U.S. patent number 3,676,967 [Application Number 05/051,523] was granted by the patent office on 1972-07-18 for forms for concrete wall construction.
Invention is credited to Augustus Frati.
United States Patent |
3,676,967 |
Frati |
July 18, 1972 |
FORMS FOR CONCRETE WALL CONSTRUCTION
Abstract
Rectangular sheets of galvanized metal pans are assembled to
construct wall forms at the construction site. Each pan includes
inwardly bent flanges along its peripheral edges. A course of
several pans is erected by joining a horizontal row of pans along
abutting vertical side flanges. Several courses are stacked in a
vertical plane to construct one face of a wall form. The other face
of the form is constructed of similar pans in spaced parallel
relationship to the first face. The abutting edges of the pans are
either welded or joined by connector plates. A plurality of spaced
vertical ribs project outwardly from the face of each pan. The ribs
provide contiguous coplanar surfaces against which sheet wall
covering may be mounted. Spaced between the ribs are columns of
louvers which serve as a lath if the wall is plastered. A further
option is the use of an insulation panel, nestably received on the
inside face of each pan between the peripheral edges thereof.
Concrete is poured into the assembled form and the forms remain
permanently affixed to the sides of the concrete core.
Inventors: |
Frati; Augustus (Greenlawn,
NY) |
Family
ID: |
21971834 |
Appl.
No.: |
05/051,523 |
Filed: |
July 1, 1970 |
Current U.S.
Class: |
52/220.2; 52/422;
52/426; 52/444; 52/715; 52/404.1 |
Current CPC
Class: |
E04B
2/8635 (20130101) |
Current International
Class: |
E04B
2/86 (20060101); E04b 002/68 (); E04f 017/08 () |
Field of
Search: |
;52/422,352,428,675,426,425,424,427,429,431,440,444,353,367,373,378,383,404,220 |
References Cited
[Referenced By]
U.S. Patent Documents
Primary Examiner: Faw, Jr.; Price C.
Claims
Having thus described the invention, there is claimed as new and
desired to be secured by Letters Patent:
1. A wall form for concrete wall construction, said form comprising
a plurality of modular pans, each pan being formed of sheet metal
and having a substantially planar rectangular face, an inturned
marginal flange adjacent each peripheral edge of the face, means
forming parallel columns of shrouded louvers extending outwardly
from the plane of the face, each pan further including a plurality
of vertical ribs projecting outwardly from the plane of the face,
the faces of several pans being substantially vertical and aligned
along a substantially horizontal course, the flanges of adjacent
pans of the course abutting one another, a second course of like
pans, the second course being spaced from the first course, means
securing adjacent flanges together and maintaining a spaced
parallel relationship between the courses, the means securing
adjacent flanges and maintaining the spaced parallel relationship
including a planar connector, said connector having a pair of
horizontal reaches, and means forming a bendable tab at each end of
each reach, said reaches being continuous from said first course to
said second course, meanS forming registered apertures in adjacent
portions of abutting pans, the bendable tabs extending through the
registered apertures and being bent to lie in a plane substantially
parallel to the plane of the reach.
2. A wall form constructed in accordance with claim 1 further
including wall tie means, said wall tie means comprising a rod
having parallel depending legs at the opposite ends thereof, each
pan being of one piece construction and having an inwardly
projecting depressed looped protuberance on its face, each leg
engaging the protuberance of an opposite pan, the wall form further
including a poured concrete core between the courses, the wall tie
means preventing the buckling of the pans when the concrete is
poured into the form.
3. A wall form constructed in accordance with claim 1 wherein
insulating pads are provided, said pads being nestably received
between the flanges of each pan.
4. A wall form constructed in accordance with claim 1 the wall form
further including a poured concrete core between the courses, a
water feed pipe, said water feed pipe being positioned adjacent the
louvers, a course including the louvered pan further including an
exterior plaster coating, the plaster coating extending into
selected shrouded louvers of the pan, the plaster coating covering
the water feed pipe, thereby concealing said pipe.
5. A wall constructed in accordance with claim 4 wherein the
louvered pan further includes a plurality of vertical ribs, said
ribs prOjecting outwardly from the plane of the face thereof, the
ribs being positioned between the columns of shrouded louvers, the
water feed pipe being positioned between two adjacent ribs.
