FORM WORK, SYSTEM, AND METHOD

Abstract

Disclosed herein is a form that includes a wall having a first surface and a second, opposing, material-receiving surface. The form further includes a slot extending substantially across the wall and between the first surface and the second surface. Furthermore, the form includes a first waler attached to the first side of the wall directly above or directly below the slot, the first waler including a plurality of openings spaced across the length of the first waler. The openings are each configured to receive an inserted wedge bolt.

Description

FIELD OF THE INVENTION

The subject matter disclosed herein relates generally to the erection of concrete walls. More particularly, this invention provides for a reusable concrete form for erecting concrete walls.

BACKGROUND OF THE INVENTION

In order to construct a concrete foundation, two opposing sets of forms must be erected in order to define a channel that retains a pour of concrete until the concrete hardens. Concrete forms are available in various sizes and configurations. These forms are typically oriented and joined together at a job site in order to create the various lengths, heights and angles needed to erect a concrete foundation. Joining together forms is typically a labor and time intensive task. Standard forms available in the industry typically come in lengths of only a couple feet. Thus, a great number of separate forms must be joined together to erect even the smallest of foundations.

Furthermore, the connection of these forms is accomplished using a plurality of flat ties that are held in position by wedge bolts. In a typical arrangement, a vertically oriented flat tie is inserted into the vertical slot that runs between two adjacent forms of a first set of forms. The flat tie is similarly inserted into the vertical slot that runs between two adjacent forms of an opposing second set of forms. A first wedge bolt is then horizontally inserted into an opening in each of the adjacent forms, and through an opening in the flat tie that is located there between. In order to ensure that the first wedge bolt does not come loose, a second wedge bolt is then inserted vertically through an opening in the first wedge bolt. However, it is sometimes the case that the vertically oriented tie is not aligned with the holes in adjacent forms. If concrete is poured between the first and second set of forms with one or more ties being unattached in this way, the sets of forms may fail. This could result in the necessity to redo the entire project.

Accordingly, an improved concrete form and system would be well received in the art.

BRIEF DESCRIPTION OF THE INVENTION

According to one aspect of the invention, a form comprises: a wall having a first surface and a second, opposing, material-receiving surface; a slot extending substantially across the wall and between the first surface and the second surface; and a first waler attached to the first side of the wall directly above or directly below the slot, the first waler including a plurality of openings spaced across the length of the first waler, wherein the openings are each configured to receive an inserted wedge bolt.

According to another aspect of the invention, a concrete form includes a wall having a rear surface and an opposing concrete receiving surface; a plurality of vertical studs attached to the rear surface of the wall and spaced across the width of the wall; a pair of walers attached to the rear surface of the wall and extending substantially between at least one pair of adjacent vertical studs; and a slot extending substantially horizontally across the wall, the slot located between each of the pairs of walers, the slot configured to receive a horizontally inserted flat tie.

According to yet another aspect of the invention, a concrete form system comprises: a first form, the first form including: a wall having a first surface and a second opposing concrete-receiving surface; a slot extending substantially across the wall; and a waler integrally attached to the first side of the wall adjacent the slot, the waler including a plurality of openings spaced across the length of the waler; a second form, the second form including: a wall having a first surface and a second opposing concrete-receiving surface; a slot extending substantially across the width of the wall; and a waler integrally attached to the first side of the wall directly adjacent the slot, the waler including a plurality of openings spaced across the length of the waler; wherein the first form and the second form are positioned such that the second opposing concrete-receiving surface of the first form and the second opposing concrete-receiving surface of the second form are facing each other; a flat tie having a first opening at a first end and a second opening at a second end, the flat tie inserted horizontally into the slots of both the first form and the second form; a first wedge bolt inserted vertically through both an opening of the waler of the first form and the first opening of the flat tie; and a second wedge bolt inserted vertically through both an opening in the waler of the second form and the second opening of the flat tie.

According to still another embodiment of the present invention, a method of erecting a foundation comprises: erecting a first concrete form; horizontally inserting a flat tie through a slot in the first concrete form; and vertically inserting a wedge bolt through each of: an opening in a top integral waler of the first concrete form; and an opening in the flat tie.

