U.S. patent application number 13/954315 was filed with the patent office on 2014-02-06 for leave-in-place concrete form.
The applicant listed for this patent is Joseph N. Bondi, Joshua Fairley, Steve B. Gross. Invention is credited to Joseph N. Bondi, Joshua Fairley, Steve B. Gross.
Application Number | 20140033643 13/954315 |
Document ID | / |
Family ID | 50024113 |
Filed Date | 2014-02-06 |
United States Patent
Application |
20140033643 |
Kind Code |
A1 |
Fairley; Joshua ; et
al. |
February 6, 2014 |
LEAVE-IN-PLACE CONCRETE FORM
Abstract
A concrete form is disclosed and can include an elongated body
having a length and a width. A cross-section of the elongated body
perpendicular to the length can include a closed, box-shaped main
body having an upper wall, a lower wall opposite the upper wall, a
first sidewall extending between and connecting the upper wall and
the lower wall, and a second sidewall opposite the first sidewall
and extending between and connecting the upper wall and the lower
wall. A lower extension can extend from the main body portion in a
first direction beyond the lower wall and an upper extension can
extend from the main body portion in a second direction opposite
the first direction beyond the upper wall.
Inventors: |
Fairley; Joshua; (King of
Prussia, PA) ; Bondi; Joseph N.; (Devon, PA) ;
Gross; Steve B.; (Holland, PA) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Fairley; Joshua
Bondi; Joseph N.
Gross; Steve B. |
King of Prussia
Devon
Holland |
PA
PA
PA |
US
US
US |
|
|
Family ID: |
50024113 |
Appl. No.: |
13/954315 |
Filed: |
July 30, 2013 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
61677235 |
Jul 30, 2012 |
|
|
|
Current U.S.
Class: |
52/836 |
Current CPC
Class: |
E04G 11/00 20130101;
E04G 13/00 20130101; E02D 27/013 20130101; E04B 1/70 20130101 |
Class at
Publication: |
52/836 |
International
Class: |
E04G 11/00 20060101
E04G011/00 |
Claims
1. A concrete form, comprising: an elongated body having a length
and a width, wherein a cross-section of the elongated body
perpendicular to the length comprises: a closed, box-shaped main
body portion comprising: an upper wall; a lower wall opposite the
upper wall; a first sidewall extending between and connecting the
upper wall and the lower wall; a second sidewall opposite the first
sidewall, the second sidewall extending between and connecting the
upper wall and the lower wall; a lower extension extending from the
main body portion in a first direction beyond the lower wall; and
an upper extension extending from the main body portion in a second
direction opposite the first direction beyond the upper wall.
2. The concrete form of claim 1, further comprising a stiffening
lip extending from the upper extension, wherein the stiffening lip
extends along the entire length of the elongated body.
3. The concrete form of claim 2, wherein the stiffening lip is
perpendicular to the upper extension.
4. The concrete form of claim 1, wherein the lower extension
extends in a downward direction and the upper extension extends in
an upward direction when the concrete form is installed.
5. The concrete form of claim 1, wherein the upper wall and the
lower wall are substantially perpendicular to the first sidewall
and the second sidewall.
6. The concrete form of claim 1, wherein the lower extension, the
upper extension and the second sidewall lie along the same
plane.
7. The concrete form of claim 2, wherein the stiffening lip is
parallel to the upper wall and the lower wall.
8. The concrete form of claim 2, wherein the elongated body
comprises an overall height, H, and wherein the stiffening lip
extends from the upper extension at a distance, D, and a ratio of
D/H is in a range of from about 5% to about 50%.
9. The concrete form of claim 2, wherein the stiffening lip extends
from the upper extension such that the upper extension does not
extend above the stiffening lip.
10. The concrete form of claim 2, wherein the body includes a
length along a longitudinal axis and the body includes a
substantially uniform cross-section perpendicular to the
longitudinal axis along the entire length of the body.
11. The concrete form of claim 1, wherein the elongated body is
molded or extruded.
12. The concrete form of claim 1, wherein the concrete form is left
in place once the form is used in the construction process.