6. A wall constructed in accordance with claim 4 wherein conduit
means is positioned between the courses, the conduit means
including electrical and sewage conduits.
7. A wall form constructed in accordance with claim 1 wherein one
of the horizontal reaches extends between a first pair of apertures
of pans in opposed courses, said first pair of apertures being
positioned in proximate relatiOn to the lower edge of the
respective pans, a second of the horizontal reaches extending
between a second pair of apertures of pans in opposed courses, said
second pair of apertures being positioned in proximate relation to
the upper edge of the respective pans, whereby a wall form for the
pouring of concrete walls and withstanding the static pressures of
the poured concrete without substantial deflection is provided.
8. A wall form constructed in accordance with claim 7 wherein each
of the horizontal reaches includes at least one other tab at each
end thereof, each of the other tabs lying in a plane substantially
perpendicular to the plane of the reach and parallel to the plane
of the face of the respective pan, and in abutting contact with the
pan, whereby displacement of the pans from their aligned course is
restricted.
9. A wall form constructed in accordance with claim 1 wherein the
connector includes means forming a notched portion on the upper
edge of a horizontal reach, means aligning the notched portions of
each connector joining successive pans of a course, the wall form
further including an elongate horizontal reinforcing rod, said rod
having an effective length greater than the combined length of at
least two successive pans in a course, said rod being nestably
received in the aligned notches of the reaches, thereby preventing
deflections of the courses during pouring of the core and
reinforcing the concrete structure of a finished wall.
10. A wall form for concrete wall construction, said form
comprising a plurality of metal pans, each of said pans having a
substantially planar rectangular face, an inturned marginal flange
adjacent each peripheral edge of the face, the flanges being
inclined from the plane of the face at an acute angle, a group of
pans being aligned along a horizontal course, a second group of
pans being aligned along an opposed horizontal course and in
parallel spaced relationship to the first mentioned course, means
for pouring a concrete core into the wall form directly between the
courses, the flanges of adjacent pans in each course abutting one
another, means securing the adjacent pans together, and means for
lockingly engaging a wall anchoring device driven toward the wall
core, the adjacent flanges forming an inwardly tapered open faced
hollow V-channel, said last named means including said hollow
V-channel, the pans having a juncture line at the intersection of
the abutting flanges, the V-channel being positioned at the
juncture line, the hollow V-channel being adapted to receive
anchoring devices which are subsequently driven into the wall with
the abutting portion of the flanges spreading apart to receive and
lockingly engage the anchoring device to affix an object to the
wall.
11. A wall form constructed in accordance with claim 10 further
including conduit means positioned between the courses.
12. A wall form constructed in accordance with claim 11 wherein the
conduit means includes at least one electrical conduit and at least
one sewage conduit.
13. A wall form constructed in accordance with claim 10 wherein the
pans are arranged in several courses with the courses being stacked
and means securing the abutting flanges of pans in adjacent
courses, the securing means including a fused weld.
14. A wall form constructed in accordance with claim 10 wherein
insulating pads are provided, said pads being nestably received
within the flanges of each pan.
15. A wall form constructed in accordance with claim 10 further
including wall tie means, said wall tie means comprising a rod
having parallel depending legs at the opposite ends thereof, each
pan having an inwardly projecting protuberance formed in its face,
the legs of each wall tie means engaging the protuberances of
opposite pans in opposed courses, the wall form further including a
poured concrete core between the courses, whereby the wall tie
means prevents buckling when the concrete is poured into the
form.
16. A wall form for concrete wall construction, said form
comprising a plurality of edge abutting modular pans, each pan
being formed of sheet metal and having a substantially planar
rectangular face, the faces of several pans being substantially
vertical and aligned along a substantially horizontal course, a
second course of like pans, the second course being spaced from the
first course, means securing adjacent pans of each course together,
means maintaining a spaced parallel relationship between courses,
means forming an opening through the wall form, said opening means
including a frame member, said frame member including a first
portion, said first portion being of a width at least equal to the
distance between the courses, the width of said first portion
bridging pans in opposed courses in a plane perpendicular to the
planes of the courses, a second portion, said second portion
including a flange extending perpendicularly to the first portion
and overlying an area of the face of a pan in one of the courses
and means for anchoring the frame member to a concrete core to be
poured into the form.
