WALL CONSTRUCTION SYSTEM
A construction system utilizes a plurality of pre-manufactured units to form a concrete wall. Structurally, each pre-manufactured unit includes a wallboard mounted to an insulation board. Specifically, each wallboard has a first surface and an opposite second surface parallel thereto. For each wallboard, the insulation board is mounted to the second surface of the wallboard and extends to a face substantially parallel to the surfaces. In addition to the pre-manufactured units, the system comprises a temporary backing frame constructed from commercially-available aluminum forms which establish a wall. Also, the system includes a plurality of ties for supporting the units at a desired distance from the backing frame to establish a cavity for receiving concrete to form the concrete wall. After the concrete wall is formed, the backing frame is removed and the pre-manufactured units remain bonded to the wall.
The present invention pertains generally to concrete wall constructions. More particularly, the present invention pertains to systems and methods for forming concrete walls with pre-manufactured units. The present invention is particularly, but not exclusively, useful as a wall forming system and method that results in concrete walls bonded to insulation board and finished with wallboards.
BACKGROUND OF THE INVENTIONTypically, interior and exterior concrete walls are constructed using temporary removable form members. These form members are often wooden, synthetic resin or metal. Generally, each wooden form member comprises plywood boards and bridges for interconnecting with adjacent boards. In order to assemble a concrete formwork, the reinforcing bridges of adjacent form members are usually fastened to each other with nails. When assembled, the formwork defines a cavity where the concrete wall will be formed. After the concrete wall is formed, the wooden formwork is removed from the concrete wall.
During construction of a wall, the concrete is poured into the cavity and sets. While setting, moisture from the concrete mix is absorbed by the wooden form member. Due to high water absorptivity of the wooden form member, the concrete loses an ideal water-cement ratio in its surface portion adjacent the wooden form member. As a result, the finished concrete's outer surface is roughened. Occasionally, the rough appearance of the concrete's outer surface leads to the conclusion that the concrete has defectively hardened. Therefore, to avoid this result, the wooden form member may be painted beforehand to reduce its water absorptivity. However, painted form members are high-priced and still may suffer from too much water absorptivity.
While synthetic resin form members do not suffer from water absorptivity like wooden forms, they are generally very heavy and difficult to work with. Further, they often fail to provide sufficient strength and are high-priced.
Also, metal form members suffer from working difficulties associated with great weight. In order to avoid such problems, metal forms are frequently made as thinly as possible. As a result, although the metal itself is relatively strong, the metal formwork has limited strength. Further, metal is prone to corrosion, oxidation and deformation as a result of use.
Regardless of the type of formwork used, the current practice is to assemble the formwork to create a cavity to receive poured concrete. After the concrete sets as a wall, the entire formwork is removed to leave the concrete wall.
In light of the above, it is an object of the present invention to provide a permanently positioned concrete wall forming system. More specifically, it is an object of the invention to provide a system that utilizes pre-manufactured units for forming concrete walls. Another object of the present invention is to provide a pre-manufactured unit comprising insulation board material mounted to a finished wall wallboard. Still another object of the present invention is to provide a concrete wall forming system that eliminates absorption of water from the concrete while the concrete sets. Another object of the present invention is to provide a system that utilizes pre-manufactured units in conjunction with commercially-available aluminum forms to form concrete walls. Yet another object of the present invention is to provide a concrete wall forming system and method that is easy to implement, is simple to use, and is comparatively cost effective.
SUMMARY OF THE INVENTIONIn accordance with the present invention, a construction system is provided for forming concrete walls. Structurally, the construction system includes a plurality of pre-manufactured units. These pre-manufactured units are used to erect a boundary for one side of the concrete wall, while a removable backing frame erected from commercially-available aluminum forms bounds the opposite side of the concrete wall. After the concrete sets into the concrete wall, the backing frame is removed and the pre-manufactured units remain bonded to the concrete wall.
For the system, each unit defines an axis and comprises a wallboard and an insulation board. Further, each wallboard includes an exterior surface and a parallel opposite surface. Also, the insulation board is mounted to the opposite surface of the wallboard and extends to a face that is parallel to the surfaces.