13. A concrete form, comprising: a closed, box-shaped main body
portion comprising: an upper wall; a lower wall opposite the upper
wall; a first sidewall extending between and connecting the upper
wall and the lower wall; a second sidewall opposite the first
sidewall, the second sidewall extending between and connecting the
upper wall and the lower wall; a lower extension extending from the
main body portion in a first direction beyond the lower wall; and
an upper extension extending from the main body portion in a second
direction opposite the first direction beyond the upper wall;
wherein a cross-section of the concrete form perpendicular to a
length of the concrete form and passing through the main body, the
lower extension, and the upper extensions is substantially uniform
along the length of the concrete form.
14. The concrete form of claim 13, wherein the concrete form is
produced via a molding process or an extrusion process.
15. The concrete form of claim 13, wherein the concrete form is
free of discontinuous structural features extending along an axis
perpendicular to a longitudinal axis of the concrete form.
16. A concrete forming system, comprising: a first concrete form
configured to provide water drainage; and a second concrete form
distanced from the first concrete form to define a channel between
the first concrete form and the second concrete form, wherein the
second concrete form comprises: an elongated body having a length
and a width, wherein a cross-section of the elongated body
perpendicular to the length comprises: a closed, box-shaped main
body portion comprising: an upper wall; a lower wall opposite the
upper wall; a first sidewall extending between and connecting the
upper wall and the lower wall; a second sidewall opposite the first
sidewall, the second sidewall extending between and connecting the
upper wall and the lower wall; a lower extension extending from the
main body portion in a first direction beyond the lower wall; and
an upper extension extending from the main body portion in a second
direction opposite the first direction beyond the upper wall.
17. The concrete form of claim 16, wherein the concrete form is
produced via a molding process or an extrusion process.
18. A concrete forming system, comprising: a first concrete form
configured to provide water drainage; a second concrete form
distanced from the first concrete form to define a channel between
the first concrete form and the second concrete form; and a
plurality of stakes placed along each concrete form at a regular
stake interval, I.sub.S, wherein the second concrete form provides
an installed deflection, D.sub.I, between adjacent stakes and
D.sub.I.ltoreq.0.75% I.sub.S.
19. The concrete forming system of claim 18, wherein D.sub.I is
measured along an axis perpendicular to a longitudinal axis of the
second concrete form.
Description
[0001] This application claims priority to and the benefit of U.S.
Prov. App. No. 61/677,235, filed Jul. 30, 2012, and is incorporated
herein by reference in its entirety.
BACKGROUND
[0002] 1. Field of the Disclosure
[0003] The following is generally directed to concrete forms, and
more particularly, to concrete forms that remain in place after
concrete held in place by the forms sets.
[0004] 2. Description of the Related Art
[0005] The use of concrete in modem construction is ubiquitous.
Concrete, or a combination of concrete and steel, serves as the
base or foundation for many structures. For example, concrete
footers, concrete slabs, etc. can be poured and allowed to set.
Once the concrete has set it has the requisite load bearing
capabilities for providing structural support.
[0006] When installing concrete, it is often necessary to provide
support for the concrete while the concrete sets. For example,
concrete forms can be assembled to establish, or define, a
volumetric space. Reinforcing rod (re-bar) can be assembled to form
an internal support structure and placed within the space defined
by the forms. Then, the volumetric space within the forms can be
filled with concrete and the re-bar can be completely entombed
within the concrete. After the concrete cures, the concrete forms
can be removed from the concrete and the set concrete can have the
shape of the volumetric space.
[0007] In certain instances, the forms can be left in place
adjacent to the set concrete. Thus, the concrete form can become
integral with the set concrete when it is left in place once the
form is used in the construction process. Further, these forms can
be configured to provide water drainage around the concrete, radon
venting, etc. As with other industries, improvements to these
concrete forms are always sought.
BRIEF DESCRIPTION OF THE DRAWINGS
[0008] The present disclosure may be better understood, and its
numerous features and advantages made apparent to those skilled in
the art by referencing the accompanying drawings.
[0009] FIG. 1 includes a plan view of a concrete forming system in
accordance with an embodiment.
[0010] FIG. 2 includes an orthogonal view of a leave-in-place
concrete form in accordance with an embodiment.
