Method and System for Forming Pre-Cast Concrete Columns

Abstract

The apparatus may include a cavity for forming pre-cast concrete structures, such as concrete columns. The cavity may be defined by a base member and two opposing side members. The two opposing side members may be pivotally interconnected to the base member such that the two opposing side members are moveable between a ready-to-use position and a release position. Projection members may be placed into the cavity to form slots in columns formed in the cavity. The slots are adapted to receive the terminal ends of concrete panels. Bulkheads may be removably installed into the cavity to vary a dimension of the concrete columns formed therein.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims the benefit of U.S. Provisional Application Ser. No. 61/019,437, filed on Jan. 7, 2008, which application is hereby incorporated by reference.

BACKGROUND OF THE INVENTION

1. The Field of the Invention

The present disclosure relates generally to devices for forming structures, and more particularly, but not necessarily entirely, to devices for forming pre-cast concrete columns.

2. The Relevant Technology

Precast concrete structures have been used in the building construction industry for many years. Precast concrete structures may include steel reinforced panels for use in constructing fences, walls, sound barriers, and the like. Precast concrete structures may also include columns for supporting panels or overhead items. High quality precast concrete structures may be formed efficiently, since they may be constructed in a factory with specialized equipment, strict quality standards, and controlled conditions not subject to rain, hot or cold temperatures, or builder errors. Moreover, labor savings may be accomplished since precast structures may be formed more efficiently in a factory than constructing a form on site to manufacture the structures in place. Use of precast concrete structures may also reduce construction delays associated with rain or inclement weather since concrete may not be properly poured on site in inclement weather.

In recent years, the use of precast concrete columns and panels with decorative patterns formed on the exterior surface has increased in popularity. The precast concrete panels may have various patterns such as stone or brick, for example. Such precast concrete panels may be easier to construct than stone or brick walls. Moreover, the precast concrete panels may be durable and provide advantages in that cracking may be reduced as compared to walls formed with grouted natural stone or brick, and no mortar joints are created with precast concrete panels to allow water to seep into the wall.

Various types of devices are known in the art for forming precast concrete structures. Despite the advantages of known devices for forming concrete structures, improvements are still being sought to improve the efficiency of the manufacturing process and the quality of the concrete structures. Also, improvements are being sought for concrete structures to facilitate installation of the structures at the construction site.

The features and advantages of the disclosure will be set forth in the description that follows, and in part will be apparent from the description, or may be learned by the practice of the disclosure without undue experimentation. The features and advantages of the disclosure may be realized and obtained by means of the instruments and combinations particularly pointed out in the appended claims.

BRIEF DESCRIPTION OF THE DRAWINGS

Various embodiments of the present invention will now be discussed with reference to the appended drawings. It is appreciated that these drawings depict only typical embodiments of the invention and are therefore not to be considered limiting of its scope.

FIG. 1 is an exploded perspective view of an apparatus made pursuant to an embodiment of the present invention;

FIG. 2 is an assembled perspective view of the apparatus depicted in FIG. 1 in a release position;

FIG. 3A is a side view of the apparatus depicted in FIG. 1 in the ready-to-use position;

FIG. 3B is another side view of the apparatus depicted in FIG. 1 in the ready-to-use position;

FIG. 4 is a top view of the apparatus depicted in FIG. 1 in the ready-to-use position;

FIG. 5 is a cross-sectional view taken along the section A-A in FIG. 4;

FIG. 6 is a cross-sectional view taken along the section B-B in FIG. 4;

FIG. 7 is a cross-sectional view taken along the section C-C in FIG. 4;

FIG. 8 is a top view of an apparatus in the ready-to-use position pursuant to another embodiment of the present invention;

FIG. 9 is a cross-sectional view taken along the section D-D in FIG. 8;

FIG. 10 is a cross-sectional view taken along the section E-E in FIG. 8;

FIG. 11 is a cross-sectional view taken along the section F-F in FIG. 8;

FIG. 12 is a top view of an apparatus in the ready-to-use position pursuant to another embodiment of the present invention;

FIG. 13 is a cross-sectional view taken along the section G-G in FIG. 12;

FIG. 14 is a cross-sectional view taken along the section H-H in FIG. 12; and

FIG. 15 is a cross-sectional view taken along the section I-I in FIG. 12.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

The present invention may be embodied in other specific forms without departing from its spirit or essential characteristics. The described embodiments are to be considered in all respects only as illustrative and not restrictive. The scope of the invention is, therefore, indicated by the appended claims rather than by the foregoing description. All changes which come within the meaning and range of equivalency of the claims are to be embraced within their scope.

For the purposes of promoting an understanding of the principles in accordance with the disclosure, reference will now be made to the embodiments illustrated in the drawings and specific language will be used to describe the same. It will nevertheless be understood that no limitation of the scope of the disclosure is thereby intended. Any alterations and further modifications of the inventive features illustrated herein, and any additional applications of the principles of the disclosure as illustrated herein, which would normally occur to one skilled in the relevant art and having possession of this disclosure, are to be considered within the scope of the disclosure claimed.