As noted, the system further includes a temporary backing frame that has a wall distanced from the face of the insulation board. Also, flat ties are provided for supporting the units at a desired distance from the backing frame. As a result, a formwork defining a cavity between the units and the backing frame is established for receiving concrete. During formation of the concrete wall, the face of the insulation board and the wall of the backing frame bound the concrete.
After formation of the concrete wall, the backing frame is removed. However, the pre-manufactured units are permanently bonded to the concrete wall and form part of the finished wall. Because the pre-manufactured units bound only one side of the concrete wall in the present invention, the need for the aluminum forms of the backing frame during wall construction is reduced by half over current practices.
The novel features of this invention, as well as the invention itself, both as to its structure and its operation, will be best understood from the accompanying drawings, taken in conjunction with the accompanying description, in which similar reference characters refer to similar parts, and in which:
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As shown, each unit 12 defines an axis 18. Further, the wallboard 14 includes a planar exterior surface 20 that is substantially parallel to the axis 18. Likewise, the wallboard 14 forms a planar opposite surface 22 that is substantially parallel to the exterior surface 20. As shown, the insulation board 16 is mounted to the opposite surface 22 of the wallboard 14 and extends to a face 24 that is substantially parallel to the surfaces 20, 22.
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In order to interconnect the units 12 to the backing frame 26, a flat tie 84 is provided at multiple positions along the interface 86 between adjacent units 12. Generally, commercially-available backing frames 26 include sections that are three feet by eight or nine feet. Further, five to six flat ties 84 are generally used at each interface 86 between adjacent units 12.
As shown, the flat tie 84 has a first end 88 at the wallboard 14 and a second end 90 at the backing frame 26. Further, a hole 92 is provided at each end 88, 90 of the tie 84. Because the unit 12 lacks sufficient strength to hold the tie 84 directly, a brace 94 is positioned on the exterior surface 20 of the wallboard 14 of adjacent units 12 along both sides of the interface 86. For purposes of the present invention, the braces 94 may extend for the entire height of the units 12. As shown, each brace 94 is provided with a plurality of holes 96 for interconnection with the first end 88 of the flat tie 84. Specifically, a pin 98 is passed through the hole 92 in the first end 88 of the flat tie 84 and the selected holes 96 in the braces 94. Also a wedge 100 is used between the pin 98 and the unit 12 to hold the pin 98 in place.
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Alternatively, the flat tie 84b may have an end plate 112b as illustrated in
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While the particular Wall Construction System as herein shown and disclosed in detail is fully capable of obtaining the objects and providing the advantages herein before stated, it is to be understood that it is merely illustrative of the presently preferred embodiments of the invention and that no limitations are intended to the details of construction or design herein shown other than as described in the appended claims. It is noted that, while the dimensions represented in this description are merely illustrative and not limiting, they are intended to provide for ease of use with backing frames constructed from presently commercially-available aluminum forms.
Claims
1. A wall construction system comprising:
- a plurality of pre-manufactured units, with each unit including a wallboard having a first surface and an opposite second surface substantially parallel thereto, wherein each unit further comprises an insulation board mounted to the second surface of the wallboard and extending therefrom to a face substantially parallel to the second surface of the wallboard;
- a temporary backing frame distanced from the face of the insulation board to establish a cavity therebetween; and
- a plurality of ties for supporting the units at a desired distance from the backing frame for receiving concrete in the cavity to create a concrete wall, wherein the backing frame is removed after formation of the concrete wall, and wherein the pre-manufactured units are permanently bonded to the concrete wall.
2. A system as recited in claim 1 wherein the first surface of each wallboard forms at least one groove for receiving a stud for bracing during formation of the concrete wall, with said groove receiving utility features after the stud is removed.
3. A system as recited in claim 2 wherein each unit defines a conduit extending between grooves for receiving utility features.
4. A system as recited in claim 1 wherein each unit further comprises at least one stud parallel to the surfaces and positioned between the insulation board and the wallboard adjacent the second surface of the wallboard.
5. A system as recited in claim 1 further comprising a means for interconnecting adjacent units.
6. A system as recited in claim 5 wherein the interconnecting means includes a notch formed between the wallboard and the insulation board at a first end of each unit and a reciprocating protrusion formed by the insulation board at a second end of each unit.