Description
BACKGROUND OF THE INVENTION
1. Field of the Invention
Concrete wall construction employing modular metal pans for
forms.
2. Description of the Prior Art
Because concrete is initially in a plastic state, it is necessary
to use forms to confine and support the poured concrete until it is
rigid and self-supporting. As a result, the cost of concrete for
most structures is relatively high because it not only includes the
actual cost of the concrete, but additionally includes the cost of
forms that are required to temporarily support the concrete.
Most concrete wall forms in present employment include spaced
parallel opposed surfaces formed of wood sheathing. The sheathing
is in turn supported by a plurality of spaced vertical studs joined
by a series of horizontal wales. The wales are usually reinforced
with shoring. This method of constructing concrete walls is
expensive due to the fact that the labor costs of constructing the
wall forms are quite high. Furthermore, expense is involved due to
the fact that the materials used in the construction of the wall
forms are costly and are only reusable for a limited number of
applications. Additionally, reuse of the conventional wall forms
entails further labor costs of reassembly. Even if the forms are
not reused, the cost of stripping the wall forms after the concrete
wall has gained sufficient strength cannot be obviated.
Metal pan form structures have been employed in concrete
construction. The previous employment of metal pans has generally
been restricted to use of the pans in the construction of concrete
floors. This type of floor construction has become popular because
the amount of concrete required to support a given floor loading is
less than is required for the beam-and-slab floor. Furthermore, the
use of the metal pan forms reduced the cost of floor construction.
The metal pan forms used in floor construction were, however,
stripped after the concrete had gained sufficient strength to be
self-supporting.
The use of metal pan forms in wall construction has not become
popular due to several factors. Among the disadvantages is the fact
that heretofore, the metal pans could not be easily and simply
joined together to erect a contiguous form for a wall. Furthermore,
the use of some metal pans rendered the resulting wall of a shape
which did not easily permit the application of plaster without the
cumbersome task of applying a lath.
Another disadvantage encountered with the use of metal pans for
wall forms was the fact that the shape of the metal pans did not
permit the easy application of sheet wall covering to interior wall
surfaces.
SUMMARY OF THE INVENTION
It is an object of the present invention to provide a form for
concrete wall construction of the general character described which
is so constructed that it is not subject to any of the foregoing
disadvantages.
More specifically it is an object of the present invention to
provide a modular form for concrete wall construction which
includes metal pans which may be joined to like pans with great
facility yet is lightweight, strong and well adapted for rapid on
site assembly.
A further object of the present invention is to provide a form for
concrete wall construction of the general character described which
includes a plurality of peripherally flanged metal pan sheets
arranged in a course with abutting flanges of each pan joined.
A still further object of the present invention is to provide a
form for concrete wall construction which includes a plurality of
substantially rectangular modular pans, each of which includes a
face and with a plurality of elongate outwardly projecting ribs
against which sheet covering may be secured.
Yet another object of the present invention is to provide a form
for concrete wall construction of the general character described
which optionally provides a plaster adhering base surface or a
planar surface against which sheet wall material may be
positioned.
A still further object of the present invention is to proVide a
concrete wall which includes a plurality of rectangular metal pans
arranged in vertically stacked horizontal courses and an opposed
plurality of like pans arranged in parallel courses with various
utility and service conduits extending within the wall and between
the opposed parallel courses.
A still further object of the present invention is to provide a
wall structure including a poured concrete core and opposite faces
clad with metal pans and wherein water feed pipes are positioned
adjacent the pans and with the pipes and pans subsequently covered
with a layer of plaster.
Yet another object of the present invention is to provide a wall
structure including a poured concrete core with metal clad faces,
the faces being formed of galvanized metal pans and with the
peripheral edges of each pan having a flange and with the flanges
of adjacent pans being joined and forming a V-notch to tightly
engage an anchoring nail used to secure sheet wall covering.