Before the present concrete structure system and apparatus and method for forming one or more concrete structures is disclosed and described, it is to be understood that this disclosure is not limited to the particular configurations, process steps, and materials disclosed herein as such configurations, process steps, and materials may vary somewhat. It is also to be understood that the terminology employed herein is used for the purpose of describing particular embodiments only and is not intended to be limiting since the scope of the present disclosure will be limited only by the appended claims and equivalents thereof.

It must be noted that, as used in this specification and the appended claims, the singular forms “a,” “an,” and “the” include plural referents unless the context clearly dictates otherwise. Similarly, as used herein, the terms “comprising,” “including,” “containing,” “characterized by,” “having,” and grammatical equivalents thereof are inclusive or open-ended terms that do not exclude additional, unrecited elements or method steps.

As used herein, the term “concrete” shall be construed broadly to include conglomerate construction materials, including construction materials formed of aggregate and cementitious materials, as well as any other known material that may be placed in a fluid or semi-fluid form and hardened or solidified, including filler materials joined together with a bonding agent or resin.

Applicants have invented an apparatus for producing one or more pre-cast concrete columns. The concrete columns may be utilized to support concrete panels in an upright position to form a barrier, such as a wall. The apparatus may include two opposing side members pivotally attached to a base member. The two opposing side members may be moveable between a ready-to-use position and a release position. In the ready-to-use position, a cavity is formed between the two opposing side members and a surface of the base member. The cavity may take the shape of a mold for a concrete column. After the concrete has been poured and allowed to cure in the cavity, the two opposing side members may be released and moved away from the new concrete column into the release position to thereby allow the concrete column to be more easily removed from the cavity.

In one embodiment, the cavity may include projections for forming slots in the concrete columns. The slots are adapted to receive the terminal ends of concrete panels. Further, removable bulkheads may be placed into the cavity to allow a dimension of the cavity, such as its length, to be variable to thereby permit the formation of columns of different dimensions using the same apparatus. The present invention may be adapted to form different variations of columns, including, a 180-degree concrete column, a 90-degree concrete column, and a 35-degree to a 55-degree column.

Referring now to FIG. 1, there is depicted an exploded perspective view of an apparatus for forming pre-cast concrete structures, generally indicated by reference numeral 10. The apparatus 10 includes a base member 12. The base member 12 includes a lowermost portion 14 for engaging a surface, such as the ground. The base member 12 extends in an elongated manner between a first end member 16 and a second end member 18. The first end member 16 and the second end member 18 may be coupled to the base member 12 using fasteners, welding or the like or they may be integrally formed with the base member 12.

Disposed on opposing sides of the base member 12 and along the length of the base member 12 are a side member 20 and a side member 22. The side member 20 and the side member 22 are pivotally attached to the base member 12 such that they may each move between a ready-to-use configuration as shown in FIG. 4 and a release position as shown in FIG. 2. Referring back to FIG. 1, extending upwardly from an uppermost portion 24 of the side member 20 are posts 26. Mounted to the topmost portion of each of the posts 26 is a fastening device 34 whose purpose and features will be described in more detail hereinafter. Likewise, extending upwardly from an uppermost portion 36 of the side member 22 are posts 38. Mounted to a topmost portion of each of the posts 38 is a fastening device 46 whose purpose and features will be described in more detail hereinafter.

Each of the side member 20 and the side member 22 comprises an inner surface 48 and 50, respectively. The inner surfaces 48 and 50 extend along the entire lateral length of the side member 20 and the side member 22, respectively. The inner surface 48 and the inner surface 50 are operable to shape and contour at least a portion of an outer surface of a concrete column formed in the apparatus 10. The inner surfaces 48 and 50 may comprise projection members 52 and 54, respectively. The projection members 52 and 54 may each comprise a pair of spaced apart walls extending orthogonally from their respective inner surfaces, 48 and 50. A third wall may span between a topmost portion of each of the spaced apart walls to complete the structure of each of the projection members 52 and 54. The interior of the projection member 52 and 54 may be hollow or solid.

It will be appreciated that the outwardly extending projection members 52 and 54 are operable to form a pair of slots in a column formed in the apparatus 10. The entrances to the slots, in this case, may be spaced at 180 degrees from each other to thereby allow a column formed in the apparatus 10 to be used in a straight or unbent portion of a barrier. Stated another way, the slots are formed on opposite sides of a column formed in an apparatus 10.

A bulkhead 64 having an I-shape, may be inserted between the side member 20 and the side member 22 as will be explained in more detail hereinafter.

Referring now to FIG. 2, where like reference numerals depict like components, there is depicted a perspective view of the apparatus 10 in the release position. In the release position, the side member 20 and the side member 22 are rotated away from the vertical position to approximately a 45 degree angle as shown by the arrows 21 and 23, respectively. The release position allows a column that is formed in the apparatus 10 to be more easily removed from the apparatus 10 as it permits the projection members 52 and 54 to disengage the slots in a column formed in the apparatus 10. The release position is also useful to allow easy cleaning of the apparatus 10. The bulkhead 64 is shown installed into it position the apparatus 10.

