FOLDED CARDBOARD CONCRETE FORM SYSTEM

Abstract

A form system for assembling a structural frame includes a base sheet of cardboard, the base sheet having a plurality of folding sections for corrugating the base sheet into a first shape, at least one additional sheet of cardboard, the additional sheet having a plurality of folding sections for corrugating the additional sheet into a second shape, wherein at least part of the second shape corresponds to at least part of the first shape such that when the additional sheet is positioned adjacent to the base sheet, the base sheet and the additional sheet form a V-shaped cavity therebetween, and a concrete fill cast within the at least one V-shaped cavity.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS

The present Application claims the benefit, under 35 U.S.C. §119(e), of U.S. Provisional Patent Application No. 61/490,812, filed on May 27, 2011, the content of which is incorporated herein by reference.

FIELD OF THE INVENTION

The invention relates to a form system for constructing a structural frame of a building, such as a wall, roof, or floor, and more specifically to a concrete form system using corrugated cardboard sheets that are arranged into a frame, the frame receiving concrete fill and facilitating the casting of concrete fill into a structure.

BACKGROUND OF THE INVENTION

With cost of constructing buildings and other structures rapidly increasing, builders and developers are constantly searching for new systems, materials and methods to help minimize construction costs and create improved concrete buildings. The major factors that determine construction costs include the cost of building materials used as well as labor costs. Conventional concrete construction techniques typically use expensive materials such as special plywood forms, erection cranes, heavy steel rebars and high strength transit mixed concrete. The necessary labor for this type of construction process requires a diverse skilled labor force, including carpenters, ironworkers, crane operators, laborers, and cement finishers, which causes labor costs to increase. Further, conventional construction techniques often require that building materials be worked on at the construction site in order to ensure conformity with building plans. It is generally recognized that if the time to erect a structure can be reduced, the labor costs can be commensurately reduced.

In order to minimize the rising costs of construction, molds and form systems are used to facilitate the manner in which structural elements, such as walls, roofs, and floors, are constructed. Such molds and form systems are meant to provide an improved means for erecting concrete structures. For example, U.S. Pat. Nos. 1,123,261, 1,219,272 and 1,326,854 to Edison all disclose a mold for constructing an entire dwelling using concrete which is poured in one single molding operation. The mold comprises a plurality of cast iron sections, wherein each section has radiating ribs extending from a central boss and a plurality of flanges disposed along its perimeter. During assembly, each section is spaced apart and held together by inserting bolts through the flanges of adjacent sections and securing said bolts with nuts. However, this mold requires a substantial amount of assembly prior to casting concrete therein, including aligning and connecting the cast iron sections using the bolts, flanges, and nuts. Further, this mold requires various building components, some of which may be expensive (i.e. cast iron sections), as well as a specially-designed cement mix to accommodate the single molding operation.

Other efforts have been made to provide a form system for easy construction of a concrete structure. U.S. Pat. No. 4,943,336 to Csont describes a fixture apparatus for assembling composite concrete building panels. The apparatus includes a base member, a first row of staves spaced apart from one another and mounted to the base member such that they extend perpendicularly away from the based member, and a second row of staves spaced apart from one another and mounted to the base member, wherein the staves of the second row extend away from the base member and are oriented parallel with and spaced apart from the staves of the first row. Multiple insulative blocks are then positioned on top of each other between the first and second rows of staves. To complete the wall panel, wire mesh are mounted to, and thereafter concrete is applied to, both sides of the frame. Although the Csont apparatus allows for fabrication of structural elements (i.e. concrete wall panels) at the construction site as opposed to shipping the structural elements from a remote location, it still requires various building materials and substantial preparation in creating the mold before application of the concrete fill.

U.S. Pat. No. 5,327,694 to Gamel discloses a system for constructing a structural column which includes a tubular cardboard element and a layer of foam applied to the exterior of the tubular element for decoration. This system also has an internal load bearing means in the form of concrete that is installed within the interior of the tubular element. However, Gamel provides a system for creating only a column and fails to provide a mold or form system for constructing other structural elements, such as walls, floors, and roofs.