Other objects of the invention in part will be obvious and in part
will be pointed out hereinafter.
The invention accordingly consists in the features of construction,
combinations of elements and arrangements of parts which will be
exemplified in the form for concrete wall construction hereinafter
described, and of which the scope of application will be indicated
in the appended claims.
BRIEF DESCRIPTION OF THE DRAWINGS
In the accompanying drawings in which are shown some of the various
possible embodiments of the invention,
FIG. 1 is a perspective view of a wall form constructed in
accordance with and embodying the invention, and with portions
thereof broken away for clarity, and showing opposed parallel
courses of galvanized metal pans;
FIG. 2 is a fragmentary enlarged exploded perspective view of an
H-shaped connector plate which joins adjacent pans along abutting
vertical side flanges of each pan;
FIG. 3 is an enlarged fragmentary sectional view taken
substantially along the line 3--3 of FIG. 1 and illustrating a
portion of a tie rod joining parallel pans and further illustrating
the contour of the face of a pan including a plurality of vertical
ribs and a plurality of shrouded louvers spaced between the
ribs;
FIG. 4 is a fragmentary perspective view of a portion of a pan
forming the end of a wall and showing the specific configuration of
an H-shaped connector plate which serves to space the parallel
opposed panS;
FIG. 5 is a fragmentary transverse sectional view through a poured
concrete wall constructed in accordance with the invention wherein
the face of the wall is plastered;
FIG. 6 is a reduced scale sectional view taken substantially along
the line 6--6 of FIG. 1 and showing, in substantially plan
configuration, the interior surface of a pan wherein an insulation
pad is nestably received between the inturned peripheral flanges of
a pan;
FIG. 7 is a transverse sectional view through a wall constructed
with the insulated pad illustrated in FIG. 6;
FIG. 8 is a longitudinal sectional view through a wall showing the
application of a sheet wall covering over the metal clad face of
the wall and With an anchoring nail being received in a V-notch
formed between adjacent flanges;
FIG. 9 is a longitudinal sectional view through a wall and showing
a utility conduit within the concrete core along with water feed
pipes positioned adjacent the face of a pan and between the
vertical ribs, with the wall face being subsequently plastered to
conceal the water feed pipes;
FIG. 10 is a fragmentary elevational view of a wall constructed in
accordance with this invention including a window frame;
FIG. 11 is a sectional view taken substantially along the line
11--11 of FIG. 10, and through a jamb of the frame, and showing the
manner in which the frame is anchored to the wall; and
FIG. 12 is a plan view of an H-shaped connector plate constructed
in accordance with an alternate embodiment of the invention wherein
the plate includes a plurality of perforations to reduce heat
transfer between opposed faces of a wall.
DESCRIPTION OF THE PREFERRED EMBODIMENT
The form of the present invention is used to erect a permanently
metal clad concrete wall structure wherein both faces of a concrete
core are encased between spaced parallel courses of galvanized
metal pans. The face of each pan includes a plurality of parallel
spaced vertical ribs which serve as surfaces against which sheet
wall covering, e.g. plaster board, wall board, plywood paneling,
tongue and groove paneling, etc., may rest to insure a smooth flat
backing for the wall covering. Furthermore, the peripheral edges of
each pan include a tapered flange so that a narrow V-notch
peripherally surrounds each interior pan, i.e. not at the periphery
of the wall form. The V-notches may easily receive nails, screws or
other anchoring implements which are forced into the wall. Thus,
the concrete wall will easily accomodate sheet wall covering as
well as provide convenient anchoring surfaces for picture hooks,
etc. The faces of the pans further include a plurality of upturned
shrouded louvers which readily catch plaster if the wall face is to
be subsequently plastered. This obviates the necessity for a
separate lath.
Window and door frames are pre-fabricated and installed in a space
provided between the pans to complete an apertured wall form before
the concrete is poured.
In order to insure against heat losses, the invention includes the
optional employment of insulating pads which are nestably received
on the inner faces of the pans and between the peripheral flanges
thereof. Furthermore, the connector members which join opposed
parallel pans and link adjacent pans in a course may be perforated
to reduce heat loss through conduction.
