the first track 8A to be slid over the slider 9A
attached to the individual connectors 40 and the second track 8B to
accept the "T" shaped slider 9B that is fabricated onto the
interior side of the second form panel 1B. Slider 9B will be slid
down the second track 8B of junction bar 31 to position form panel
1B and close the form 10.
[0116] Also shown in FIG. 19B is the raceway 60 into which wires
and cables from switches and outlets may be located. The raceway 60
is attached to the form panel 1B and the area between the plastic
sheet 2 and the raceway is filled with foam or other filler
material.
[0117] FIG. 20A shows the section view of the components of FIG.
19A as assembled and
[0118] FIG. 20B shows the plan view of FIG. 20A. FIGS. 20A and 20B
also shows one configuration of the internal bracing on the
interior side of either form panel as it connects to the interior
side of the second side form. The form 10 is now ready for concrete
11 cast between the panel 1A and the foam board 65. FIG. 20B also
shows how the junction bar 31 is attached to both the individual
connectors 40 and the track 8. The lateral pressure of the concrete
pushes the two form panels 1A and 1B away from each so as to create
a firm and solid wall section.
[0119] As a result of this configuration a form panel 1A in on one
side and form panel 1B is on a second side (or vice versa) of form
10 and each form panel has reinforcement and connection means
arranged across their respective interior sides and are connected
to internal bracing that connects to a second side of form 10,
which can be either form panel 1A or 1B.
[0120] FIGS. 21 and 22 shows another configuration disclosed herein
as applied to forming a concrete wall. In FIG. 21 the individual
form components "A" thru "G" are shown and FIG. 22 shows the form's
components assembled.
[0121] FIG. 21A is a plastic sheet 2 extruded with ribs 7 as
reinforcement means and lips 5 as connection means. FIG. 21B shows
the plastic sheet 2 with foam board 65 bonded for additional
reinforcement and insulation and comprises form panel 1A, which is
one side of the form 10 as depicted in FIG. 22. There is an
optional housing 77 that surrounds the lip 5 to keep this area
clear of foam that may be sprayed or otherwise liquid applied to
the plastic sheet 2. The form panel 1A also has a wire raceway 60
attached which is supported by a rib 7.
[0122] FIG. 21C shows one of two lateral supports 30A as internal
bracing with connection means as used in this form 10. This lateral
support 30A connects to the lip 5 of form panel 1A to provide both
support from the pressure of the wet concrete and a means for
connecting form panel 1A to a second side of form 10, which in this
configuration is form panel 1B. The lateral support 30A when
attached to the form panel 1A acts as a truss to strengthen form
panel 1A to withstand the pressure of the wet concrete. While the
ribs 7 may be in close proximity to reinforce the plastic sheet 2,
the sliders 9B on the second side of the lateral support 30A may be
spaced much further apart since they only provide a means for
connecting.
[0123] FIG. 21D shows the junction bars 31 as internal braces that
run the full length (height) of the form panels 1A and 1B. The
junction bars 31 provide vertical tracks 8A and 8B as a means for
connecting to other internal bracing shown such as the lateral
supports 30A and/or the individual connectors 40 that are inserted
(on either side) and slid to their final position. The sliders 9,
as the means for connecting on the ends of the individual
connectors 40 may be deformed or otherwise altered after they are
positioned so that they remain fixed at set locations.
[0124] FIG. 21E shows individual connectors 40 that attach to the
lateral supports 30A and 30B that support form panels 1A and 1B
respectively. The individual connectors 40 connect the two sides
together and, in this configuration, are simply a straight bar with
a slider 9 as a means for connecting on both ends.
[0125] FIG. 21F shows the second lateral support 30B used in this
configuration. The lateral supports may be of different
configurations as required by the application and the means by
which the form panels are reinforced. The lateral support 30B in
FIG. 21F is used to support form panel 1B, which is reinforced with
ribs 7 of a different configuration than used in form panel 1A.