[0011] FIG. 3 includes a first end plan view of a leave-in-place
concrete form in accordance with an embodiment.
[0012] FIG. 4 includes a second end plan view of a leave-in-place
concrete form in accordance with an embodiment.
[0013] FIG. 5 includes a front plan view of a leave-in-place
concrete form in accordance with an embodiment.
[0014] FIG. 6 includes a back plan view of a leave-in-place
concrete form in accordance with an embodiment.
[0015] FIG. 7 includes a top plan view of a leave-in-place concrete
form in accordance with an embodiment.
[0016] FIG. 8 includes a bottom plan view of a leave-in-place
concrete form in accordance with an embodiment.
[0017] FIG. 9 includes a cross-sectional view of a leave-in-place
concrete form in accordance with an embodiment taken along line 9-9
in FIG. 7.
[0018] FIG. 10 includes a plan view of a die for shaping a
leave-in-place concrete form in accordance with an embodiment.
[0019] FIG. 11 includes a front plan view of a coupler for a
leave-in-place concrete form in accordance with an embodiment.
[0020] FIG. 12 includes a side plan view of a coupler for a
leave-in-place concrete form in accordance with an embodiment.
[0021] FIG. 13 includes a top plan view of a coupler for a
leave-in-place concrete form in accordance with an embodiment.
[0022] FIG. 14 includes an exploded plan view of adjacent
leave-in-place concrete forms in accordance with an embodiment.
[0023] FIG. 15 includes an assembled plan view of adjacent
leave-in-place concrete forms in accordance with an embodiment.
[0024] The use of the same reference symbols in different drawings
indicates similar or identical items.
DETAILED DESCRIPTION
[0025] According to an embodiment, a concrete forming system
includes a first concrete form configured to provide water drainage
and a second concrete form distanced from the first concrete form
to define a channel between the first concrete form and the second
concrete form. The second concrete form can include an elongated
body having a length and a width. The cross-section of the
elongated body perpendicular to the length can include a closed,
box-shaped main body portion. The main body portion can include an
upper wall, a lower wall opposite the upper wall, a first sidewall
extending between and connecting the upper wall and the lower wall,
and a second sidewall opposite the first sidewall extending between
and connecting the upper wall and the lower wall. The second
concrete form can also include a lower extension extending from the
main body portion in a first direction beyond the lower wall and an
upper extension extending from the main body portion in a second
direction opposite the first direction beyond the upper wall.
[0026] Referring to FIG. 1, a concrete forming system is shown and
is generally designated 100. As illustrated in FIG. 1, the concrete
forming system 100 can include a first concrete form 102 that can
be configured to provide water drainage. The system 100 can also
include a second concrete form 104 that is distanced from the first
concrete form 102 to define a channel 106 between the first
concrete form 102 and the second concrete form 104. The second
concrete form 104 may not be configured to provide water
drainage.
[0027] As depicted in FIG. 1, the concrete forming system 100 can
also include a spacer strap 108 that can extend between the first
concrete form 102 and the second concrete form 104. The spacer
strap 108 can include a first hook 110 and a second hook 112
separated by a spacer body 114. The first hook 110 can be
configured to fit over the first concrete form 102 and the second
hook 112 can be configured to fit over the second concrete form
104. The spacer strap 108, e.g., the spacer body 114 of the spacer
strap 108, can maintain the spacing between forms 102, 104 can help
define the width of the channel 106.
[0028] FIG. 1 further indicates that the concrete forming system
100 can further include a plurality of grade stakes 116 placed
along the concrete forms 102, 104 at a regular stake interval,
I.sub.S. The stakes 116 can be placed along the outside of the
concrete forms 102, 104 in order to further maintain the channel
width between the forms 102, 104 and to prevent the forms 102, 104
from deflecting outward due to the hydraulic pressure of wet,
uncured concrete that is pumped or otherwise placed within the
channel 106.