Referring now to FIG. 3A, there is depicted a side view of the apparatus 10 in the ready-to-use position. As can be observed, the side member 20 comprises a top support member 100 and a bottom support member 102 that extend horizontally along the length of the side member 20. The posts 26 extend above the top support member 100. It will be appreciated that this raises the fastening devices 34 such that they do not interfere with pouring or finishing concrete in the apparatus 10. Interposed between the posts 26 are posts 112. The posts 112 do not extend above the top support member 100. It will be noted that posts 26 and 112 both extend below the bottom support member 102 to provide a pivot attachment point to the base member 12 as will be explained hereinafter. Stiffeners 108 are attached to each of the posts 26 and 112 to provide further strength for the side member 20. The stiffeners 108 extend vertically between the top support member 100 and the bottom support member 102 and abut into posts 26 and 112.

Referring now to FIG. 3B, there is depicted a side view of the apparatus 10 in the ready-to-use position opposite from that view shown in FIG. 3A. As can be observed, the side member 22 comprises a top support member 104 and a bottom support member 106 that extend horizontally along the length of the side member 22. The posts 38 extend above the top support member 104. It will be appreciated that this raises the fastening devices 46 such that they do not interfere with pouring or finishing concrete. Interposed between the posts 38 are posts 114. The posts 114 do not extend above the top support member 104. It will be noted that posts 38 and 114 extend below the bottom support member 106 to provide an attachment point to the base member 12 as will be explained hereinafter. Stiffeners 110 are attached to each of the posts 38 and 114 to provide further strength for the side member 22. The stiffeners 110 extend vertically between the top support member 104 and the bottom support member 106 and abut into posts 38 and 114.

Referring now to FIG. 4, there is depicted a top view of the apparatus 10 in the ready-to-use position. In the ready-to-use position, the side member 20 and the side member 22 are closed and locked into place using fastening devices 34 and 46. A cavity 56 is defined by the side member 20, the side member 22, the first end member 16, the second end member 18, and the surface 13 of the base member 12. The top of the cavity 56 is open.

Inserted into the cavity 56 is the bulkhead 64. The bulkhead 64 may be secured in place using fastening members (not explicitly shown). The fastening members suitable for securing the bulkhead 64 in place may include clamps, bolts, pins and the like. The placement of the bulkhead 64 into the interior of the cavity 56 divides the cavity 56 into a first cavity section 58 and a second cavity section 60. It will be appreciated that the use of the bulkhead 64 to divide the cavity 56 into the first cavity section 58 and the second cavity section 60 allows separate column structures to be formed simultaneously within the apparatus 10 on either side of the bulkhead 64. It will be further appreciated that the placement of the bulkhead 64 may be varied along the length of the apparatus 10 to thereby correspondingly vary a dimension of the columns formed in the cavity 56. Further, the bulkhead 64 may be omitted all together to thereby allow the formation of a column along the full length of the cavity 56. Further, as can be observed in FIG. 4, the projection member 52 and the projection member 54 extend inwardly into the interior of the cavity 56 to form the slots in a column formed in the cavity 56 as discussed above.

Referring now to FIG. 5, where like reference numerals indicate like components, there is depicted a cross-sectional view of the apparatus 10 taken along the section A-A indicated in FIG. 4. The posts 26 and 38 are disposed in a substantially vertical and parallel arrangement. The fastening device 34 disposed on the top of post 26 includes a lever 70 pivotally attached at one end to the top of the post 26. Coupled to the lever 70, proximate the end of the lever 70 attached to the top of the post 26, is a rod assembly 72. The rod assembly 72 includes a linkage 74 to the lever 70, a shaft portion 76, and a ring portion 78.

The lever 70 may pivotally rotate in the directions indicated by the double arrows indicated by the reference numeral 80. The rotation of the lever 70 causes the rod assembly 72 to move in a generally linear direction as shown by the double arrows indicated with the reference numeral 82. The ring portion 78 of the rod assembly 72 is configured and adapted to engage the fastening device 46 on the top of post 38. As the lever 70 is moved downwards, the inner portion of the ring portion 78 engages the side walls of the fastening device 46. The side walls may be concave to further enhance the engagement between the ring portion 78 and the fastening device 46.

As discussed above, the base member 12 includes a lowermost portion 14. The lowermost portion 14 includes a bottom surface for engaging a surface onto which the apparatus 10 is placed. The width of the lowermost portion 14 should be sufficient to provide the necessary stability to the apparatus 10. Extending upwardly from the lowermost portion 14 to a top plate 86 is a wall 84. Extending downwardly from the top plate 86 are flanges 88 and 90.