U.S. Patent Application Publication No. 2007/0094963 to McDonald describes a modular construction system comprising a plurality of panels, each panel having peripheral frame elements defining a top channel, bottom channel, and side channels. The panels are assembled together by struts and tie rods disposed along the channels. McDonald further discloses planar sheets made of concrete that are attached to the surfaces of the panels using an adhesive bonding material. However, the frame of each panel is made of steel, which is an expensive material. Moreover, the system still requires substantial amount of labor in creating the form system.

While the prior art molds and form systems may provide benefits over conventional concrete construction systems, they still suffer from several disadvantages. One of such disadvantages is that the prior art form systems often require use of wood, steel, or other metallic material, which are expensive building materials. Such materials also may not be easily transported to a remote construction site. Further, the prior art concrete form systems often require the assembly of multiple components to create the frame within which the concrete will be cast. As such, these systems do not provide for a quick and easy construction of a concrete form system.

SUMMARY OF THE INVENTION

Accordingly, it is an object of the present invention to provide a concrete form system having a flexible and efficient means of creating a frame for receiving concrete fill. A form system that can be quickly and easily erected in place ready for concrete fill becomes more apparent when a natural disaster, such as an earthquake, hurricane, tornado or flood, has destroyed previously constructed buildings. In this situation, there is often an immediate need for permanent forms of housing or shelter.

It is an additional object to provide a concrete form system that requires minimal construction materials for the erection of a structural element. By keeping the amount of construction materials to a minimum, the cost associated with erecting a building can be minimized. A form system that is able to reduce overall construction costs is important when trying to provide affordable housing or low-cost concrete buildings.

It is another object of the present invention to provide a concrete form system that is lightweight and easily transported to a remote construction site.

These and other objectives are achieved by providing a concrete form system including a base sheet of cardboard, at least one additional sheet of cardboard, the base sheet and at least one additional sheet having respectively a first and second shape, wherein a portion of the first shape corresponds with a portion of the second shape such that a V-shaped cavity is created therebetween, and a concrete fill cast within the cavity.

These and other objectives are also achieved by providing a system for assembling a structural frame having a base sheet of cardboard, at least one additional sheet of cardboard, the base sheet and at least one additional sheet having respectively a first and second shape, wherein a portion of the first shape corresponds with a portion of the second shape such that a V-shaped cavity is created therebetween, at least one further sheet of cardboard, the further sheet forming a brace for supporting the base sheet, and concrete fill cast within the cavity.

Further objectives are achieved by providing a form system for assembling a structural frame including a base sheet of cardboard, at least one additional sheet of cardboard, the base sheet and at least one additional sheet having respectively a first and second shape, wherein a portion of the first shape corresponds with a portion of the second shape such that a V-shaped cavity is created therebetween, a wire grid disposed around the at least one additional sheet and anchored to said base sheet, and a concrete fill cast within the cavity.

Other objectives of the invention are achieved by providing a form system including a base sheet of cardboard, at least one additional sheet of cardboard, the base sheet and at least one additional sheet having respectively a first and second shape, wherein a portion of the first shape corresponds with a portion of the second shape such that a V-shaped cavity is created therebetween, a wire mesh and concrete slab disposed over the V-shaped cavity and above the base sheet and the at least one additional sheet, and concrete fill cast within the cavity.

Additional objectives of the invention are achieved by providing a form system for assembling a structural frame having a base sheet of cardboard, at least one additional sheet of cardboard, the base sheet and at least one additional sheet having respectively a first and second shape, wherein a portion of the first shape corresponds with a portion of the second shape such that a V-shaped cavity is created therebetween, the cavity being adapted to receive a fluid material that casts therein.

The folded cardboard concrete form system according to the present invention improves the ease and efficiency of constructing a structural frame and avoids the disadvantages/inconveniences associated with prior art form systems. It reduces the number of building materials needed to create a concrete structure. Furthermore, by using lightweight cardboard, the form system according to the present invention can be easily transported to a remote construction site and facilitate quick construction of a concrete structure.