[0029] In a particular embodiment, the second concrete form 104,
which is described in greater detail below, can provide an
installed deflection, D.sub.I, between adjacent stakes 116 along
the second concrete form 104 that can be .ltoreq.1% I.sub.S,
.ltoreq.0.9% I.sub.S, such as .ltoreq.0.8% I.sub.S, or
.ltoreq.0.75% I.sub.S. In a particular aspect, D.sub.I can be
measured at a top of the second concrete form 104. Further, D.sub.I
can be measured along an axis perpendicular to a longitudinal axis
of the second concrete form 104.
[0030] FIG. 2 through FIG. 9 depict the details concerning the
second concrete form 104. As illustrated, the concrete form 104 can
include an elongated body 200 having an overall length, L.sub.O, an
overall width, W.sub.O, and an overall height, H.sub.O.
[0031] As indicated in FIG. 3, FIG. 4, and FIG. 9, the elongated
body 200 can be configured so that when viewed from an end or when
viewed in cross-section taken perpendicular to the length of the
elongated body 200, the elongated body 200 can include a closed,
box-shaped main body portion 202. The box-shaped main body portion
202 can include an upper wall 204 and a lower wall 206 opposite the
upper wall 204. The main body portion 202 can also include a first
sidewall 208. The first sidewall 208 can extend between and connect
the upper wall 204 and the lower wall 206. Further, the main body
portion 202 can include a second sidewall 210 opposite the first
sidewall 208. The second sidewall 210 can extend between and
connect the upper wall 204 and the lower wall 206.
[0032] In a particular aspect, the upper wall 204 and the lower
wall 206 are parallel to each other. Further, the upper wall 204
and the lower wall 206 are perpendicular to the first sidewall 208
and the second sidewall 210.
[0033] In a particular aspect, a lower extension 212 can extend
from the main body portion 202 in a first direction beyond the
lower wall 206. An upper extension 214 can extend from the main
body portion 202 in a second direction beyond the upper wall 204.
The second direction can be opposite the first direction of the
lower extension 206. The upper extension 214 can also include a
distal end 216. The lower extension 212, the upper extension 214,
and the first sidewall 208 can lie along the same plane. Moreover,
in another aspect, the lower extension 212 can extend in a downward
direction and the upper extension 214 can extend in an upward
direction when the concrete form 104 is correctly installed in
accordance with an embodiment herein.
[0034] Further, as mostly clearly depicted in FIG. 3, FIG. 4, and
FIG. 9, the concrete form 104 can further include a stiffening lip
218 that can extend from the upper extension 214 such that the
upper extension 214 does not extend above the stiffening lip 218.
In one aspect, the stiffening lip 218 can extend from the upper
extension 214 at or near the distal end 216 of the upper extension
214. In another aspect, the stiffening lip 218 can extend from the
upper extension 214 at some location between the distal end 216 of
the upper extension 214 and the main body portion 202 of the
concrete form 104. In yet another aspect, the stiffening lip 218
can extend along the entire length of the elongated body 200 of
they concrete form 104.
[0035] As illustrated, the stiffening lip 218 can extend at an
angle, .alpha., with respect to the upper extension 214. In a
particular aspect, .alpha. can be .ltoreq.90.degree., such as
.ltoreq.89.degree., .ltoreq.88.degree., or .ltoreq.85.degree..
Further, .alpha. can be .gtoreq.30.degree., such as
.gtoreq.45.degree., .gtoreq.60.degree., or .gtoreq.75.degree.. In
another aspect, .alpha. can be within a range between and including
any of the values described above. Additionally, in a particular
aspect, the stiffening lip 218 can be perpendicular to the upper
extension 214. Further, the stiffening lip 218 can be parallel to
the upper wall 204 and the lower wall 206. The stiffening lip 218
can extend from the upper extension 214 such that the upper
extension 214 does not extend above the stiffening lip 218.
[0036] In another aspect, the elongated body 200 can include a
overall height, H.sub.O, and wherein the stiffening lip extends
from the upper extension at a distance, D, from the upper wall, and
wherein D.ltoreq.50% H.sub.O, such as D.ltoreq.45% H.sub.O,
.ltoreq.40% H.sub.O, or .ltoreq.35% H.sub.O. Further, D.gtoreq.5%
H.sub.O, such as .gtoreq.10% H.sub.O, .gtoreq.15% H.sub.O,
.gtoreq.20% H.sub.O, or .gtoreq.25% H.sub.O. In other embodiments,
a ratio of D/H can be in a range of about 5% to about 50%.