Extending inwardly from the bottom portions of the posts 26 and 38 are flanges 92 and 94, respectively. The flanges 92 and 94 are pivotally mounted to flanges 88 and 90, respectively. This may be done by inserting a shafted member, such as a bolt, through each of bores 96 and 98 which pass through their respective flanges. The bolts may be secured in place with a nut or pin. The pivotal engagement between the side members 20 and 22 and the base member 12 allow the side members 20 and 22 to be operable between a ready-to-use position and a release position. The benefits of this feature have been previously noted above.

Base member 12 also includes a liner 11 positioned on top of top plate 86. Liner 11 can be either fixed or removably mounted on top plate 86. Liner 86 can also be integral with top plate 86. In one embodiment, liner 11 is comprised of a flexible polymeric material. Liner 11 can also comprise a strip of wood, such as plywood, or some other structural material on which a layer of flexible polymeric material is applied. Other materials can also be used. Liner 11 includes a forming surface 13 on which concrete is poured when forming a column within apparatus 10. Forming surface 13 can be smooth so as to form a complementary smooth finished surface on the column. Alternatively, forming surface 13 can have a texture formed thereon so that a complementary texture is formed on the column as the concrete is poured onto forming surface 13. The texture can be of any desired form such as representing brick, stone, or any other design or configuration.

Forming surface 13 of liner 11 includes a middle portion 28 and two end portions 30 and 32 and terminates at opposing edges. The middle portion 28 of the forming surface 13 is substantially flat while the end portions 30 and 32 of the forming surface 13 slope upwardly from the middle portion 28 as they approach the edges of the surface 13. It will be appreciated that the shape of the end portions 30 and 32 of the forming surface 13 imparts beveled corners onto a column formed in the cavity 56. The edges of the forming surface 13 abut against the inner surfaces 48 and 50 of the side members 20 and 22, respectively. The sloping of end portions 30 and 32 also helps effect a seal against inner surfaces 48 and 50. Above each of the projection members 52 and 54 of the inner surfaces 48 and 50, respectively, the inner surfaces 48 and 50 slope inwardly. This inward slope of each of the inner surfaces 48 and 50 above the projection members 52 and 54, respectively, also impart a beveled corner onto a column formed in the cavity 56 similar to the end portions 30 and 32 of the forming surface 13.

The inner surfaces 48 and 50 may each be formed from a thin sheet of metal sufficient in strength to carry out the functionality described herein of the inner surfaces 48 and 50. The sheets of metal may be bent to form the projection members 52 and 54 and the inward slopes on the top portions of the inner surfaces 48 and 50. The sheets of metal forming the inner surfaces 48 and 50 may be attached to the side members 20 and 22, respectively, through any number of techniques including the use of fastening devices, such as bolts, or the use of welding. The inner surfaces 48 and 50 may be replaceable with other surfaces of different configurations.

The end member 18 serves to form an end of a column formed in the cavity. Alternatively, a bulkhead similar in configuration to bulkhead 64 may be placed in an abutting relationship to the end member 18.

The top support member 100, the bottom support member 102 and the stiffener 108 of the side member 20 provide support for the post 26. Likewise, the top support member 104, the bottom support member 106 and the stiffener 110 of the side member 22 provide support for the post 38. It will be noted, that the uppermost portions 24 and 36 are the tops of top support members 100 and 104, respectively.

Referring now to FIG. 6, where like reference numerals indicate like components, there is depicted a cross-sectional view of the apparatus 10 taken along the section B-B indicated in FIG. 4. In this view, posts 112 and 114 are seen to extend downward from the top support member 100 and the top support member 104, respectively, to and past the bottom support member 102 and the bottom support member 106, respectively. Disposed on the lowermost portions of posts 112 and 114 are flanges 92 and 94, respectively. The flanges 92 and 94 in conjunction with flanges 88 and 90, respectively, form a pivotal coupling of the side members 20 and 22, respectively, to the base member 12. As before, this may be done by inserting a shafted member, such as a bolt, through each of bores 96 and 98 which pass through their respective flanges. The bolts may be secured in place with a nut or pin. The pivotal engagement between the side members 20 and 22 and the base member 12 allow the side members 20 and 22 to be operable between a ready-to-use position and a release position.

The bulkhead 64 is shown in the cavity 56 and abuts against the forming surface 13 of the base member 12 and the inner surfaces 48 and 50, including the projection members 52 and 54. The stiffener 108 extends from the top support member 100 to the bottom support member 102. Likewise, the stiffener 110 extends from the top support member 104 to the bottom support member 106.

Referring now to FIG. 7, there is depicted a cross-sectional view of the apparatus 10 taken along the section C-C indicated in FIG. 4, where like reference numerals indicate like components.

Referring now to FIG. 8, there is depicted a top view of another apparatus, generally indicated at 130, pursuant to another embodiment of the present disclosure. It will be appreciated that the apparatus 130 has the same exploded view as the apparatus 10 depicted in FIG. 1 except for the differences noted herein. The apparatus 130 includes a base member 132 having a liner 111 with a forming surface 133. Liner 111, as with other liners discussed herein, can be formed from the same materials and have the same texturing as discussed above with regard to liner 11. The base member 132 further includes a first end member 136 and a second end member 138. Pivotally attached on opposing sides of the base member 132 are a side member 140 and a side member 142.