The concrete form system according to the present invention, which goes by the name “Go-“V” Building Systems,” is a flexible building system which uses reinforced sheets of cardboard corrugated to fashion V-shaped cavities for casting concrete therein. When assembled, this form system creates a strong structural element with V-shaped “ribs”—which increases strength and load bearing capacity—that can be used in many types of buildings. Furthermore, apart from the concrete fill, cardboard sheets make up the main component of the form system. As a result, the form system comprising lightweight, compact sheets of cardboard can be efficiently transported and erected to create houses or other buildings.

Other features and aspects of the invention will become apparent from the following detailed description, taken in conjunction with the accompanying drawings, which illustrate by way of example, the features in accordance with embodiments of the invention. The summary is not intended to limit the scope of the invention, which is defined solely by the claims attached thereto.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1A is a top view of a base sheet of cardboard which forms one element of a form system according to an exemplary embodiment of the present invention.

FIG. 1B is a top view of a second sheet of cardboard which forms a second element of the form system according to an exemplary embodiment of the present invention.

FIG. 2 is a top view of a third sheet of cardboard which forms a third element of the form system according to an exemplary embodiment of the present invention.

FIG. 3 is a perspective view of a concrete form system using corrugated sheets of cardboard according to an exemplary embodiment of the present invention.

FIG. 4A is a cross-sectional view of the first sheet of cardboard shown in FIG. 1 folded into a first shape to serve as a base for the concrete form system.

FIG. 4B is a cross-sectional view of the second sheet of cardboard shown in FIG. 1B folded into a second shape with wire grid disposed there around.

FIG. 4C is a cross sectional view of a concrete form system with the second sheet of cardboard shown in FIG.4B positioned adjacent to the first sheet of cardboard shown in FIG. 4A.

FIG. 5A is a top view of two concrete form systems according to an exemplary embodiment of the present invention that are positioned adjacent to each other and anchored to exterior walls and girders

FIG. 5B is a side view taken along A-A of FIG. 5A showing a cross section of the concrete form systems mounted between exterior walls.

FIG. 6 is a side view taken along B-B of FIG. 5A showing a cross section of the concrete form systems mounted to an exterior wall and girder.

DETAILED DESCRIPTION OF THE INVENTION

Referring to the figures in detail and first to FIG. 1A, there is shown an exemplary embodiment of a first sheet (hereinafter, also referred to as “base sheet”) of cardboard 10 used in the form system of the present invention. In one embodiment, the base sheet 10 comprises double thick cardboard. In other embodiments, the base sheet 10 can comprise cardboard having other thicknesses (e.g., single thick, triple thick). FIG. 1A shows the base sheet 10 having a plurality of folding sections 11, 12 defined by creases or pre-scored lines extending the length of the base sheet. The folding sections 11, 12 provide for the base sheet 10 to be corrugated into a first shape. More specifically, folding sections 12 with its pre-scored lines are adapted to allow for the base sheet 10 to be folded in one direction (e.g. upward direction) while the folding sections 11 with its pre-scored lines are adapted to allow for the base sheet 10 to be folded in an opposite direction (e.g. downward direction). The first shape that is created by folding the base sheet 10 comprises alternating horizontal sections 11 and V-shaped recessed sections 12. When the corrugated base sheet 10 is properly oriented, the horizontal sections 11 are disposed at an elevated position with respect to the V-shaped recessed sections 12, as shown in FIG. 4A. Further, each V-shaped recessed section 12 is defined by a flat base 12a and two sloped sides 12b diverging from each other.