Referring now in detail to the drawings, the reference numeral 10
denotes a metal wall form constructed in accordance with and
embodying the invention. The wall form 10 is constructed of stacked
horizontal courses of aligned galvanized modular metal pans 12. The
stacked courses provide one face of a wall form and the opposite
face is provided by similar pans 12 aligned in courses in parallel
spaced relationship to the opposed side.
It will be appreciated that although the metal pans forming the
wall form are joined together and rigidified through various
securing devices, the application of the present wall form securing
devices alone are indicated wherein the stacked courses do not
reach extensive heights, e.g. more than two courses, because the
increased pressure of the plastic concrete necessitates further
external rigidifying structures, e.g. wales, shores, etc., to
prevent the pans in opposed courses from bulging or separating.
It should also be noted that a concrete wall constructed in
accordance with the present invention will be permanently clad on
each face thereof with the galvanized metal pans 12. The metal pans
12 render a wall essentially vermin proof as this structure is
impenetrable. Further, the galvanized cladding reduces seepage of
air and/or moisture through the concrete core.
Each of the pans 12 is generally rectangular in configuration and
includes an inwardly bent horizontal flange 14 adjacent the top and
bottom edges thereof. The flanges 14 are not perpendicular to a
plane of the face of the pan 12, however, and are bent to an acute
angle of approximately 80.degree.. The purpose of the angular
orientation of the flanges 14 will be subsequently described. Each
of the side edges of the pan 12 includes a vertical flange 16 which
is also bent to the same acute angle to the plane of the pan
12.
It will be noted that a substantially rectangular vertical notch 18
is formed at the base of the flanges 16 adjacent the top and bottom
edges of the pan 12 and with a longitudinal edge of each notch
coinciding with the side edges of the pan 12. The notches 18 are
used to join side edges of adjacent pans 12 and are engaged by a
connector in a manner hereinafter described.
Referring now to FIG. 2 wherein a connector device used to join
adjacent side flanges 16 of the pans 12 is illustrated, it will be
seen that an H-shaped connector plate 20 is employed. The plate 20
is shaped with two spaced parallel horizontal reaches 21 joined by
a short vertical reach 23. The overall configuration of the
connector is in the shape of the letter "H" lying on one side.
Adjacent each of the ends of the horizontal reaches 21, the reaches
are bifurcated to form two spaced tabs 22 which are bent to lie in
a plane perpendicular to that of the horizontal reaches 21. A tab
portion 24 of the horizontal reach intermediate the two tabs 22 is
bent in an opposite direction to lie in the same plane as the tabs
22.
It will be observed that to join (lock) adjacent flanges 16, the
tab portion 24 is forced through registered notches 18 of adjacent
pans 12 and is subsequently bent to lie in a plane substantially
parallel to the reach 21 and overlies the interior surface of a
flange 16. In this locked position, the horizontal reaches 21 will
lie in juxtaposition with the adjacent flange 16 sandwiched between
the reach 21 and the bent tab portion 24. In the locked position,
the tabs 22 lie flush against the interior of the face of a pan
12.
In FIG. 4 a fragmentary view of an end of a wall form is
illustrated. It will be observed that the H-shaped connector 20
does not join a pan 12 to an adjacent pan but that the tab portion
24 merely overlies the outer surface of the flange 16 while the
tabs 22 abut the interior surface of the face of the pan 12. When
the concrete is poured into a completed wall form, the open ends of
the wall forms are blocked off by any suitable strippable
sheathing. During such pouring, the sheathing is secured against
the end of the wall form and abuts the end flanges 16 along with
the end connector 20.
In order to provide strength not only for the form, but also to
reinforce the concrete wall itself, a reinforcing rod 26 is
received within aligned notches 28 formed in the horizontal reaches
21 of each H-shaped connector 20. The reinforcing rod 26 is
circular in transverse cross section, and bridges between the
H-shaped connectors within the notches 28.
It will be noted that each of the horizontal reaches 21 of each
H-shaped connector are correspondingly notched adjacent each end
thereof. This is to reduce the time required to set up the wall
form by eliminating the necessity of finding out which side of each
connector 20 is "up". Thus, when the pans are assembled to erect
two parallel courses, the notches 28 will automatically be aligned
and thereby nestably receive a reinforcing rod 26.