Extending from an uppermost portion 144 of the side member 140 are posts 146. Disposed on the top of each of the posts 146 is a fastening device 154. Extending from an uppermost portion 156 of the side member 142 are posts 158. Disposed to the top of each of the posts 158 is a fastening device 166. Extending inwardly from the side member 140 is a projection member 172. Extending upwardly from the forming surface 133 of the base member 132 is a projection member 174.

It will be appreciated that the forming surface 133 of the base member 132, the side member 140 and the side member 142, and the first end member 136 and the second end member 138, together define a cavity 176. Also, the side member 140 and the side member 142 are operable between a ready-to-use position and a release position similar to apparatus 10 described above, but not explicitly shown herein. That is, the side member 140 and the side member 142 are pivotally engaged to the base member 132 such that they may open and close.

Referring now to FIG. 9, there is depicted a cross-sectional view of the apparatus 130 taken along the section D-D indicated in FIG. 8. The posts 146 and 158 are disposed in a substantially vertical arrangement and parallel arrangement. The fastening device 154 disposed on the top of post 146 includes a lever 190 pivotally attached at one end to the top of the post 146. Coupled to the lever 190, proximate the end of the lever 190 attached to the top of the post 146, is a rod assembly 192. The rod assembly 192 includes a linkage 194 to the lever 190, a shaft portion 196, and a ring portion 198.

The lever 190 may pivotally rotate in the directions indicated by the double arrows indicted by the reference numeral 200. The rotation of the lever 190 causes the rod assembly 192 to move in a generally linear direction as shown by the double arrows indicated with the reference numeral 202. The ring portion 198 of the rod assembly 192 is configured and adapted to engage the fastening device 166 on the top of post 158. As the lever 190 is moved downwards, the inner portion of the ring portion 198 engages the side walls of the fastening device 166. The side walls may be concave to further enhance the engagement between the ring portion 198 and the fastening device 166.

The base member 132 includes a lowermost portion 134. The lowermost portion 134 includes a bottom surface for engaging a surface onto which the apparatus 130 is placed. The width of the lowermost portion 134 should be sufficient to provide the necessary stability to the apparatus 130. Extending upwardly from the lowermost portion 134 to a top plate 206 is a wall 204. Extending downwardly from the top plate 206 are flanges 208 and 210.

Extending inwardly from the bottom portions of the posts 146 and 158 are flanges 212 and 214, respectively. The flanges 212 and 214 are pivotally mounted to flanges 208 and 210, respectively. This may be done by inserting a shafted member, such as a bolt, through each of bores 216 and 218 which pass through their respective flanges. The bolts may be secured in place with a nut or pin. The pivotal engagement between the side members 140 and 142 and the base member 132 allow the side members 140 and 142 to be operable between a ready-to-use position and a release position. The benefits of this feature have been previously noted above.

The forming surface 133 of the liner 111 includes a middle portion 148 and two end portions 150 and 152. As can be observed in FIG. 9, the middle portion 148 is substantially flat while the end portions 150 and 152 slope upwardly from the middle portion 148 as they approach the edges of the forming surface 133. It will be appreciated that the shape of the end portions 150 and 152 of the forming surface 133 imparts beveled corners onto a column formed in the cavity 176. The edges of the forming surface 133 abut against the inner surfaces 168 and 170 of the side members 140 and 142, respectively.

Coupled to the middle portion of the forming surface 133 is the projection member 174. The projection member 174 includes two side walls and a top wall that extends from the topmost portions of the side walls. The projection member 174 may be secured using fasteners as seen in FIG. 9. Thus, it will be understood that the projection member 174 is removable from the forming surface 133.

A topmost portion of the inner surfaces 168 and 170 slope inwardly. This inward slope of each of the inner surfaces 168 and 170 imparts a beveled corner onto a column formed in the cavity 176. As before, the inner surfaces 168 and 170 may be formed from a thin sheet of metal. In regard to the inner surface 168, the sheet of metal may be bent to form the projection members 172. In regard to inner surface 170, the sheet of metal may be kept substantially flat. The sheets of metal forming the inner surfaces 168 and 170 may be attached to the side members 140 and 142, respectively, through any number of techniques including the use of fastening devices, such as bolts, or the use of welding.

As can be further observed, the side member 140 includes a top support member 220 and a bottom support member 222. A stiffener 228 extends from the top support member 220 to the bottom support member 222. Likewise, the side member 142 includes a top support member 224 and a bottom support member 226. A stiffener 230 extends from the top support member 224 to the bottom support member 226.