Although the base sheet 10 shown in FIG. 1A has three horizontal sections 11 and two V-shaped recessed sections 12, the base sheet can be designed with any number of horizontal sections and V-shaped sections such that it can accommodate any required dimensions of a structural frame. For example, the base sheet 10 can comprise seven horizontal sections 11 alternating with six V-shaped recessed sections 12. Further, in other embodiments, the base sheet 10 can comprise multiple base sheets lapped and glued together to create a frame which has the required and/or desired dimensions. As one example, three base sheets each having three horizontal sections 11 and two V-shaped recessed sections 12 can be connected together to form one continuous base sheet having seven horizontal sections 11 alternating with six V-shaped recessed sections 12. Thus, the base sheet 1 can be adapted to meet any size needs and/or requirements for the structural frame that is to be erected.

The form system of the present invention also includes an additional sheet of cardboard 20 (also referred to as “second sheet”) as shown in FIG. 1B. Like the base sheet 10, the second sheet 20 can comprise either single or double thick cardboard. FIG. 1B shows the second sheet 20 having a plurality of folding sections 21, 22 defined by creases or pre-scored lines extending the length of the second sheet. The folding sections 21, 22 provide for the second sheet 20 to be corrugated into a second shape. The second shape is defined by the folding sections 21, 22 being folded towards each other to create a triangular tube (see FIG. 4B). In one embodiment, the cross section of the second shape is an equilateral triangle, such that the folding section 21 has the same dimensions as folding sections 22. In another embodiment, the cross section of the second shape is an isosceles triangle, wherein the folding section 21 has a different width than that of folding sections 22. The second sheet 20 maintains the second shape by connecting the folding sections 22 to each other. In some embodiments, an adhesive, such as glue or adhesive tape, can be used to bind together the edges of folding sections 22 that contact one another. Alternatively, mechanical fasteners can be used to bind the folding sections 22 to each other in other embodiments of the present invention.

The second sheet 20 further includes folding sections 23a, 23b, 23c. Once the second sheet has been folded into the second shape (triangular tube) via folding sections 21, 22, the folding sections 23a, 23b, 23c fold in and partially overlap to create closed ends of the triangular tube. The overlapping portions of the folding sections 23a, 23b, 23c are then attached to each other using either an adhesive (e.g. glue, adhesive tape) or fastener. After folding sections 21, 22 and folding sections 23a, 23b, 23c have been properly configured, a dead air cavity 26 is created therein, as shown in FIGS. 3 and 4B-4C. The air cavity 26 within the triangular tube provides several design advantages. First, the air cavity helps regulate and reduce heat transfer, and therefore gives the overall structural frame its own natural thermal insulation. Accordingly, separate insulation and insulative materials, such as loose-fill insulation, blanket insulation, and spray foam insulation, are not required and do not have to be installed in the structural frame. Moreover, without the weight of these separate insulation materials, the total weight of the structural frame can further be minimized.

As shown in FIGS. 3 and 4A-4C, when the second sheet 20 is positioned adjacent to the base sheet 10, at least part of the first shape of said base sheet 10 corresponds to at least part of the second shape of said second sheet 20. In particular, as the second shape of said second sheet 20 (FIG. 4B) is disposed within one of the V-shaped recessed sections 12 of the base sheet 10 (FIG. 4A), the folding sections 22 of the second sheet 10 become substantially parallel to the two sloped, diverging sides 12b (FIG. 4C). Furthermore, the folding section 21 of second sheet 20 becomes substantially level and planar with the horizontal sections 11 of the base sheet 10. Upon configuring these two sheets of cardboard together, a V-shaped cavity 13 that is adapted to receive a fluid material, such as concrete fill 9, is formed therebetween.

To assist in positioning the triangular tube (i.e. second shape of second sheet 20) within the V-shaped recessed section 12 of base sheet 10, a tab 24, which extends from a vertex formed between the folding sections 22, is mounted to flat base 12a. The tab 24 is formed from folding sections 24a, 24b, 24c of second sheet 20. The folding sections 24a are first folded into a position where they become flush with each other. The folding sections 24a can then be attached to each other by means of an adhesive or fastener. The folding sections 24b then fold away from each other such that they form a level plane that is perpendicular to the folding sections 24a. Thereafter, folding sections 24c are folded into a position such that they correspond with the two sloped sides 12b of the V-shaped recessed section 12. In one embodiment, the tab 24 is mounted to the flat base 12a using an adhesive, such as glue. In another embodiment, the tab 24 is mounted to the flat base 12a using a fastener.