BRIEF DESCRIPTION OF THE DRAWINGS

The subject matter which is regarded as the invention is particularly pointed out and distinctly claimed in the claims at the conclusion of the specification. The foregoing and other features and advantages of the invention are apparent from the following detailed description taken in conjunction with the accompanying drawings in which:

FIG. 1 depicts a perspective view of a first side of a concrete form apparatus in accordance with one embodiment of the present invention;

FIG. 2 depicts a perspective view of a second opposing, material receiving side of the concrete form apparatus;

FIG. 3 depicts a perspective view of a longitudinal slot between two walers;

FIG. 4 depicts a cross sectional view of a longitudinal slot and waler tie location between two panels of the concrete form apparatus;

FIG. 5 depicts a perspective view of a longitudinal slot between two walers having an inserted tie and wedge bolt; and

FIG. 6 depicts a perspective view of a concrete form combination integrating prior-art concrete forms with the concrete form apparatus.

DETAILED DESCRIPTION OF THE INVENTION

A detailed description of the hereinafter described embodiments of the disclosed apparatus and method are presented herein by way of exemplification and not limitation with reference to the Figures.

Referring firstly to FIGS. 1 and 2, a concrete form 10 is shown in accordance with one embodiment of the present invention. The concrete form 10 may also be referred to as formwork or a form and may be useable with other hardenable flowable materials that would cure similar to concrete such as geopolymers, hemperete, mudcrete, papercrete and Portland cement. Furthermore, the hardenable flowable material may be poured in-situ or precast. The concrete form 10 includes a wall 12. FIG. 1 depicts a first surface 14, or rear surface, of the wall 12, while FIG. 2 depicts a second opposing concrete receiving surface 16 of the wall 12. The concrete form 10 includes three slots 18 that are spaced on the wall 12 that extend substantially across the wall 12. The slots 18 are generally vertically spaced and extend horizontally. The slots 18 may also be referred to as openings, cracks, cuts, gaps, holes, slits or divisions. The slots 18 are configured to receive a horizontally inserted flat tie 20 (shown in FIG. 3). A plurality of vertical studs 22 are attached and spaced horizontally across the rear surface 14 of the wall 12. Three pairs of walers 24a, 26a, 24b, 26b, 24c, 26c are vertically spaced on the wall 12 between each of the vertical studs 22. A top waler 24a, 24b, 24c is integrally attached to the rear surface 14 directly above each of the three slots 18, between each of the vertical studs 18, along the length of the wall 12. Likewise, a bottom waler 26a, 26b, 26c is integrally attached to the rear surface 14 directly beneath each of the three slots 18, between each of the vertical studs 22, along the length of the wall 12. A plurality of openings 28 are spaced across the length of each waler 24a, 26a, 24b, 26b, 24c, 26c that are each configured to receive a vertically inserted wedge bolt 30 (shown in FIG. 3). The opening 28 may also be referred to as holes, gaps, cavities, recesses, foramens or the like. The spacing, materials, and integrated assembly of the walers 24a, 26a, 24b, 26b, 24c, 26c vertical studs 22 and wall 12, described in further detail herein below, may provide for a concrete form 10 that is capable of having larger height and length dimensions than a typical prior art concrete form while retaining the structural integrity that is necessary to withstand the pouring of concrete for concrete foundations. The walers 24a, 26a, 24b, 26b, 24c, 26c are formed from angle iron, an L-bar, or other iron, wood, steel, composite or metallic bar, brake or cleat. Furthermore, the concrete form 10 may be structured to allow for a single wedge bolt 30 to secure each end of a flat tie 20 when erecting and securing two opposing concrete form sets. The wedge bolt 30 may also be a pin or screw. Still further, the spaced openings 28 may provide for ease of alignment of two opposing concrete form sets in a concrete form system. The spacing of the openings 28 may also provide for an increased number of options for inserting each of the flat ties 20 along the length of a concrete form set or wall. Still further, the present invention also allows the simple relocation of the flat ties 20 in order to miss embedded obstacles between the forms 10 such as reinforcing steel, windows, sleeves and the like.

