Abstract: A method for constructing site-cast or precast concrete floors, roofs and decks by first forming one piece elongated foam forms having an elongated cavity for reception of concrete. A pair of elongated slots is formed along the bottom of each of the forms. Wooden members are placed into each of the elongated slots to form an assembled combination of the foam form and wood members. A plurality of the assembled combinations are placed in juxtaposition with respect to each adjacent assembled combination on a support surface, rebar is placed in the cavity of each assembled combination and then concrete in an uncured form if poured over the assembled combinations and into the cavities of the forms so that once the concrete has cured a concrete panel has been formed.

Abstract: A method and apparatus using foam forms for poured concrete roof and floor decks for on-site concrete structural joists is shown that may be integrated into the concrete deck formed by the forms or otherwise used as structural supports. Greater joist strength results from providing a communication channel in the forms between an opening in C channel metal studs used in such panel forms and a space between piers that forms the main concrete beam portion of a finished concrete structural joist. By providing such flow of concrete, when the joist is completed, the concrete structural joint is stronger because the concrete is disposed inside of the C channel studs and continuously between the inside of the C channel studs and the main concrete beam portion. The concrete thereby interlocks the C channels to the main concrete portion of beam.

Abstract: A foam panel concrete form is provided for using concrete reinforcement rods which extend on each side of a joint in the foam panel concrete form and into complementary shaped openings in ties which hold two adjacent panels in a spaced and parallel relationship. The concrete reinforcement rod can pass into the openings in adjacent ties with little resistance in a first rotary position of the concrete reinforcement rod. When the concrete reinforcement rod is rotated to a second rotational position within the openings the reinforcement rod is in a tight frictional fit in the openings for helping to hold adjacent ties and the adjacent foam panels in a fixed relationship with respect to each other during a time when concrete is poured between the foam panels, thereby also serving to re-enforce the concrete after the concrete has cured.

Abstract: A foam panel concrete form is provided for using connectors which extend on each side of a joint in the foam panel concrete form and into complementary shaped openings in ties which hold two adjacent panels in a spaced and parallel relationship. The connector can pass into the openings in adjacent ties with little resistance in a first rotary position of the connector. After the connector is inserted a predetermined distance into the openings, then the connector is rotated to a second rotational position within the openings so that flanges of the connector are disposed on each side of respective ties and thereby hold adjacent ties and the adjacent foam panels in a substantially fixed relationship with respect to each other during a time when concrete is poured between the foam panels.

Abstract: A foam panel concrete form is provided for using concrete reinforcement rods which extend on each side of a joint in the foam panel concrete form and into complementary shaped openings in ties which hold two adjacent panels in a spaced and parallel relationship. The concrete reinforcement rod can pass into the openings in adjacent ties with little resistance in a first rotary position of the concrete reinforcement rod. When the concrete reinforcement rod is rotated to a second rotational position within the openings the reinforcement rod is in a tight frictional fit in the openings for helping to hold adjacent ties and the adjacent foam panels in a fixed relationship with respect to each other during a time when concrete is poured between the foam panels, thereby also serving to re-enforce the concrete after the concrete has cured.

Abstract: A concrete form panel system includes a basic form panel of expanded polystyrene material having at least one slot formed in the top surface along its length, to divide the panel top surface into piers. A series of top hats are provided for selective attachment to the piers to increase the depth of the slots between piers, and thereby increase the depth of a joist formed by hardened concrete poured into the slot. Transverse slots may also be formed by separating top hats along their lengths. The transverse slots create transverse bracing between T-joists in a concrete deck. The form panels and top hats may also be used to create separate structural joists with attachment lifts, to permit connection of the joists to a subsequently constructed floor or deck system.

Abstract: A method of manufacturing a concrete deck form panel includes the initial step of cutting an insert within the panel, which may be removed by sliding the insert longitudinally from the panel. A pair of structural members are attached to the longitudinal sides of the insert, and then the insert is returned to the original position within the panel. A series of panels are connected to form a floor for supporting concrete, thereby forming a concrete deck system. In a second embodiment of the invention each form panel is formed by attaching a pair of structural members to longitudinal sides of a central body and then attaching L-shaped members to the structural members. A top plate is mounted to the top of the L-shaped members and the central body to form the integrated form panel.