Sliders 9 are fabricated onto one side of the lateral support 30B
and a slot 78 is on the other side and the slider 9 of the
individual connectors 40 snaps or slides into said slot 78 so as to
attach to the lateral support 30B as a means for connecting. The
second side of this lateral support 30B has slider 9 that snaps or
slides onto the lip 5 on form panel 1B as a means for
connecting.
[0126] FIG. 21G shows form panel 1B, which consists of a plastic
sheet 2 to which ribs 7 and a lip 5 are attached. The lip 5
provides a track as a means for connecting to the lateral support
30B through its sliders 9. The ribs 7 support the form panel 1B in
one direction while the lateral support 30B provides support in the
direction perpendicular to the ribs 7. FIG. 22 shows the components
of FIG. 21 assembled and the form 10 is complete and ready for
concrete (rebar not shown).
[0127] To assemble the form in FIGS. 21 and 22, the form panels 1A
and 1B are each assembled with their respective lateral supports
attached. The individual connectors 40 are then placed in the slots
78 of lateral support 30B and form panel 1B is set in place. The
rebar (not shown) is then set in place inside form 10 and the form
10 is ready to be closed
[0128] To close the form 10 the junction bar 31 with its track 8B
is slid vertically down the open ends of the individual connectors
40 to align, brace and connect the individual connectors 40 and to
create a truss. The junction bar 31 runs the full vertical length
(height) of the form panel 1B and said truss is created by the
junction bar 31, the individual connectors 40 and the form panel
1B.
[0129] Form panel 1A is then slid vertically down the opposite and
open side of the track 8A of junction bar 31 as a means for
connecting. Form panel 1A is easily slid into its final position
because of the limited number of connection points between the
junction bar 31 and the lateral support 30A. For example while the
form panel 1A may have ribs 7 in close proximity that attach to the
lateral support 30A, the lateral support 30A may have a connection
point to the junction bar 31 much further apart. As such, a
4'.times.8' form panel 1A may have very few connection points to
the junction bar 31.
[0130] As a result of this configuration shown in FIGS. 21A-G and
FIG. 22, a form panel 1A in on one side and form panel 1B is on a
second side (or vice versa) of form 10 and each form panel has
reinforcement and connection means arranged across their respective
interior sides and are connected to internal bracing that has a
means for connecting to a second side of form 10, which can be
either form panel 1A or 1B.
[0131] In another configuration the form is comprised of a form
panel on one side of a multi-sided form and is connected to a stud
that is supporting foam boards or other panels in predetermined
positions on a second side of the form. In this configuration the
backside of the stud connects to the internal bracing while the
stud's front side may provide a nailable and/or screwable surface
to which claddings such as drywall or other wall surface sheets may
be attached on the second side of the form. The stud may also
facilitate externally bracing the form.
[0132] FIG. 23 shows a section view of an elongated rigid stud 80
that is made of any materials including plastic, metal, wood or a
combination thereof. FIGS. 24 to 26 shows several means for
connecting the backside of the stud to the internal bracing. FIG.
24A shows a plan view of one configuration of stud 80 into which a
track 8 has be molded or fabricated as a means for connecting to
internal bracing. The sliders 9 connected to the individual
connectors 40 are inserted or otherwise attached to the track 8
that provides the means for connecting to the stud 80. Also shown
in FIG. 24A is a flange 13 attached to the stud 80 that enables the
stud 80 to support foam boards, or other insulation boards on the
backside of the flange 13 and to support wall board, panels or
other materials that may be attached to the front side of the stud.
FIG. 24B shows the section view of FIG. 24A and the extended length
of the slider 9 that may be on the end of the individual connector
40.