Referring now to FIG. 10, where like reference numerals indicate like components, there is depicted a cross-sectional view of the apparatus 130 taken along the section E-E indicated in FIG. 8. In this view, posts 232 and 234 are seen to extend downward from the top support member 220 and the top support member 224, respectively, to and past the bottom support member 222 and the bottom support member 226, respectively. Disposed on the lowermost portions of posts 232 and 234 are flanges 212 and 214, respectively. The flanges 212 and 214 in conjunction with flanges 208 and 210, respectively, form a pivotal coupling of the side members 140 and 142, respectively, to the base member 132. As before, this may be done by inserting a shafted member, such as a bolt, through each of bores 216 and 218 which pass through their respective flanges. The bolts may be secured in place with a nut or pin. The pivotal engagement between the side members 140 and 142 and the base member 132 allow the side members 140 and 142 to be operable between a ready-to-use position and a release position. A stiffener 228 extends from the top support member 220 to the bottom support member 222. Likewise, a stiffener 230 extends from the top support member 224 to the bottom support member 226.

Referring now to FIG. 11, there is depicted a cross-sectional view of the apparatus 130 taken along the section F-F indicated in FIG. 8, where like reference numerals indicate like components. However, in contrast to prior figures of this embodiment, it is appreciated that a liner 171 can be secured on inner surface 170. Again, liner 171 can be comprised of a polymeric material having a forming surface 173 with a desired texture formed thereon. It is understood that in each of the different embodiments, liners having a textured or finished surface can be mounted on any desired surface of apparatus 10 so as to impart the textured or finished surface to the finished column.

Referring now to FIG. 12, there is depicted a top view of another apparatus, generally indicated at 250, pursuant to another embodiment of the present disclosure. It will be appreciated that the apparatus 250 has the same exploded view as the apparatus 10 depicted in FIG. 1 except for the differences noted herein. The apparatus 250 includes a base member 252 having a liner 255 with a forming surface 253. The base member 252 further includes a first end member 256 and a second end member 258. Pivotally attached to the base member 252 are a side member 260 and a side member 262.

Extending from an uppermost portion 264 of the side member 260 are posts 266. Disposed on the top of each of the posts 266 is a fastening device 274. Extending from an uppermost portion 276 of the side member 262 are posts 278. Disposed to the top of each of the posts 278 is a fastening device 286. Extending inwardly from the side member 260 is a projection member 292. Extending inwardly from the side member 262 is a projection member 294.

It will be appreciated that the forming surface 253 of the base member 252, the side member 260 and the side member 262, and the first end member 256 and the second end member 258, together define a cavity 296. Also, the side member 260 and the side member 262 are operable between a ready-to-use position and a release position similar to apparatus 10 described above. That is, the side member 260 and the side member 262 are pivotally engaged to the base member 252 such that they may open and close.

Referring now to FIG. 13, there is depicted a cross-sectional view of the apparatus 250 taken along the section G-G indicated in FIG. 12. An upper portion of the posts 266 and 278 are disposed in a substantially non-vertical arrangement. That is, the posts 266 and 278 slant inwardly towards the cavity 296. The slanted upper portion of the posts 266 and 278 cause the walls of a column formed in the apparatus 250 to be non-parallel.

The fastening device 274 disposed on the top of post 266 includes a lever 310 pivotally attached at one end to the top of the post 266. Coupled to the lever 310, proximate the end of the lever 310 attached to the top of the post 266, is a rod assembly 312. The rod assembly 312 includes a linkage 314 to the lever 310, a shaft portion 316, and a ring portion 318.

The lever 310 may pivotally rotate in the directions indicated by the double arrows indicted by the reference numeral 320. The rotation of the lever 310 causes the rod assembly 312 to move in a generally linear direction as shown by the double arrows indicated with the reference numeral 322. The ring portion 318 of the rod assembly 312 is configured and adapted to engage the fastening device 286 on the top of post 278. As the lever 310 is moved downwards and locked into place, the inner portion of the ring portion 318 engages the side walls of the fastening device 286. The side walls may be concave to further enhance the engagement between the ring portion 318 and the fastening device 286.

The base member 252 includes a lowermost portion 254. The lowermost portion 254 includes a bottom surface for engaging a surface onto which the apparatus 250 is placed. The width of the lowermost portion 254 should be sufficient to provide the necessary stability to the apparatus 250. Extending upwardly from the lowermost portion 254 to a top plate 326 is a wall 324. Extending downwardly from the top plate 326 are flanges 328 and 330.

Extending inwardly from the bottom portions of the posts 266 and 278 are flanges 332 and 334, respectively. The flanges 332 and 334 are pivotally mounted to flanges 328 and 330, respectively. This may be done by inserting a shafted member, such as a bolt, through each of bores 336 and 338 which pass through their respective flanges. The bolts may be secured in place with a nut or pin. The pivotal engagement between the side members 260 and 262 and the base member 252 allow the side members 260 and 262 to be operable between a ready-to-use position and a release position. The benefits of this feature have been previously noted above.