As was previously mentioned, the rod 26 serves to strengthen the
wall form. It reinforces the form by providing a stiff pan
connector thereby reducing lateral deflection as well as serving to
reinforce the poured concrete.
The function of the H-shaped connector in securing adjacent pans 12
forming a course has been previously described. The H-shaped
connectors 20 serve a second purpose, however, to wit, they
maintain the spaced relationship between opposed pans against the
deflecting forces of the weight of the poured concrete, thereby
reducing the tendency of the opposed pans to separate.
A further device is provided to support the pans 12 and prevent
outward deflection, i.e. buckling, when the concrete is plastic. A
tensile reinforcing member which is provided is a tie rod 30 of
circular transverse cross section. The tie rod 30 includes a
generally straight central portion and a pair of parallel depending
legs 32 with one leg at each end of the central portion.
The leg portions 32 engage an inwardly struck protuberance 34 which
extends from the approximate center of the face of each pan 12. The
protuberances 34 include upper and lower open edges and the legs 32
extend between said edges and are captively retained therebetween.
The weight of the tie rod 30 maintains the legs 32 in engagement
with the protuberances 34. It will be appreciated that when the
concrete is poured, the tie rod 30 is put under tensile stress and
maintains the faces of the pans 12 in substantially co-planar
relationship for each course.
A complete wall form is erected by aligning and stacking successive
courses of pans 12. Each of the courses are placed with the
horizontal flanges 14 in abutting contact. It should be noted that
the exterior surface of each flange 14 is roughened to prevent
slipping of abutting flanges 14 during initial assembly. After the
pans are stacked atop one another, the adjacent flanges 14 are spot
welded as at 36 (see FIG. 1).
The face of each pan 12 includes a series of vertical parallel ribs
38 which are stamped. The ribs 38 include ridges which provide a
continuous co-planar surface against which sheet wall covering such
as wallboard or paneling may rest. This is more fully illustrated
in FIG. 8. It will also be appreciated from an observation of FIG.
8 that an anchoring nail 40 for sheet wall covering 41 is secured
to the wall through the wall covering and extends between the
angular flanges 16 which form a hollow tapered V-channel. The edges
of the flanges 16 bear against the nail 40 to securely anchor the
nail.
Referring now to FIGS. 1 and 3, it will be observed that a
plurality of upwardly struck louvers 42 are positioned in vertical
rows and spaced between the ribs 38. The louvers 42 serve as
anchoring surfaces for a wall covering such as stucco or plaster.
This is more readily observed in FIG. 5 wherein the surface of a
wall having a core 46 of poured concrete is covered by a layer of
plaster 44. It will be seen that portions of the plaster 44 seep
into the open mouth at the top of each louver 42 between the upper
edge of the louver and the face of the pan 12.
Referring again to FIG. 3 it will be seen that the louvers 42
project from the plane of the face of the pan 12 a distance less
than the distance that the ribs 38 project. Thus, the option of
either using sheet wall covering which rests against the ribs 38 or
plastering, stuccoing, etc. is left open to meet the needs of the
individual application.
It will be seen that the wall board or wall paneling may be applied
without any impediment being presented by the louvers. Furthermore,
the upper edge of each louver 42 is at an elevation approximately
equal to that of the edge of the face of the pan 12 from which the
louver was struck. Thus, the tendency for the plastic concrete to
seep or ooze from the louvers is reduced.
It should be noted at this time that the wall form 10 is well
adapted for use in constructing walls in submerged or
semi-submerged areas. When the concrete is poured between the
courses, ny water between the courses will be forced out through
the louvers by the concrete.
If it is desired to have additional insulation material within the
wall, the present invention provides for the placement of
insulating pads 48 adjacent the interior surface of each pan and
nested within the confines of the flanges 14, 16. Because the pads
46 are of a thickness less than the width of the flanges, the
insulating pads will not have a tendency to catch or snag the
concrete as it is being poured. The pad 48 may be formed of any
suitable insulating material, e.g. Fiberglas, polyurethane,
etc.