[0133] FIG. 25 shows another configuration of the stud 80 wherein
the stud's 80 means for connecting to the individual connector 40
is by snapping them together. In FIG. 25, the snap insert 6 of the
individual connector 40 is shaped such that it will slip into and
snap open behind a lip 5 fabricated on the stud 80
[0134] FIG. 26 shows another configuration by which the slider 9 on
the individual connector 40 is connected to the stud 80 by either
snapping over or sliding down the lip 5 on the end of rib 7
protruding from the backside of the stud 80 as a means for
connecting. The ribs 7 or other element extending inward from the
flange 13 may be short or may extend beyond the thickness of the
insulation boards or panels.
[0135] The stud enables the plastic form panel to be economically
used in conjunction with various wallboards, siding and panels that
are commonly used in the construction of a wall. One advantage of
the stud is that it allows for open access into the area between
the forms where the concrete is to be cast to facilitate the
placement and securing of the concrete reinforcement materials
(rebars). For example, FIG. 27A shows a partially completed form 10
with one side closed with a form panel 1A and the second side open
through which the horizontal rebar 45A and the vertical rebar 45B
can easily be set in place. FIG. 27B also shows the stud 80 being
slid down a track on the end members 82 of the individual
connectors 40 as a means for connecting the stud to the internal
bracing which in turn are connected to the form panel 1A. In this
embodiment the stud 80 ties together or locks the individual
connectors 40 into a rigid alignment.
[0136] FIG. 28 shows the plan view of FIG. 27B with stud 80 that
has flanges 13. Although the stud 80 is shown as "T: shaped with a
flange 13 on two opposite sides, the stud 80 may also have a single
flange on only one side, such as a "L" shape, and may be used for
corners or other conditions. Also shown in FIG. 28 is an optional
connector support 84 as a means for connecting the studs 80 so as
to secure them in a set vertical alignment to facilitate sliding
the stud 80 down the individual connectors 40. The optional
connector support 84 attaches horizontally from individual
connector 40 to connector and may also be used a horizontal support
for the form board. Or, as an alternative, the individual
connectors 40 may also have flanges on both sides (not shown) a set
distance from the stud so as to secure the backside of the foam
board in place.
[0137] FIG. 29A is a section view of the closed form 10 showing the
addition of a foam board 65 having been slid down between the
flanges 13 and the connector supports 84 as shown in FIG. 29B. The
foam board 65 is supported by the stud's flanges and closes the
form 10 so as to be ready for concrete. In this configuration the
stud 80 and foam board 65 comprise the second side form of the
multi-sided form and by connecting the internal bracing to the
backside of the stud the second side form is being connected on its
interior side. The connector supports 84 acts to hold the foam
board 65 in position before and during the casting of the concrete
into the form 10.
[0138] FIG. 29B is a plan view of FIG. 29A showing the foam board
65 in position between and supported by the flanges 13 that are
part of the studs 80, and also by the connector supports 84. When
concrete is cast inside form 10, the foam board 65 or other such
board or panel is of such strength that it can withstand the
hydrostatic pressure from the wet concrete as supported by the stud
80 and its flanges 13 and the individual connectors 40.
[0139] The stud 80 may be made of a nailable/screwable material to
which drywall or other materials may be attached to the stud's
front side. The stud may be used in either a vertical or a
horizontal direction and may also be shaped as an angle for
corners.
[0140] The stud, foam boards and/or form panels can be set in
levels on one or more sides of a multi-sided form, to utilize the
means for reducing hydrostatic pressure on the form as disclosed
above. In this instance the stud, form boards and/or form panels
one at least one side of the form are in shorter sections that are
vertically stacked for each level until the full height of the
structure is reached. The low or no-slump concrete is placed into
each level prior to setting the next level of studs, foam boards
and/or form panels to enable visual observation of the concrete
being placed (cast and vibrated) in each level. Such a process
greatly reduces the hydrostatic pressure on the form and thereby
allows for less bracing.
[0141] Another configuration of the plastic form panel is its use
as a stay-in-place form on one or more sides of a multi-sided form
and at least a second side of the form is comprised of a different
type of form that has the ability to connect to the internal
bracing. For example the form panel may be on one side of a two
sided form and internally braced and connected to a one-sided
insulated concrete form (ICF) on the second side of the form. Or
the second side form may be a removable form that has the means for
connecting to the internal bracing. Any type of form that is
capable of having a means for connecting to the internal bracing
may be used in this configuration.