The wall 12 of the concrete form 10 may comprise one or more panels 32, 34, 36, 38 that extend across the length of the concrete form 10. The slots 18 may be located between each of these panels 32, 34, 36, 38. While the embodiment depicted in the Figures includes three slots 18 located between four panels 32, 34, 36, 38 it should be understood that any number of slots 18 and panels are contemplated. In another embodiment, for example, a single slot may divide two panels. The number of slots 18 and panels 32, 34, 36, 38 may be determined by the required height of the concrete form 10 and the amount of support that is necessary to be provided by the ties 20 during the pouring of concrete. Furthermore, the panels 32, 34, 36, 38 may not have the same width. As shown, the bottom panel 32 may be narrower. The lower middle panel 34 may be wider than the bottom panel 32 but narrower than the upper middle panel 36. The top panel 38 may be similarly dimensioned than the lower middle panel 34. However, it should be understood that the invention is not limited to these panel sizes. Furthermore, the entire wall 12 may comprise a single panel having slots that extend less than the entire length of the wall 12.

The panels 32 of the wall 12 may be made from ½ inch thick form plywood. However, it should be understood that other materials and thicknesses are contemplated. For example, the wall 12 may also be made from a plastic, metallic, or composite material. Other durable and robust materials that are configured to withstand one or more pours of concrete may also be used for the panels 32 of the wall 12.

In the embodiment depicted in the Figures, the three slots 18 are shown extending across the width of the wall 12. The slots 18 may each have a thickness that is greater than the thickness of one of the flat ties 20 such that flat ties 20 may be inserted horizontally there through. For example, the slots 18 may each have a thickness between ¼ and ¾ of an inch. In one embodiment, the slots 18 have a thickness of 5/16 of an inch. This thickness may allow for self sealing of concrete. Thus, when concrete is poured between two opposing concrete form sets, only a minimum amount of concrete may escape between the slots 18 before a seal is formed. Other slot thicknesses are contemplated. For example, in the case that a thicker flat tie 20 is required, the slots 18 may have a greater thickness. However, the slots 18 should allow for the slideable insertion of a flat tie 20.

Five vertical studs 22 are shown integrally attached to the rear surface 14 of the wall 12. The studs 22 may also be referred to as a beam, brace, post, stanchion, column, bar, scantling or the like. The vertical studs 22 may be attached by any appropriate attachment means. For example, the vertical studs may be attached with weld, rivets, bolts, or a similar attachment means. Adhesives are also contemplated. The vertical studs 22 are shown extending from the bottom side to the top side of the wall 12. However, in other embodiments, the vertical studs 22 may not extend the entire height of the wall 12. The vertical studs 22 are shown spaced about two feet apart from each other. However, the spacing of the vertical studs 22 is not limited to this embodiment. The vertical studs 22 may be made of a robust and metallic material, such as iron, steel or stainless steel. However, other materials are contemplated. Whatever the material, the vertical studs 22 should help support the structure of the concrete form 10 during concrete pours.

Along each of the slots 18 between each of the vertical studs 22 is a pair of walers 24a, 26a that are integrally attached to the rear surface 14 of the wall 12. FIG. 3 more closely shows one of these pairs of walers 24a, 26a. The walers 24a, 26a may fully extend between two vertical studs 22. Thus, in the case that the vertical studs 22 are spaced about two feet apart, the walers 24a, 26a may be about two feet in length. In the embodiment depicted in the Figures, the integral walers 24a, 26a are L-beam angle irons having a first leg 40, 42 attached to the rear surface 14 of the wall 12 and a second leg 44, 46 extending perpendicular to the rear surface 14 of the wall 12. Those skilled in the art will understand that the term “angle iron” refers to the perpendicular shape rather than the particular material that walers 24a, 26a are made from. Similar to the vertical studs 22, the walers 24a, 26a may be made from iron, steel, stainless steel, or the like. Other materials are contemplated and may be apparent to those skilled in the art.

It should be understood that the flat ties 20 may be standard flat ties known to those skilled in the art. The flat ties may have a thickness of between ⅛-¼ inches. Flat ties may be manufactured in different lengths depending on the thickness of the concrete foundation to be erected. In other embodiments, the flat ties 20 may have rounded or tapered ends, and may be reusable. Furthermore, the flat ties 20 may include one or more holes 82 at each end through which a wedge bolt may be inserted. In an embodiment with more than one hole 82, the holes 82 may range in different thicknesses for differently sized wedge bolts. Flat ties may be fashioned from a metallic material such as steel, iron, or the like. Alternately, the flat ties 20 may be a fiberglass or a plastic flat tie. Preferably, the flat tie 20 should be inexpensive, as it may only be used once in most circumstances due to the fact that it is generally submerged in concrete that is poured during the erection of a concrete foundation.