[0037] In a particular aspect, the elongated body 200 can include a
substantially uniform cross-section perpendicular to a longitudinal
axis of the elongated body 200 along the entire length of the
elongated body 200. The substantially uniform cross-section can be
achieved by forming the elongated body 200 via an extrusion process
from an extrudable material. A suitable extrudable material, e.g.,
an extrudable polymer, an extrudable metal, etc., can be mixed and
forced through a die to create an uncured extruded body.
[0038] Thereafter, the extruded body can be cured to create the
concrete form 104. The curing process can include the application
of radiation (e.g., heat), the application of a cooling fluid
(e.g., chilled air), allowing the uncured extruded body to cure
naturally as time passes. The extruded body can be formed in
various lengths, e.g., 4 feet, 6 feet, 8 feet, 10 feet, etc.
[0039] Referring briefly to FIG. 10, an exemplary die for shaping
the elongated body 200 is illustrated and is generally designated
1000. The die 1000 can include a body 1002 formed with an opening
1004. The opening 1004 within the body 1002 of the die 1000 can
have the same shape as the external shape of the cross-section of
the elongated body 200. FIG. 10 also shows that the body 1002 of
the die 1000 can include a mandrel 1006 disposed within the opening
1004. The mandrel 1006 can include an outer shape that corresponds
to the inner shape of the main body portion 202 of the elongated
body when cross-sectioned as shown in FIG. 9.
[0040] In a particular aspect, the elongated body 200 can include a
height, H, and the box-shaped main body portion 202 can include a
height, H.sub.B. H.sub.B can be .ltoreq.75% H, such as .ltoreq.70%
H, .ltoreq.65% H, .ltoreq.60% H, .ltoreq.55% H, .ltoreq.50% H,
.ltoreq.45% H, or .ltoreq.40% H. Further, H.sub.B can be .gtoreq.5%
H, such as .gtoreq.10% H, .gtoreq.15% H, .gtoreq.20% H, .gtoreq.25%
H, or .gtoreq.30% H. H.sub.B can be within a range between and
including any of the values for H.sub.B described above.
[0041] In another aspect, the box-shaped main body portion 202 can
include a width, W.sub.B, and W.sub.B can be .ltoreq.75% H, such as
.ltoreq.70% H, .ltoreq.65% H, .ltoreq.60% H, .ltoreq.55% H,
.ltoreq.50% H, .ltoreq.45% H, or .ltoreq.40% H. Moreover,
W.sub.B.gtoreq.15% H, such as .gtoreq.20% H, .gtoreq.25% H, or
.gtoreq.30% H. W.sub.B can be within a range between and including
any of the values for W.sub.B described above.
[0042] In another aspect, the stiffening lip 218 can include a
width, W.sub.SL, and W.sub.SL can be .ltoreq.35% H, such as
.ltoreq.30% H, .ltoreq.25% H, or .ltoreq.20% H. Also, W.sub.SL can
be .gtoreq.5% H, such as .gtoreq.10% H, or .gtoreq.15% H. In
addition, W.sub.SL can be within a range between and including any
of the values for W.sub.SL described above. Further, W.sub.SL can
be .ltoreq.50% W.sub.B, such as .ltoreq.45% W.sub.B, .ltoreq.40%
W.sub.B, or .ltoreq.35% W.sub.B. W.sub.SL can also be .gtoreq.5%
W.sub.B, such as .gtoreq.10% W.sub.B, .gtoreq.15% W.sub.B,
.gtoreq.20% W.sub.B, or .gtoreq.25% W.sub.B.
[0043] In yet another aspect, the lower extension 212 can includes
a height, H.sub.LE, and H.sub.LE.ltoreq.35% H, such as .ltoreq.30%
H, .ltoreq.25% H, or .ltoreq.20% H. Further, H.sub.LE, can be
.gtoreq.5% H, such as .gtoreq.10% H, or .gtoreq.15% H. In addition,
H.sub.LE can be within a range between and including any of the
values for H.sub.LE described above.
