LEAVE-IN-PLACE CONCRETE FORM
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.
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.
BACKGROUND1. Field of the Disclosure
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.
2. Description of the Related Art
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.
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.
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.
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.
The use of the same reference symbols in different drawings indicates similar or identical items.
DETAILED DESCRIPTIONAccording 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.
Referring to
As depicted in
In a particular embodiment, the second concrete form 104, which is described in greater detail below, can provide an installed deflection, DI, between adjacent stakes 116 along the second concrete form 104 that can be ≦1% IS, ≦0.9% IS, such as ≦0.8% IS, or ≦0.75% IS. In a particular aspect, DI can be measured at a top of the second concrete form 104. Further, DI can be measured along an axis perpendicular to a longitudinal axis of the second concrete form 104.
As indicated in
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.
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.
Further, as mostly clearly depicted in
As illustrated, the stiffening lip 218 can extend at an angle, α, with respect to the upper extension 214. In a particular aspect, α can be ≦90°, such as ≦89°, ≦88°, or ≦85°. Further, α can be ≧30°, such as ≧45°, ≧60°, or ≧75°. In another aspect, α 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.
In another aspect, the elongated body 200 can include a overall height, HO, and wherein the stiffening lip extends from the upper extension at a distance, D, from the upper wall, and wherein D≦50% HO, such as D≦45% HO, ≦40% HO, or ≦35% HO. Further, D≧5% HO, such as ≧10% HO, ≧15% HO, ≧20% HO, or ≧25% HO. In other embodiments, a ratio of D/H can be in a range of about 5% to about 50%.
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.
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.
Referring briefly to
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, HB. HB can be ≦75% H, such as ≦70% H, ≦65% H, ≦60% H, ≦55% H, ≦50% H, ≦45% H, or ≦40% H. Further, HB can be ≧5% H, such as ≧10% H, ≧15% H, ≧20% H, ≧25% H, or ≧30% H. HB can be within a range between and including any of the values for HB described above.
In another aspect, the box-shaped main body portion 202 can include a width, WB, and WB can be ≦75% H, such as ≦70% H, ≦65% H, ≦60% H, ≦55% H, ≦50% H, ≦45% H, or ≦40% H. Moreover, WB≧15% H, such as ≧20% H, ≧25% H, or ≧30% H. WB can be within a range between and including any of the values for WB described above.
In another aspect, the stiffening lip 218 can include a width, WSL, and WSL can be ≦35% H, such as ≦30% H, ≦25% H, or ≦20% H. Also, WSL can be ≧5% H, such as ≧10% H, or ≧15% H. In addition, WSL can be within a range between and including any of the values for WSL described above. Further, WSL can be ≦50% WB, such as ≦45% WB, ≦40% WB, or ≦35% WB. WSL can also be ≧5% WB, such as ≧10% WB, ≧15% WB, ≧20% WB, or ≧25% WB.
In yet another aspect, the lower extension 212 can includes a height, HLE, and HLE≦35% H, such as ≦30% H, ≦25% H, or ≦20% H. Further, HLE, can be ≧5% H, such as ≧10% H, or ≧15% H. In addition, HLE can be within a range between and including any of the values for HLE described above.
Further, in another aspect, the upper extension 214 can include a height, HUE, and HUE can be ≦60% H, such as ≦55% H, ≦50% H, or ≦45% H. HUE can be ≧20% H, such as ≧25% H, ≧30% H, or ≧35% H. In addition, HUE can be within a range between and including any of the values for HUE described above.
In another aspect, the ratio of HB:WB≧4:1, such as ≧3:1, or ≧2:1. Further, HB:WB≦0.25:1, such as ≦0.33:1, ≦0.5:1, or ≦1:1. Moreover, the box-shaped main body portion 202 can include a wall thickness, TW, and TW can be ≦15% H, such as ≦10% H, or ≦5% H. Further, T2≧0.5% H, such as ≧1.0% H, ≧1.5% H, ≧2.0% H, ≧2.5% H, or ≧3.0% H. In addition, the ratio can be within a range between and including any of the values described above.
In still another aspect, HB can be ≧400% WB, such as ≧200%, or ≧100%. Further, HB can be ≦0.25% WB, such as ≦0.5%, ≦0.8%, ≦1.0%, ≦10%, ≦25%, or ≦50% WB. In addition, the relative values of HB and WB can be within a range between and including any of the values described above.
In another particular aspect, the elongated body 200 can include an installed stake interval, IS, measured between adjacent stakes 116, e.g., from center line to center line. Also, the upper extension 214 can include an installed deflection, DI, measured the upper extension 214 in an outward direction, i.e., in the same direction in which the stiffening lip 218 extends. DI 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, DI can be measured at or near the distal 216 end (aka the top) of the upper extension 214. DI 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, DI can be measured along the length of the elongated body 200 at a midpoint between adjacent stakes 116.
DI 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 DI and substantially prevent DI 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.
In a particular aspect, DI can be ≦0.2% IS, such as ≦0.6% IS≦1%, ≦5% IS≦10% IS≦20% IS, or even IS≦25% IS. Further, DI may be ≧0.00625% IS, such as ≧0.025% IS, or even ≧0.05% IS. DI can be within a range between and including any of the DI values above. IS can be ≧0.91 meters (3.0 feet), such as ≧1.22 meters (4.0 feet), or ≧1.52 meters (5.0 feet). Moreover, IS can be ≦3.05 meters (10.0 feet), such as ≦2.74 meters (9.0 feet), ≦2.44 meters (8.0 feet), ≦2.13 meters (7.0 feet), or ≦1.83 meters (6.0 feet).
As illustrated in
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.
In one aspect, the upper extension 214 can include a thickness, TUE, and TUE 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, TUE can decreases along the upper extension 214 from the upper wall 204 to the distal end 216 of the upper extension 214.
In another aspect, the lower extension 212 can include a thickness, TLE, and the stiffening lip 218 can include a thickness, TSL. Further, TUE, TLE, and TSL can be the same as TW 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.
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.
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.
Referring to
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.
As illustrated in
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, IS. The second concrete form can provide an installed deflection, DI, between adjacent stakes that is, in some embodiments, ≦0.5% IS, such as ≦0.3% IS, or even ≦0.2% IS. The second concrete form can be a molded or an extruded form which can substantially reduce the manufacturing costs.
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.
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.
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.
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, IS, wherein the second concrete form provides an installed deflection, DI, between adjacent stakes and DI≦0.75% IS.
19. The concrete forming system of claim 18, wherein DI is measured along an axis perpendicular to a longitudinal axis of the second concrete form.
Type: Application
Filed: Jul 30, 2013
Publication Date: Feb 6, 2014
Inventors: Joshua Fairley (King of Prussia, PA), Joseph N. Bondi (Devon, PA), Steve B. Gross (Holland, PA)
Application Number: 13/954,315
International Classification: E04G 11/00 (20060101);