The forming surface 253 of the liner 255 includes a middle portion 268 and a pair of first sloped portions 269 and 270 and a pair of second sloped portions 271 and 272. The forming surface 253 may terminate at edges. As can be observed in FIG. 13, the middle portion 268 is substantially flat while the first sloped portions 269 and 270 slope upwardly from the middle portion. The second sloped portions 271 and 272 slope upwardly from the first sloped portions 269 and 270. The first sloped portions 269 and 270 may have a slope of about 20 to 30 degrees while the second sloped portions 271 and 272 may have a slope of about 65 to 75 degrees. It will be appreciated that the slope of the first sloped portions 269 and 270 of the forming surface 253 impart a curvature onto a column formed in the cavity 296. It will be further appreciated that the slope of the second sloped portions 270 and 271 of the forming surface 253 impart beveled corners onto a column formed in the cavity 296. The edges of the forming surface 253 abut against the inner surfaces 288 and 290 of the side members 260 and 262, respectively.

A topmost portion of the inner surfaces 288 and 290 slope inwardly. This inward slope of each of the inner surfaces 288 and 290 imparts a beveled corner onto a column formed in the cavity 296. The inner surfaces 288 and 290 may be formed from a thin sheet of metal. The sheets of metal used to form the inner surface 288 and 290 may be bent to form the projection members 292 and 294. The sheets of metal forming the inner surfaces 288 and 290 may be attached to the side members 260 and 262, respectively, through any number of techniques including the use of fastening devices, such as bolts, or the use of welding.

As can be further observed, the side member 260 includes a top support member 340 and a bottom support member 342. A stiffener 348 extends from the top support member 340 to the bottom support member 342. Likewise, the side member 262 includes a top support member 344 and a bottom support member 346. A stiffener 350 extends from the top support member 344 to the bottom support member 346.

Referring now to FIG. 14, where like reference numerals indicate like components, there is depicted a cross-sectional view of the apparatus 250 taken along the section H-H indicated in FIG. 12. In this view, posts 352 and 354 are seen to extend downward from the top support member 340 and the top support member 344, respectively, to and past the bottom support member 342 and the bottom support member 346, respectively. It will be noted that the posts 352 and 354 extend approximately vertically upwards from their bottommost portions until the bottom support members 342 and 346, respectively. At this point, the posts 352 and 354 slant inwardly towards the cavity 296.

Disposed on the lowermost portions of posts 352 and 354 are flanges 332 and 334, respectively. The flanges 332 and 334 in conjunction with flanges 328 and 330, respectively, form a pivotal coupling of the side members 260 and 262, respectively, to the base member 252. As before, this may be done by inserting a shafted member, such as a bolt, through each of bores 336 and 338 which pass through their respective flanges. The bolts may be secured in place with a nut or pin. The pivotal engagement between the side members 260 and 262 and the base member 252 allow the side members 260 and 262 to be operable between a ready-to-use position and a release position. A stiffener 348 extends from the top support member 340 to the bottom support member 342. Likewise, a stiffener 350 extends from the top support member 344 to the bottom support member 346.

Referring now to FIG. 15, there is depicted a cross-sectional view of the apparatus 250 taken along the section I-I indicated in FIG. 12, where like reference numerals indicate like components.

It will be noted that in the embodiments described and referenced above, that one of the side members may be fixed in place while the other side member is movable with respect to a base member.

International patent application no. PCT/US2005/039009, which was filed internationally on Oct. 27, 2005, is hereby incorporated by reference in its entirety.

Those having ordinary skill in the relevant art will appreciate the advantages provided by the features of the present disclosure. For example, it is a feature of the present disclosure to provide an apparatus for forming pre-cast concrete columns for use in constructing physical and sound barriers. Another feature of the present disclosure is to provide such an apparatus with two opposing side members that are moveable between a ready-to-use configuration and a release position. It is a further feature of the present disclosure, in accordance with one aspect thereof, to provide a cavity with non-permanent bulkheads such that the dimensions of concrete columns formed in the cavity may be varied.

In the foregoing Detailed Description of the Disclosure, various features of the present disclosure are grouped together in a single embodiment for the purpose of streamlining the disclosure. This method of disclosure is not to be interpreted as reflecting an intention that the claimed disclosure requires more features than are expressly recited in each claim. Rather, as the following claims reflect, inventive aspects lie in less than all features of a single foregoing disclosed embodiment. Thus, the following claims are hereby incorporated into this Detailed Description of the Disclosure by this reference, with each claim standing on its own as a separate embodiment of the present disclosure.

It is to be understood that the above-described arrangements are only illustrative of the application of the principles of the present disclosure. Numerous modifications and alternative arrangements may be devised by those skilled in the art without departing from the spirit and scope of the present disclosure and the appended claims are intended to cover such modifications and arrangements. Thus, while the present disclosure has been shown in the drawings and described above with particularity and detail, it will be apparent to those of ordinary skill in the art that numerous modifications, including, but not limited to, variations in size, materials, shape, form, function and manner of operation, assembly and use may be made without departing from the principles and concepts set forth herein.

Claims

1. An apparatus for forming pre-cast concrete structures, said apparatus comprising:

a base member having a forming surface;

two opposing side members, at least one of the two opposing side members pivotally engaging the base member such that the at least one of the two opposing side members is operable between a ready-to-use position and a release position; and

two opposing end members;

wherein the forming surface of the base member, the two opposing side members and the two opposing end members together define a cavity for receiving poured concrete to thereby form at least one pre-cast concrete structure.