[0044] Further, in another aspect, the upper extension 214 can
include a height, H.sub.UE, and H.sub.UE can be .ltoreq.60% H, such
as .ltoreq.55% H, .ltoreq.50% H, or .ltoreq.45% H. H.sub.UE can be
.gtoreq.20% H, such as .gtoreq.25% H, .gtoreq.30% H, or .gtoreq.35%
H. In addition, H.sub.UE can be within a range between and
including any of the values for H.sub.UE described above.
[0045] In another aspect, the ratio of H.sub.B:W.sub.B.gtoreq.4:1,
such as .gtoreq.3:1, or .gtoreq.2:1. Further,
H.sub.B:W.sub.B.ltoreq.0.25:1, such as .ltoreq.0.33:1,
.ltoreq.0.5:1, or .ltoreq.1:1. Moreover, the box-shaped main body
portion 202 can include a wall thickness, T.sub.W, and T.sub.W can
be .ltoreq.15% H, such as .ltoreq.10% H, or .ltoreq.5% H. Further,
T.sub.2.gtoreq.0.5% H, such as .gtoreq.1.0% H, .gtoreq.1.5% H,
.gtoreq.2.0% H, .gtoreq.2.5% H, or .gtoreq.3.0% H. In addition, the
ratio can be within a range between and including any of the values
described above.
[0046] In still another aspect, H.sub.B can be .gtoreq.400%
W.sub.B, such as .gtoreq.200%, or .gtoreq.100%. Further, H.sub.B
can be .ltoreq.0.25% W.sub.B, such as .ltoreq.0.5%, .ltoreq.0.8%,
.ltoreq.1.0%, .ltoreq.10%, .ltoreq.25%, or .ltoreq.50% W.sub.B. In
addition, the relative values of H.sub.B and W.sub.B can be within
a range between and including any of the values described
above.
[0047] In another particular aspect, the elongated body 200 can
include an installed stake interval, I.sub.S, measured between
adjacent stakes 116, e.g., from center line to center line. Also,
the upper extension 214 can include an installed deflection,
D.sub.I, measured the upper extension 214 in an outward direction,
i.e., in the same direction in which the stiffening lip 218
extends. D.sub.I can be measured from the base of the upper
extension 214, i.e., near the interface between the upper extension
214 and the main body portion 202. Moreover, D.sub.I can be
measured at or near the distal 216 end (aka the top) of the upper
extension 214. D.sub.I can also be measured anywhere along the
upper extension 214 between the base of the upper extension 214 and
the top of the upper extension 214. Further, D.sub.I can be
measured along the length of the elongated body 200 at a midpoint
between adjacent stakes 116.
[0048] D.sub.I can be caused by the weight or hydraulic pressure of
the green concrete disposed between the forms 102, 104. Further,
certain features of the elongated body 200, e.g., the box-shaped
main body portion 202, the stiffening lip 218, or a combination
thereof, can substantially reduce D.sub.I and substantially prevent
D.sub.I from reaching a critical value in which failure can occur.
That failure can include the form bowing or breaking and allowing
concrete to flow out of the channel 106 between the forms 102, 104
or otherwise causing a level change of the concrete.
[0049] In a particular aspect, D.sub.I can be .ltoreq.0.2% I.sub.S,
such as .ltoreq.0.6% I.sub.S.ltoreq.1%, .ltoreq.5%
I.sub.S.ltoreq.10% I.sub.S.ltoreq.20% I.sub.S, or even
I.sub.S.ltoreq.25% I.sub.S. Further, D.sub.I may be
.gtoreq.0.00625% I.sub.S, such as .gtoreq.0.025% I.sub.S, or even
.gtoreq.0.05% I.sub.S. D.sub.I can be within a range between and
including any of the D.sub.I values above. I.sub.S can be
.gtoreq.0.91 meters (3.0 feet), such as .gtoreq.1.22 meters (4.0
feet), or .gtoreq.1.52 meters (5.0 feet). Moreover, I.sub.S can be
.ltoreq.3.05 meters (10.0 feet), such as .ltoreq.2.74 meters (9.0
feet), .ltoreq.2.44 meters (8.0 feet), .ltoreq.2.13 meters (7.0
feet), or .ltoreq.1.83 meters (6.0 feet).