A further sheet of cardboard 30 (also referred to as “third sheet”) having a plurality of folding sections 31, 32, 33, as shown in FIG. 2, is used in the form system of the present invention. The folding sections 31, 32, 33 are adapted for corrugating the third sheet 30 into a brace, wherein the brace supports the base sheet 10. The brace comprises a third shape that corresponds with the first shape of base sheet 10. Illustrated in detail in FIG. 3, the brace is a tube having an isosceles trapezoidal cross section. The brace is formed by folding the third sheet 30 along the pre-scored lines such that folding section 31 is parallel to folding sections 33, and folding sections 32 are non-parallel with each other. For the third sheet 30 to maintain the third shape, the folding sections 33 are attached to each using an adhesive in one embodiment or a fastener in another embodiment.

In order for the brace 30 to provide support to the base sheet 10, the brace is positioned adjacent to the base sheet 10, underneath one horizontal section 11 and between two V-shaped recessed sections 12 (FIGS. 3 and 4A). Since the brace corresponds to the first shape of the base sheet 10, folding sections 33 of the brace 30 are flush with the sloped sides 12b of the V-shaped recessed sections 12. Furthermore, the folding section 31 is flush with the horizontal section 11. Given this configuration, the brace 30 helps maintain the first shape of the base sheet 10 while concrete fill 9 is disposed within the V-shaped cavity 13. However, once the concrete fill 9 in the cavity cures, the brace 30 is no longer needed for support to the base sheet 10 and thus can be removed.

Referring back to FIG. 2, the third sheet of cardboard 30 can also comprise a plurality of closure panels 35. The closure panels 35 serve to cover and cap open ends of the base sheet 10 located under the horizontal section 11 and between V-shaped recessed sections 12, as shown in FIGS. 3 and 4C. Accordingly, each closure panel 35 has the shape of an isosceles trapezoid, and more specifically the same shape as the isosceles trapezoidal cross section of the brace 30 (i.e. third shape). The closure panels 35 must first be separated into individual components either by cutting (e.g. scissors, knife) or tearing them from the third sheet 30. Once the closure panels are separated, one closure panel 35 is placed at an open end of the base sheet 10. To mount the closure panel 35 to the open end, the closure panel 35 has folding sections 35a, 35b, 35c. The folding section 35a is configured such that it folds and overlaps with a part of horizontal section 11 of the base sheet 10. When the folding sections 35b are folded properly, each folding section overlaps a part of one sloped side 12b of one V-shaped recessed section 12. With regard to folding section 35c, it does not mount to any portion of the base sheet 10 and is merely configured as a lip of the closure panel 35. In one embodiment, the folding sections 35a, 35b are attached to the base sheet 10 at the areas of overlap using an adhesive, such as glue. In another embodiment, however, a fastener can be used to achieve the necessary attachment. Once mounted, the closure panels 35 help ensure that concrete fill 9 does not leak into the open ends of the base sheet 10 as the concrete fill is disposed within the V-shaped cavity 13.

It should be noted that in one embodiment of the present invention, all cardboard sheets of the form system are 3/16″ type “C” cardboard. In other embodiments, different cardboard having different flute type (e.g., A, B, C, D, E, F) and flute size/strength (e.g., 3/16″, ⅛″, 5/32″, 1/16″) can be used for the base sheet, second sheet, and third sheet. In yet further embodiments, each cardboard used for the base sheet, second sheet, and third sheet may differ from one another.