Abstract: A tie for interconnecting a pair of parallel form panels includes an elongated strap with an end plate pivotally connected at each end of the strap, permitting the end plate to be pivoted from a position generally orthogonal to the strap to a position generally parallel to the strap. Once an end plate is pivoted to a position parallel to the strap, the end plate is pushed through a polystyrene form panel to project therefrom. The end plate is then pivoted to a position orthogonal to the strap, and pulled into engagement with the outer face of the form panel. The second end plate is pivoted, pushed through a second form panel, and pivoted to the orthogonal position, in the same manner. Concrete is then poured between the panels and allowed to harden. After the concrete is cured, a form panel may be removed by striking the end plate with a rubber mallet in a direction aligned with the longitudinal axis of the strap.

Abstract: A tie includes an elongated strap with an end plate pivotally connected at each end of the strap, permitting the end plate to be pivoted from a position generally orthogonal to the strap, to a position generally parallel to the strap. Once an end plate is pivoted to a position parallel to the strap, the end plate can be pushed through a polystyrene form panel to project therefrom. The end plate is then pivoted to the position orthogonal to the strap, and pulled into engagement with the outward face of the form panel. The second end plate on the tie is pivoted, pushed through a second form panel, pivoted to the orthogonal position, and thence the second form panel is pulled outwardly into contact with the second end plate. In this way, the tie will interconnect a pair of parallel form panels in spaced apart position, to receive poured concrete therebetween.

Abstract: A double tie includes a pair of upper and lower straps connected in parallel relationship by a pair of vertical plates attached to the outward ends of the straps. The plates are oriented orthogonally relative to the straps to form a general "T" shape. A pair of stop straps are mounted on the plates intermediate the upper and lower straps, and projecting towards one another. The stop straps have orthogonal heads spaced inwardly from the plates a distance to retain a form panel between the head and plate. Each upper and lower strap has a hinge formed at each end, the hinges at each end of the upper and lower straps being coaxial and parallel to the plates, such that the upper and lower straps may be pivoted from a position generally orthogonal to the plates, to a position generally parallel to the plates.

Abstract: A two-piece corner tie includes first and second tie halves which are removably connected together. The first tie half includes forward and rearward form panel retainers for holding form panels in upright spaced apart parallel relationship. The second tie half is preferably identical to the first tie half, and retains a second pair of form panels in upright spaced apart parallel relationship. The tie halves are connected by a pair of pins journaled through co-axial sleeves, to retain a first pair of form panels at a predetermined angle relative to a second pair of form panels, to thereby form a corner.

Abstract: A corner joint tie includes first and second forward plates connected along a common vertical edge and oriented at an angle of less than 180.degree. with respect to one another. A pair of first and second rearward plates are connected together at the same angle as the forward plates, and spaced rearwardly from the respective first and second forward plates by first and second straps. A rib is affixed along the length of each rearward plate to strengthen the rearward plates against flexion along their lengths. The inner and outer plates, associated straps, and associated ribs form an inner tie portion for retaining a pair of form panels at a corner. An outer tie portion is connected to the inner tie portion so as to retain a second pair of form panels parallel to the first pair of form panels at a corner.

Abstract: A quick release tie includes an elongated strap having retainer plates removably connected to the opposing ends of the strap. Each retainer plate includes a cylindrical body portion which extends through an aperture in a form panel, a generally flat panel affixed to an outer end of the body portion to prevent movement of the form panel outwardly off of the retainer plate, and a conical inner end tapering to a smaller diameter at the inner end of the body portion. The body portion inner end is interiorly threaded, and selectively engages exterior threads on the opposing ends of the strap to permit selective removal of the retainer plates. A socket formed in an outer surface of the retainer plate panel permits engagement of a tool for rotating the retainer plate so as to engage or disengage the retainer plate from the strap ends.

Abstract: An apparatus for interconnecting a pair of spaced-apart form panels includes a tie having opposing ends inserted through apertures in the panels, and retainer plates on each end to lock the panels in position. Each tie includes an elongated strap having an expanded lug at each end to prevent movement of the panel inwardly past the lug. A loop member is mounted on each lug which projects outwardly through the panel and which will receive the retainer plate to lock the panel in position on each end of the strap. The retainer plate has an aperture therethrough and a finger extending downwardly into the aperture. The retainer plate finger is journaled through the loop of the strap to lock the retainer plate onto the strap end to hold the form panel in position.

Abstract: A hinged tie is designed to connect the ends of two elongated polystyrene form panels at a predetermined angular orientation. Each tie includes first and second plate members hinged along a common vertical edge to form a vertical pivotal axis. Each plate member has a strap projecting therefrom with a paddle mounted at the projecting end of the strap oriented parallel to the corresponding plate member. The straps correspond with tie slots cut in each form panel such that the form panels are retained between the paddles and plate members. The hinge permits the form panels to be retained in abutting contact at a variety of predetermined angles.