[0050] As illustrated in FIG. 3, FIG. 4, and FIG. 9, the elongated
body 200 of the concrete form 104 can also include a first upper
fillet 220 formed at a first upper corner established between the
upper wall 204 and the first sidewall 208. The elongated body 200
can include a second upper fillet 222 at a second upper corner
established between the upper wall 204 and the first sidewall 208,
wherein the first upper fillet 220 and the second upper fillet 222
are located on opposite sides of the upper wall 204, i.e., the
first upper fillet 220 is above the upper wall 204 and the second
upper fillet 222 is below the upper wall 204.
[0051] The elongated body 200 of the concrete form 104 can also
include a first lower fillet 230 at a first lower corner
established between the lower wall 206 and the first sidewall 208.
Further, the elongated body 200 can include a second lower fillet
232 at a second lower corner established between the lower wall 206
and the first sidewall 208. The first lower fillet 230 and the
second lower fillet 232 are located on opposites sides of the lower
wall 206, i.e., the first lower fillet 230 is above the lower wall
206 and the second lower fillet 232 is below the lower wall
206.
[0052] In one aspect, the upper extension 214 can include a
thickness, T.sub.UE, and T.sub.UE can be uniform throughout the
upper extension 214, i.e., uniform from the base of the upper
extension 214 to the distal end 216 of the upper extension 214. In
another aspect, T.sub.UE can decreases along the upper extension
214 from the upper wall 204 to the distal end 216 of the upper
extension 214.
[0053] In another aspect, the lower extension 212 can include a
thickness, T.sub.LE, and the stiffening lip 218 can include a
thickness, T.sub.SL. Further, T.sub.UE, T.sub.LE, and T.sub.SL can
be the same as T.sub.W so that the elongated body 200 of the
concrete form 104 has a uniform wall thickness throughout a
cross-section of the elongated body 200 taken perpendicular to the
length of the elongated body 200. Moreover, the uniform wall
thickness can extend along the entire length of the elongated body
200 of the concrete form 104.
[0054] A cross-section, or a cross-sectional shape, of the concrete
form 104 perpendicular to the length of the concrete form 104 and
passing through the main body 202, the lower extension 212, the
upper extension 214, the stiffening lip 216, or a combination
thereof is substantially uniform along the length of the concrete
form 104. Further, a cross-section of the upper extension 214
perpendicular to a length of the concrete form 104 and is
substantially uniform along the length of the concrete form
104.
[0055] Further, the concrete form 104 is free of discontinuous
structural features extending from the upper extension. In
particular, the concrete form 104 is free of discontinuous
structural features extending along an axis perpendicular to a
longitudinal axis of the concrete form 104. Moreover, the concrete
form 104 is free of discontinuous structural features that are
non-parallel to a longitudinal axis of the concrete form 104. These
structural features can include lateral, discrete stiffening ribs,
buttresses, webs, brackets, other discrete structures, or a
combination thereof.
[0056] Referring to FIG. 11 through FIG. 13 a concrete form coupler
is illustrated and is designated 1100. The concrete form coupler
1100 can include a generally hollow body 1102 having a first end
1104 and a second end 1106. The body 1102 can be configured to fit
into the ends of adjacent concrete forms, i.e., concrete forms
placed end-to-end.
[0057] Specifically, the body 1102 of the concrete form coupler
1100 can have an upper wall 1120 and a lower wall 1122 and spaced
apart from the upper wall 1120. The upper wall 1120 and the lower
wall 1122 can be parallel to each other. The concrete form coupler
1100 can also include a first side wall 1124 and a second side wall
1126. The first side wall 1124 can extend between and connect the
upper wall 1120 and the lower wall 1122. The second wall 1126 can
extend between and connecting the upper wall 1120 and lower wall
1122.
[0058] As illustrated in FIG. 12, the concrete form coupler 1100
includes an outer shape, when viewed from the first end 1104 or the
second end 1106, that corresponds to the internal shape of the main
body portion 202, depicted in cross-section in FIG. 9. FIG. 11
through FIG. 13 also indicate that the concrete form coupler 1100
can include an arm 1130 that can extend from the second sidewall
1126 of the body 1102. A generally cylindrical, hollow collar 1132
can be attached to, or otherwise formed on, the arm 1130. The
collar 1132 can be configured to receive a stake, as described
below and as illustrated in FIG. 15.