7. A system as recited in claim 1 further comprising fasteners for mounting the wallboard to the insulation board.
8. A system as recited in claim 7 wherein each fastener includes a shaft having a proximal end and a distal end, with a head mounted to the proximal end, wherein the shaft passes through the wallboard and the insulation board with the head abutting the first surface of the wallboard, and wherein a receiver engages the distal end of the shaft to hold the wallboard and insulation board therebetween.
9. A system as recited in claim 1 wherein an interface is established between each pair of adjacent pre-manufactured units, wherein each tie is positioned at an interface with a first end at the wallboard of the pre-manufactured unit and a second end at the backing frame.
10. A system as recited in claim 9 wherein each tie includes an engineered weakness at the second end to provide for separation of the second end from the tie after the backing plate has been removed.
11. A system as recited in claim 9 further comprising a brace positioned on the first surface of each wallboard at the interface, with the braces on adjacent pre-manufactured units surrounding the respective tie for connection therewith.
12. A system as recited in claim 9 further comprising a bracket positioned on the first surfaces of adjacent pre-manufactured units and spanning the interface therebetween, with the bracket forming an aperture for positioning the respective tie in the interface.
13. A system as recited in claim 9 wherein each tie includes an end plate at the first end for mounting to adjacent pre-manufactured units.
14. A system as recited in claim 13 wherein the end plate of each tie is U-shaped and has a central portion and two legs, wherein the central portion abuts the first surface of the wallboard of each adjacent pre-manufactured unit, and wherein each leg is received within a slot formed in the wallboard of each adjacent pre-manufactured unit.
15. A system as recited in claim 1 further comprising a plurality of intermediate plates positioned at the face of the insulation board, wherein each intermediate plate includes an opening, with a respective tie passing through the opening, and wherein each intermediate plate includes means for engaging the insulation board.
16. A system as recited in claim 1 further comprising a tie sleeve defining a channel, wherein the tie sleeve is forced through the wallboard and into the insulation board at a desired position relative to the backing frame, and wherein a tie is positioned in the sleeve with a first end at the wallboard of the pre-manufactured unit and a second end at the backing frame.
17. A wall construction which comprises:
- a substantially flat wallboard having a first surface and a second surface, wherein the second surface is substantially parallel to the first surface;
- an insulation board mounted against the second surface of the wallboard;
- a concrete wall formed against the insulation board to position the insulation board between the wall board and the concrete wall, wherein the concrete wall is formed with an external surface substantially parallel to the first surface of the wall board; and
- a plurality of ties for holding the wall board against the insulation board and for positioning a backing frame at a distance from the insulation board during formation of the concrete wall, wherein the ties are subsequently used for anchoring the combination of wall board and insulation board against the concrete wall after removal of the backing frame.
18. A method for constructing a concrete wall comprising the steps of:
- arranging a plurality of pre-manufactured units, with each unit including a wallboard having a first surface and an opposite second surface substantially parallel thereto, wherein each unit further comprises an insulation board mounted to the second surface of the wallboard and extending to a face substantially parallel to the second surface for bounding concrete during formation of the concrete wall;
- erecting a temporary backing frame distanced from the face of the insulation board;
- supporting the units at a desired distance from the backing frame to establish a cavity therebetween;
- pouring concrete into the cavity and setting the concrete therein to construct the concrete wall; and
- removing the backing frame after formation of the concrete wall, wherein the pre-manufactured units are permanently bonded to the concrete wall.
19. A method as recited in claim 18 wherein the arranging step is accomplished by interconnecting adjacent pre-manufactured units.
20. A method as recited in claim 18 wherein the supporting step is accomplished by connecting each pre-manufactured unit to a first end of a respective tie and connecting the backing frame to a second end of the respective tie, and wherein the method further comprises the step of separating each second end from each tie after the backing frame is removed.
Type: Application
Filed: Jun 10, 2008
Publication Date: Dec 10, 2009
Inventors: Tamio Nojima (West Linn, OR), Susan L. Guinn (San Diego, CA)
Application Number: 12/136,685
International Classification: E04C 2/04 (20060101); E04G 21/02 (20060101); E04B 1/35 (20060101);