FIG. 6 illustrates a pad 48 placed in the pan 12 positioned to the
right of the forwardmost pan 12 in FIG. 1. The pad 48 includes a
crossed slot 49 at the center thereof, through which the tie rod 30
is fed. The pad 48 is placed within the confines of the peripheral
flanges during the assembly of the wall form.
Referring now to FIG. 7 showing a poured concrete wall having a
core 46, an insulating pad 48 and a plaster outer facing, it will
be seen that the concrete core 46 is in abutting contact with one
face of the pad 48, while the inner face of the pan 12 is in
abutting contact with the other face of the pad 48. Additionally it
will be observed that the plaster coating 44 has seeped deeply into
each louver 42 because the concrete core 46 did not reach the
interior surfaces of the louvers.
Turning again to the wall form 10 illustrated in FIG. 1, prior to
pouring the concrete, it is highly advantageous to place service
conduits between the courses of the form. A typical installation
would include a plastic conduit 50 within which electrical cable
may be threaded. The plastic conduit 50 is of circular transverse
cross section to allow the concrete to easily flow and set up. Any
commercially available plastic having sufficient compressive
strength is suitable for such application. Typical examples of
suitable plastics are polyethylene, polystyrene,
acrylonitile-butadiene-styrene, etc.
Various sewage pipes and venting pipes 52 are also expeditiously
positioned between the conFines of the wall form prior to pouring
the concrete.
The conduit 50 through which electrical cables may be threaded
extends along the longitudinal axis of a course while the sewage
pipes 52 are positioned between the courses and extend in a
vertical direction. The sewage pipes 52 are illustrated in FIG. 1
and, additionally, in the sectional view of FIG. 9.
In FIG. 9 a wall having an outer covering of stucco 54, a poured
concrete core 46 and a vertically extending sewage pipe 52 is
shown. It should be additionally noted that the inner face of the
wall includes a layer of plaster 44. Two water feed pipes 56 are
positioned adjacent the pans 12 and between the vertical ribs 38.
It will be observed that the layer of plaster covers the pipes 56
to thus conceal the pipes.
Normal utility connections, e.g. between the sewage pipes 52 and a
drain or sump; between circuit breakers, switches, and the
electrical cables, etc. will be constructed in the usual manner as
will be the connections between the sinks, tubs, etc. to the water
feed and sewage pipes. In order to provide suitable inlets to the
sewage pipes 52, a T-fitting is provided in a sewage pipe 52 with a
trunk of the fitting extending out of the wall through an opening
in a pan 12. After the concrete core 46 is poured, the facilities,
e.g. sinks, tubs, wash basins, lavatories, are connected into the
T-fittings in the conventional manner and final electrical
connections are completed.
It should also be understood that although the use of plastic
conduits and pipes have been described, the use of metal pipes
within the wall core 46 is equally feasible.
The present invention also provides for the installation of window
and door frames within the wall forms prior to pouring of the
concrete. Referring now to FIG. 10 wherein a window frame 58 is
illustrated, the pans 12 adjacent the frame 58 have been cut on the
site to accomodate the positioning of the frame 58. Such on site
modification of the pan 12 is easily accomplished with the use of
conventional sheet metal snips or shears.
The frame 58 includes a top beam 60, a sill 62 and a pair of
upright jambs 64 interconnecting the ends of the beams. From an
observation of FIG. 11 it will be seen that the beam 60, sill 62
and jambs 64 are preferably constructed of angle iron, although
other suitable metals may be used, e.g. aluminum or galvanized
metal of L-shaped transverse cross section. The frame 58 includes a
peripheral flange 66 which extends along the inner surface of the
wall form 10 and overlies a portion of the pans. After the concrete
core 46 has been poured, the wall form 10 is covered with either
plaster or sheet wall covering. When the form covering is applied,
it may be applied over the peripheral flange 66 to conceal the same
or, optionally, it may terminate at the edge of the flange 66 so
that the flange 66 serves as decorative trim.
A door frame is constructed in a similar manner and may include, in
lieu of a sill, an open floor engaging bottom. The door frame is,
of course, proportioned differently than a window frame and the
jambs thereof are considerably longer.