[0059] FIG. 14 and FIG. 15 indicate that the concrete form coupler
1100 can be placed between adjacent concrete forms, e.g. a first
concrete form 1302 and a second concrete form 1304. Thereafter, an
end 1310 of the first concrete form 1302 can be fitted over the
first end 1104 of the concrete form coupler 1100. Moreover, an end
1312 of the second concrete form 1304 fitted over the second end
1106 of the concrete form coupler 1100. The concrete forms 1302,
1304 can be brought together over the concrete form coupler 1100 as
illustrated in FIG. 14. The concrete form coupler 1100 can prevent
the ends 1310, 1312 of the concrete forms 1302, 1304 from moving
with respect to each other while concrete is being poured, or
otherwise deposited, into a channel at least partially established
by the concrete forms 1302, 1304. Additionally, as illustrated in
FIG. 15, a stake 1320, or spike, can be driven through the collar
1132 of the coupler 1100 and can provide further support for the
assembly.
[0060] According to an embodiment, a concrete forming system can
include a first concrete form that is configured to provide water
drainage and a second concrete form that is distanced from the
first concrete form to define a channel between the first concrete
form and the second concrete form. The concrete forming system can
also include a spacer strap extending between the first concrete
form and the second concrete form. The spacer strap can define a
channel width. The system can also include a plurality of stakes
placed along each concrete form at a regular stake interval,
I.sub.S. The second concrete form can provide an installed
deflection, D.sub.I, between adjacent stakes that is, in some
embodiments, .ltoreq.0.5% I.sub.S, such as .ltoreq.0.3% I.sub.S, or
even .ltoreq.0.2% IS. The second concrete form can be a molded or
an extruded form which can substantially reduce the manufacturing
costs.
[0061] With the configuration of structure described herein, a
leave-in place concrete form is provided that can be molded or
extruded. The extrusion process can utilize less material than
other forming processes, such as a molding process. Further, the
less material utilized can result in reduced material costs. One or
more features of the leave-in place concrete form, e.g., the shape
and placement of the box-shaped main body portion, the lower
extension, the upper extension, the stiffening lip, or a
combination thereof, can provide a concrete form that can perform
and withstand substantially the same fluid pressure as traditional
concrete forms. As such, after concrete is poured within a channel
adjacent to the leave-in place concrete form, the likelihood of
failure of the leave-in place concrete form before the concrete is
substantially cured or the likelihood of unwanted deflection of the
leave-in place concrete form is substantially the same as
traditional concrete forms.
[0062] In the foregoing, reference to specific embodiments and the
connections of certain components is illustrative. It will be
appreciated that reference to components as being coupled or
connected is intended to disclose either direct connection between
said components or indirect connection through one or more
intervening components as will be appreciated to carry out the
methods as discussed herein. As such, the above-disclosed subject
matter is to be considered illustrative, and not restrictive, and
the appended claims are intended to cover all such modifications,
enhancements, and other embodiments, which fall within the true
scope of the present invention. Thus, to the maximum extent allowed
by law, the scope of the present invention is to be determined by
the broadest permissible interpretation of the following claims and
their equivalents, and shall not be restricted or limited by the
foregoing detailed description.
[0063] The Abstract of the Disclosure is provided to comply with
Patent Law and is submitted with the understanding that it will not
be used to interpret or limit the scope or meaning of the claims.
In addition, in the foregoing Detailed Description of the Drawings,
various features may be grouped together or described in a single
embodiment for the purpose of streamlining the disclosure. This
disclosure is not to be interpreted as reflecting an intention that
the claimed embodiments require more features than are expressly
recited in each claim. Rather, as the following claims reflect,
inventive subject matter may be directed to less than all features
of any of the disclosed embodiments. Thus, the following claims are
incorporated into the Detailed Description of the Drawings, with
each claim standing on its own as defining separately claimed
subject matter.
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