The base sheet, second sheet, and/or third sheet of cardboard may also be moisture treated. In one embodiment, a layer of waterproof coating is applied to the lower (exterior) surface of the base sheet. In another embodiment, both surfaces of the base sheet are coated with a layer of waterproof material. In a further embodiment, both surfaces as well as the edges of the base sheet may also be waterproof coated. Similarly, both surfaces and edges of the second sheet of cardboard can be waterproof coated in one embodiment of the present invention. The third sheet of cardboard may also have its edges and surfaces waterproof coated. In another embodiment, the lower (exterior) surface of the base sheet may be pre-finished such that additional rubbing, smoothing down, and/or patching typically required of conventional raw concrete work is not necessary.

Before concrete fill 9 is disposed within the V-shaped cavity, at least one reinforcement wire grid 3 is disposed around the second shape (i.e. triangular tube) of the second sheet 20. In one embodiment, the wire grid 3 comprises a standard trussed steel reinforced grid. Normally, wire grids are used as horizontal joint reinforcement grids in concrete block masonry construction. In this embodiment of the present invention, the wire grid 3 is used vertically to exploit the grid's added strength in this configuration. The wire grid 3 helps with strengthening the structural frame once concrete is cast within the V-shaped cavity. Furthermore, the wire grid helps to prevent any surface cracking once the concrete cures. The use of a wire grid provides time and cost saving benefits when compared to the use of conventional steel rebars. Although steel rebars provide sufficient reinforcement to concrete, they are expensive and require extensive labor in bending and setting within a structural frame.

In one embodiment of the present invention, multiple grid supports 6 are disposed within the V-shaped cavity 13, as shown in FIG. 4C. More specifically, the grid supports 6 are mounted along the sloped sides 12b of the V-shaped recessed section 12 and the folding sections 24b of end tab 24. The grid supports 6 also attach to the wire grid 3, thereby anchoring the wire grid to the base sheet 10. In a further embodiment, at least one grid support 3 is also mounted on the second shape of the second sheet 20, thereby anchoring the wire grid 3 to the second sheet 20. The plurality of grid supports 6 ensures that the wire grid 3 does not shift during the process of pouring concrete fill within the V-shaped cavity 13. The grid supports also ensure that the concrete fill is properly distributed within the V-shaped cavity.

Referring to FIGS. 3, 4B and 4C, at least one wire mesh 4 is disposed over the entire length of the base sheet 10, such that it covers the horizontal sections 11 of base sheet 10, the folding section 21 of second sheet 20 and the V-shaped cavities 13. Note, only a portion of the wire mesh 4 is shown in FIG. 3 in order to demonstrate other parts of the present invention. Having similar characteristic benefits as the wire grid 3, the wire mesh 4 helps in preventing surface cracking of the concrete fill 9 as well as the concrete slab 5 (discussed further below).

Also prior to concrete fill 9 being poured into the V-shaped cavity, the form system of the present invention is configured with a scaffolding unit 1 to support and/or elevate the first shape of base sheet 10 with the second shape of second sheet 20 positioned adjacently as well as brace 30 (FIGS. 3 and 4C). The scaffolding unit 1 can be made of one or more pre-fabricated, reusable steel rolling scaffolding sections or a network of steel studs or conventional wood framed shoring systems that span the alternating horizontal sections 11 and V-shaped recessed sections 12. FIG. 4C shows, in particular, the scaffolding unit 1 comprising at least one shoring support element 2 disposed in a substantially vertical orientation and at least one runner 8 mounted to a top end of the shoring support element 2 at a desired elevation. FIG. 3 shows the scaffolding unit 1 comprising two runners 8, each runner being mounted to a shoring element 2. In one embodiment, the shoring support element 2 is made of steel while the runner 8 is made of wood. The scaffolding unit 1 further comprises at least one spacer cleat 7 mounted to the wood runner 8. The purpose of the cleat 7 is to hold the brace 30 in place with respect to the runner 8. As a result, the cleat 7 further ensures that the base sheet 10 maintains its first shape and does not move or collapse when concrete fill 9 is poured into the V-shaped cavity 13. In one embodiment, the cleat 7 is shaped as a trapezoidal block having parallel upper and lower surfaces, and non-parallel side surfaces. The side surfaces are dimensioned such that they correspond with the sloped sides 12b of the V-shaped recessed section 12, as shown in FIG. 4A.