The L-beam angle iron integral walers 24a, 26a may be mirrored in orientation about the slot 18, as shown in the Figures. The first leg 40 of the top waler 24a may extend away from the slot 18 and the first leg 42 of the bottom waler 26a may also extend away from the slot 18. The second legs 44, 46 of the walers 24a, 26a may be parallel and may be spaced apart with the same spacing as the slot 18. For example, the space between the second legs 44, 46 may be about 5/16 inches in the case that the slot thickness is about 5/16 inches. In other words, the length of the perpendicularly extending second legs 44, 46 may extend the width of the slot 18 through which the flat ties 20 may be inserted. It should be understood that other configurations of the walers 24a, 26a may be apparent to those skilled in the art. For example, the cross sectional shape of the walers 24a, 26a does not have to be an L. U-beams, I-beams, T-bars and the like are also contemplated. Furthermore, in another embodiment (not shown) a single waler may be attached next to each of the slots 18, above or below the slot 18. In this embodiment, the single waler may be more robust in order to sufficiently carry the load of the pair of walers 24a, 26a shown in the embodiment depicted in the Figures.

The walers 24a, 26a may include a plurality of rivet holes 48 in order to accommodate fastening to the rear surface 14 of the wall 12 by a plurality of rivets 50. The rivet holes may also be referred to as openings, gaps, bores, or the like. Likewise, the rivets may also be referred to as screws, bolts, fasteners, staples, studs or the like. As shown in the Figures, each of the two foot walers 24a, 26a may each include four rivets 50. However, other dimensions and number of rivet holes 48 and rivets 50 are contemplated. The walers 24a, 26a may also be attached with other attachment means such as bolts, welding, an adhesive, or the like. It may be preferable that the attachment means does not protrude into the concrete receiving surface 16 to assure a smoother concrete foundation. In one embodiment, the walers 24a, 26a are welded to the vertical studs 22 to enhance the structural integrity of the concrete form 10.

The openings 28 of the walers 24a, 26a may be located on the perpendicularly extending second legs 44, 46. In the embodiment shown in the Figures each waler 24a, 26a includes eleven openings 28 spaced about two inches apart. The openings 28 of the top waler 24a and the bottom waler 26a may be aligned such that a wedge bolt 30 is vertically insertable simultaneously into each of the walers 24a, 26a (as shown in FIGS. 4-5). The openings 28 may be circular in shape. Alternately, the openings 28 may be rectangular, oval, square or any other appropriate shape that will receive one of the wedge bolts 30. Furthermore, the openings 28 may be spaced closer or further together. Additionally, the openings 28 may or may not be spaced evenly along the length of the walers 24a, 26a.

Shown in FIGS. 4-5 is one of the slots 18 and the top and bottom walers 24a, 26a having a flat tie 20 horizontally inserted and securely connected with a single vertically inserted wedge bolt 30. The wedge bolt 30 may be vertically inserted through one of the openings 28 of the top waler 24a, then through an opening 46 at an end of the wedge bolt 30, then finally through one of the openings 28 of the bottom waler 26a. The wedge bolt 30 may be a standard wedge bolt known to those skilled in the art and having a pointed tip 52 at one end, and an expanded base 54. The wedge bolt 30 may also include an opening 55. This opening 55 may be receptive of another wedge bolt, for example, in the case of a prior art concrete form (shown in FIG. 6). As previously described, prior art concrete forms (shown in FIG. 6) require a first wedge bolt to be horizontally inserted and a second wedge bolt to be vertically inserted through the opening 55 of the first wedge bolt to secure the wedge bolts. The expanded base 54 has larger dimensions than the opening 28 such that the wedge bolt 30 cannot be fully inserted there through. The weight of the wedge bolt 30 retains it in the securely and vertically inserted position even if the flat tie 20 or the concrete form 10 is shaken, jiggled, wiggled, or otherwise moved during a concrete pouring process. Furthermore, the structure of the concrete form 10, and particularly the coordinating openings 28 of the walers 26a, 24a, allows a construction worker to look through each of the tie holes 82 from above to make sure that the wedge bolt 30 is properly inserted through each of the holes 82. This may help to prevent a situation where the concrete form system fails during pouring because one or more flat ties 20 are not secured sufficiently to bear the required load.