2. The apparatus of claim 1, further comprising at least one fastener, said at least one fastener operable to secure the at least one opposing side member in the ready-to-use position.

3. The apparatus of claim 1, wherein the cavity comprises a shape, wherein the shape of the cavity is in that of a column.

4. The apparatus of claim 1, wherein at least one of the two opposing side members comprises a projection member for forming a slot in the at least one pre-cast concrete structure.

5. The apparatus of claim 4, wherein each of the two opposing side members comprises a projection member for forming a slot in the at least one pre-cast concrete structure.

6. The apparatus of claim 1, further comprising at least one bulkhead that is variably positionable in the cavity to thereby vary a dimension of the at least one pre-cast concrete structure.

7. The apparatus of claim 1, further comprising at least one bulkhead that is variably positionable into the cavity to thereby divide the cavity into a first section and a second section, wherein a first pre-cast concrete structure may be formed in the first section of the cavity and a second pre-cast concrete structure may be formed in the second section of the cavity, and wherein the first pre-cast concrete structure and the second pre-cast concrete structure may be formed simultaneously in the first section and second sections, respectively.

8. The apparatus of claim 1, wherein the two opposing end members are fixedly attached to the base member.

9. The apparatus of claim 1, wherein at least one of the two opposing side members and the forming surface of the base member comprises a projection member for forming a slot in the pre-cast concrete structure.

10. The apparatus of claim 1, wherein the forming surface of the base member comprises a middle portion and two side portions, wherein the middle portion is substantially planar and the two side portions slant upwardly with respect to the middle portion.

11. The apparatus of claim 1, wherein both of the two opposing side members pivotally engage the base member such that each of them is operable between a ready-to-use position and a release position.

12. The apparatus of claim 1, wherein the base member comprises a plate having a liner positioned thereon, the liner being comprised of a polymeric material and having the forming surface formed thereon.

13. The apparatus of claim 12, wherein the forming surface on the liner has a texture formed thereon.

14. An apparatus for forming pre-cast concrete structures, said apparatus comprising:

a base member having a forming surface, said forming surface terminating at a first edge and a second edge; and

two opposing side members, the two opposing side members operable between a ready-to-use position and a release position with respect to the base member, each of the two opposing side members having an inner surface;

wherein the first edge of the forming surface engages one of the inner surfaces and the second edge of the forming surface engages the other inner surface when the two opposing side members are in the ready-to-use position.

15. The apparatus of claim 14, wherein each of the inner surfaces of the two opposing side members comprises a means for imparting a bevel onto a corner of a pre-cast concrete structure.

16. The apparatus of claim 14, wherein each of the two opposing side members are substantially parallel to each other in the ready-to-use position.

17. The apparatus of claim 14, wherein each of the two opposing side members are non-parallel to each other in the ready-to-use position.

18. The apparatus of claim 14, wherein each of the two opposing side members further comprises a plurality of spaced apart posts, each of the posts having a fastening device disposed on a topmost portion that is operable to lock the two opposing side members in the ready-to-use position.

19. The apparatus of claim 14, further comprising at least one fastening device for locking the two opposing side members in the ready-to-use position.

20. The apparatus of claim 14, further comprising a bulkhead insertable between the two opposing side members.

21. An apparatus for forming pre-cast concrete structures, said apparatus comprising:

a base member, said base member having a plurality of flanges;

two opposing side members, the two opposing side members operable between a ready-to-use position and a release position with respect to the base member;

each of the two opposing side members having a first group of posts, a second group of posts, a top lateral support member and a bottom lateral support member;

said first group of posts extending above the top lateral support member;

said first group of posts and second group of posts extending below the bottom lateral support member; and

a plurality of flanges disposed on the first group of posts and the second group of posts, said plurality of flanges disposed below the bottom lateral support member;

wherein said plurality of flanges disposed on the first group of posts and the second group of posts are pivotally coupled to the plurality of flanges of the base member.

22. The apparatus of claim 21, further comprising a wall extending upwardly from said lowermost portion to a top plate, wherein said plurality of flanges of the base member are grouped into a first group of flanges and a second group flanges, said first group of flanges disposed on a first side of said wall and said second group of flanges disposed on a second side of said wall.

23. The apparatus of claim 21, further comprising fastening devices disposed on a topmost portion of each of the first group of posts, said fastening devices operable to lock the two opposing side members in the ready-to-use position.

24. The apparatus of claim 21, wherein at least one of the two opposing side members comprises a projection member for forming a slot in a pre-cast concrete structure.

25. The apparatus of claim 21, wherein the base member comprises a plate having a liner positioned thereon, the liner being comprised of a polymeric material and having a forming surface formed thereon.

26. The apparatus of claim 21, further comprising a bulkhead movably disposed between the side members for varying a length of a pre-cast concrete structure.

27. The apparatus of claim 21, further comprising a first end member and a second end member, said first and second end members disposed on opposing ends of said base member.