With the scaffolding unit 1 positioned in place with respect to the base sheet 10 and brace 30, the process of pouring concrete fill 9 into the V-shaped cavities 13 can begin (FIG. 3). The concrete fill 9 can be any lightweight cellular concrete mixture or an equivalent thereof. Once the V-shaped cavities 13 are completely filled with concrete 9, a layer of concrete fill 9 is further applied over the horizontal sections 11 of base sheet 10 and folding section 21 of the second sheet 20. Thereafter, a concrete slab 5 is placed over the wire mesh 4 and concrete fill 9. The concrete fill 9 is then allowed to cure, which causes the base sheet 10 and second sheet 20 to adhere to the concrete slab 5, and thus create one comprehensive structural frame. The structural frame exhibits exceptional strength due to the V-shaped cavities 13 with concrete fill 9 cured therein. Specifically, the V-shaped configuration of the concrete acts like ribs which reinforce the concrete slab 5 as well as the entire structural frame. The “ribbing” not only improves the strength and load-bearing characteristics of the structural frame, it does so without increasing the amount of concrete used. Instead, the structural frame uses less concrete fill due to the air cavities 26 present in the second shape of the second sheet of cardboard 20.

Once the structural frame has been assembled, the brace 30 and the scaffolding unit 1 (i.e. shoring element 2, wood runner 8, and cleat 7) can be separated from the structural frame. The structural frame can then be erected to serve as a floor, wall, roof, or other structural element of a building.

As demonstrated in FIG. 5A, the structural frame constructed using the form system of the present invention has sufficient strength to be used as roof panels of a building. FIG. 5A is a layout view of two structural frames 50 positioned adjacent to each other and mounted to exterior walls 15 and composite design steel-concrete girders 14. Specifically, one structural frame spans from an exterior wall 15 to a girder 14, while the other structural frame spans between two girders 14. In addition, the structural frames can further accommodate projecting exterior balconies or overhands 18. FIG. 5B is a cross sectional view taken along A-A of FIG. 5A. FIG. 5B shows the structural frame 50 mounted to two exterior bearing walls 15. In addition, side elevations 17 can be mounted to a steel column, such as a shoring element 2, to provide additional load bearing support to the structural frame.

FIG. 6 is a cross sectional view taken along B-B of FIG. 5A. In particular, it shows in detail the structural frame 50 anchored to an exterior bearing wall 15 and a girder 14. The girder 14 comprises two back-to-back light weight steel “C” channels 14, which are bolted together and set separately to maximize strength when encased in concrete fill 9. Additional steel reinforcing rods and steel plates 16 can be disposed in place maintaining proper concrete embedment and cover. The steel plates, in one embodiment, can be tack welded 3/16″ steel plates. However, different size steel plates can be used with the present invention. The configuration of the structural frame assembled from the form system of the present invention further allows for an easy and improved connection/mounting with the bottom flange of the girders 14 as well as with the exterior walls 15, whether they be concrete tilt ups, masonry or steel stud framing. In one embodiment, the structural frame also includes sloping beveled end panels to facilitate anchoring the structural frame to the girders and/or exterior bearing walls.

Although the invention has been described with reference to particular arrangements of parts, features, and the like, these are not intended to exhaust all possible arrangements or features, and indeed many modifications and variations will be ascertainable to those of skill in the art.

Claims

1. A system for assembling a structural frame, said system comprising:

a base sheet of cardboard, the base sheet having a plurality of folding sections for corrugating the base sheet into a first shape;

at least one additional sheet of cardboard, the additional sheet having a plurality of folding sections for corrugating the additional sheet into a second shape;

wherein at least part of the second shape corresponds to at least part of the first shape such that when the additional sheet is positioned adjacent to the base sheet, the base sheet and the additional sheet form a V-shaped cavity therebetween; and

a concrete fill cast within the at least one V-shaped cavity.