[0142] Another configuration is of the form panel reinforced on its
interior side but is externally braced. For example the ceiling
form shown in FIG. 16 is one such application wherein the form
panel forms the bottom side of a ceiling/floor form and is
externally braced from below. Beyond the ceiling form application,
the form panels are all internally braced in relatively close
proximity to withstand the wet concrete's hydrostatic pressure.
[0143] On Jan. 17, 2012, applicant filed copending application Ser.
No. 13/374,839 filed 17 Jan. 2012 entitled the Thixotropic Building
System, incorporated herein by reference. This application
disclosed a new method for reducing the hydrostatic pressure in
concrete wall forms to such a degree that form ties may be
eliminated and external bracing may be solely used to brace wall or
other vertically oriented forms. Also disclosed in this application
were plastic, stay-in-place forms that have ridges that embed into
the wet concrete and may be externally braced.
[0144] The significant reduction in hydrostatic pressure and the
resulting elimination of form ties, makes it possible for the
plastic form panel disclosed herein to still bond to the concrete
and have reinforcement means on its interior side but replace the
connecting means for internal bracing with external bracing. This
was disclosed in the above referenced copending application. In
addition, with adequate reinforcement and external bracing (to
include a removable form) or other support, such a plastic form
panel may be used in all casting methods.
[0145] As such, FIGS. 4 through 7A show a form panel 1 comprising a
plastic sheet 2 with reinforcement means attached to the interior
side of the plastic sheet 2 and the lips 5 enable the form panel to
bond to the concrete. In this configuration the form panel 1 may be
used to form one or more sides of a multi-sided concrete form and
be externally braced and/or supported by removable forms. The form
panel 1 may also have a finished appearance or a cladding attached
to its exterior side such as siding, boards, panels or provide a
backing for all types of claddings and/or coatings.
[0146] From the description above, a number of advantages of some
embodiments of my plastic stay-in-place forming system become
evident:
[0147] (a) A thin plastic sheet is reinforced with protrusions to
create a rigid form panel capable of forming wet concrete despite
high levels of hydrostatic pressure.
[0148] (b) The protrusions attached to the interior side of the
thin plastic sheet act to bond the form's thin plastic sheet to the
cured concrete such that the plastic form provides a firm, sturdy
and solid covering to the concrete member.
[0149] (c) The forms are internally braced with connecting frames,
lateral supports and individual connectors which provide
substantial flexibility and efficiency in their placement. This
results in the use of fewer connecting frames, supports and
connectors and thinner plastic sheets.
[0150] (d) The individual connectors create an open access form
into which concrete reinforcement, including welded wire fabric can
easily be placed.
[0151] (e) A special stud that supports foam boards as one side of
a form and uses individual connectors to connect to a second
form.
[0152] (f) A means wherein the rebar is used to support the form
panels.
[0153] (g) The plastic forms are lightweight, easy to handle,
simple to assemble, highly flexible. and use less plastic
materials. They may be used for columns, walls, beams and
floor/ceilings.
[0154] (h) Since the plastic covering is firmly attached to the
concrete, it provides a suitable surface to which attractive
exterior claddings may be attached.
[0155] Accordingly the reader will see that thin plastic sheets may
be used as concrete forms when they are reinforced with ribs,
grates and the like and further supported by lateral supports or
connecting frames. These thin plastic sheets provide an attractive
and permanent covering because they are firmly bonded to the
concrete. The individual connectors provide a flexible and
inexpensive approach to connecting one or more plastic forms.
[0156] Although the description above contains many specifications,
these should not be construed as limiting the scope of the
embodiments but as merely providing illustrations of some of
several embodiments. Thus the scope of the embodiments should be
determined by the appended claims and their legal equivalents,
rather than by the examples given.
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