In order to assure that the frame 58 is securely joined and
anchored to the concrete core 46, a plurality of metal anchoring
straps 68 (see FIG. 11) are affixed to the surfaces of the frame 58
which abut the concrete core. The straps 68 are of U-shaped
longitudinal cross-section and include planar feet 70 at the tips
of the free ends thereof. The feet 70 are conventionally joined to
the frame 58 as by spot welding, rivets, etc.
When the concrete is poured into the wall form 10, the concrete
will flow around the U-shaped strap 68 and into the space between
the mid length of the strap and the frame and thereby the straps
will tightly anchor the frame 58 to the core 46. On the exterior
(outside) wall surface of a wall having a window frame 58, a
suitable bead is provided along with trim and flashing, all in the
conventional manner.
In FIG. 12 an alternate form of the H-shaped connector is
illustrated. This modified connector 20a is of the same general
configuration as the previous H-shaped connector 20 and includes
parallel top and bottom reaches 21a, each of which includes notches
28a a and with tabs formed at the ends of the horizontal reaches
21a. A tab 24a extends in a direction perpendicular to the plane of
the connectors and this tab engages slots in the vertical flanges
of the pans to secure adjacent pans together as well as to provide
parallel spacing between opposed pans. The tabs 24a are bent to
overlie a flange 16 as previously discussed with respect to the
first described embodiment.
The H-shaped connector 20a differs in construction from the
H-shaped connector 20 previously described because it includes a
plurality of perforations 72 which are presently illustrated as
circular. The perforations 72 are distributed uniformly throughout
the structure of the H-shaped connector 20a and serve the primary
function of reducing the quantity of metal in a connector 20a. The
reduction in the quantity of metal results in a lowering of the
heat transfer characteristics of the connector 20a as compared to
the connector 20. With a reduced heat transfer capability, heat
loss through a concrete wall by virtue of heat conductivity of a
connector is thereby lowered.
A wall constructed with the modular metal pans described in the
present invention will be economically and rapidly fabricated on
site at reduced cost compared to previous construction techniques.
Furthermore, the wall will be highly resistant to wind, water and
vermin penetration. Additionally, the pan surfaces will readily
accomodate any conventional wall covering and the pans themselves
are highly adaptable for use with various framed openings, so that
an entire wall including window and door openings may be poured
uniformly at sequential steps building up the height of the wall as
by two stacked courses at a time.
It will be appreciated that poured concrete walls constructed in
accordance with this invention are well suited for use in areas
where wood lumber construction is undesirable or impractical, e.g.
humid areas, or where wood is unavailable or so costly that it is
impractical even for use as wall forms. Furthermore, because the
modular pans can be arrayed in stacked courses, the concrete core
poured, and then subsequent stacked courses arrayed above the
previously poured section, this construction technique is highly
desirable where concrete delivery is restricted. If delivery is
restricted for a period of time, wall forms for further walls may
be erected during this time. If the concrete deliveries are in
limited quantities, the assembly of the wall forms may be readily
geared to accomodate such deliveries.
A further feature of the present wall forms is the fact that if the
forms are to be used as interior non-load bearing walls, e.g.
curtain walls, etc., it is not necessary to pour a concrete core.
This wall may optionally be a hollow wall of stacked courses of
pans with plaster or wallboard directly applied over the faces of
the pans.
It will also be appreciated thAt the thickness of any wall form may
be varied by altering the length of both the reaches of the
H-shaped connectors and the tie rods.
If it is desirable to erect a wall of plane curved configuration,
e.g. in a silo, etc., the pans used on the concave side of the wall
will be of a shorter length than those on the convex side.
Furthermore, if a spherically curved wall is to be erected, e.g. in
a stadium, amphitheater, planetarium, etc., the pans on the concave
side of the wall will be smaller than the pans on the convex side
in both length and height.
Thus it will be seen that there has been described a modular form
for concrete wall construction which achieves the various objects
of the invention and which is well adapted to meet the conditions
of practical use.
As various possible embodiments might be made of the present
invention, and as various changes might be made in the embodiment
above set forth, it is to be understood that all matter herein
described or shown in the accompanying drawings is to be
interpreted as illustrative and not in a limiting sense.
* * * * *