2. The system of claim 1, wherein the first shape of said base sheet includes alternating horizontal sections and V-shaped recessed sections.

3. The system of claim 2, wherein each of the V-shaped recessed sections has a flat base and two diverging sides.

4. The system of claim 2, wherein the second shape of said at least one additional sheet is defined by a triangular tube.

5. The system of claim 4, wherein the triangular tube is disposed within one of the V-shaped recessed sections.

6. The system of claim 5, wherein the second shape includes a tab that extends from a vertex of the triangular tube for mounting the triangular tube to a base of one of the V-shaped recessed sections.

7. The system of claim 2, further comprising at least one further sheet of cardboard, the further sheet having a plurality of folding sections for corrugating the further sheet into a brace, said brace supporting the base sheet.

8. The system of claim 7, wherein the brace comprises a third shape that corresponds to the first shape of said base sheet when the brace is positioned adjacent to the base sheet.

9. The system of claim 8, wherein the third shape of said brace is a tube having a trapezoidal cross section, said brace is positioned under one of the horizontal sections and next to at least one of the V-shaped recessed sections.

10. The system of claim 1, further comprising a wire grid disposed around an outside of the at least one additional sheet and a plurality of grid supports disposed within the V-shaped cavity for anchoring said wire grid to said base sheet.

11. The system of claim 1, further comprising:

a wire mesh disposed over the V-shaped cavity and above the base sheet and the at least one additional sheet; and

a concrete slab disposed over the wire mesh, wherein a portion of the concrete fill disposed within the V-shaped cavity adheres to the concrete slab when cured.

12. A system for assembling a structural frame, said system comprising:

a base sheet of cardboard, the base sheet having a plurality of folding sections for corrugating the base sheet into a first shape;

at least one additional sheet of cardboard, the additional sheet having a plurality of folding sections for corrugating the additional sheet into a second shape;

wherein at least part of the second shape corresponds to at least part of the first shape such that when the additional sheet is positioned adjacent to the base sheet, the base sheet and the additional sheet form therebetween a V-shaped cavity for receiving a fluid material to cast therein.

13. The system of claim 12, wherein the base sheet and the at least one additional sheet are moisture treated for waterproofing.

14. The system of claim 12, wherein the first shape of said base sheet includes alternating horizontal sections and V-shaped recessed sections;

each of said V-shaped recessed sections has a flat base and two diverging sides; and

wherein the second shape of said at least one additional sheet is defined by a triangular tube.

15. The system of claim 14, wherein the triangular tube is disposed within one of the V-shaped recessed sections.

16. The system of claim 14, further comprising at least one further sheet of cardboard, the further sheet having a plurality of folding sections for corrugating the further sheet into a brace, said brace supporting the base sheet.

17. The system of claim 16, wherein the brace comprises a third shape that corresponds to the first shape of said base sheet when the brace is positioned adjacent to the base sheet.

18. The system of claim 16, further comprising at least one scaffolding for supporting and elevating the base sheet and brace;

each scaffolding comprising at least one shoring support element disposed vertically, at least one runner mounted at a top end of the shoring support element and at least one cleat mounted to the runner;

the runner spanning the alternating horizontal sections and V-shaped recessed sections of the base sheet; and

the cleat being disposed under the base sheet at the flat base of one of the V-shaped recessed sections and holding the brace in place with respect to the runner such that the base sheet remains stationary on the at least one scaffolding.

19. The system of claim 12, further comprising a wire grid disposed around an outside of the at least one additional sheet and a plurality of grid supports disposed within the V-shaped cavity for anchoring said wire grid to said base sheet.

20. The system of claim 12, further comprising:

a wire mesh disposed over the V-shaped cavity and above the base sheet and the at least one additional sheet; and

a slab disposed over the wire mesh, said slab comprising precast fluid material;

wherein a portion of the fluid material disposed within the V-shaped cavity adheres to the slab when cured.