Referring back to FIG. 1, the concrete form 10 may also include a plurality of angle deflection braces 56. The angle deflection braces 56 may also be an L-beam angle iron, similar to the walers 24a, 24b, 24c, 26a, 26b, 26c. However, no openings are necessary to be manufactured in the angle deflection braces 56, as the angle deflection braces 56 are not required to receive a wedge bolt 30. Like the vertical studs 22 and the walers 24a, 24b, 24c, 26a, 26b, 26c, the angle deflection braces 56 may be made from a robust metallic material such as iron, steel, stainless steel or the like. However, other materials are contemplated. Furthermore, the angle deflection braces 56 may not be angle irons, but may instead be I-beams, U-beams, H-beams or the like.

The angle deflection braces 56 may be vertically spaced on the rear surface 14 of the wall 12 at regular intervals between the walers 24a, 24b, 24c, 26a, 26b, 26c Like the walers 24a, 24b, 24c, 26a, 26b, 26c, each of the angle deflection braces 56 may fully extend between two vertical studs 22. The angle deflection braces 56 may be attached with rivets and rivet holes, similar to the walers 24a, 24b, 24c, 26a, 26b, 26c. Alternately, the angle deflection braces 56 may be adhered, welded, or otherwise attached to the rear surface 14 of the wall. The angle deflection braces 56 may also be welded to the vertical studs 22 to enhance the structural integrity of the concrete form 10.

The concrete form 10 may also include end rails 58 running along the top, bottom and sides. The end rails 58 may be made from a robust metallic material such as iron, steel, stainless steel or the like. However, other materials are contemplated. Like the previous metallic components of the concrete form 10, the end rails 58 may be adhered, welded or otherwise attached to the rear surface 14 of the wall 12. Furthermore, the end rails 58 may be similarly attached to the vertical studs 22, the walers 24a, 24b, 24c, 26a, 26b, 26c, the angle deflection braces 56, and any additional structural components of the concrete form 10.

The end rails 58 may include openings 60 for attachment of the concrete form 10 to other concrete forms. To attach two of the concrete forms 10 next to each other, the wedge bolts 30 may used. Other attachment means are contemplated, however. For example, bolts, fasteners, screws, or other suitable attachment means may be utilized to secure two adjacent concrete forms 10. Furthermore, the openings 60 are located on the top and bottom end rails 58 in order to allow for stacking of the concrete forms 10 in the case that a higher concrete foundation is required.

Furthermore, the concrete form 10 may include cat walk anchors 62 having openings 64. The catwalk anchors 62 may be vertically oriented angle irons. However, other embodiments are contemplated. Whatever, the embodiment, the catwalk anchors 62 may be attached to the rear surface 14 of the wall 12 at an upper vertical location. The catwalk anchors 62 should be configured for attachment of a catwalk (not shown) for bracing the concrete form 10 during the pouring of concrete. For example, the catwalk (not shown) may be a metallic or wooden beam that is leaned against the ground and extends to the catwalk anchor 62 at a supporting angle to prevent the concrete form 10 from falling outwardly with respect to the concrete. Various embodiments of catwalk anchors 62 and corresponding catwalks will be apparent to those skilled in the art.

The concrete form 10 may further include a lifting bracket 66. The lifting bracket 66 is configured to allow the concrete form 10 to be machine handled by a crane, boom truck, excavator or the like. The lifting bracket includes an opening 68 through which a hook at the end of a crane rope or line may be inserted. The crane (not shown) may then lift the concrete form 10 into position. A crane, boom truck, excavator, or the like may be necessary because of the expansive size of the concrete form 10 compared to concrete forms of the prior art. However, the size of the concrete forms 10 of the present dimension allow for a faster and less labor intensive erection of a concrete form system than prior art systems. The lifting bracket 66 may also be attachable and detachable to the concrete form 10. This may be used, for example, in the case where stacking is required. In this case, the lifting bracket 66 may be removed in order to provide a flat surface to place a stacked concrete form 10 on a lower concrete form 10.

Still further, the concrete form 10 may include a plurality of tabs 70 with rivet holes 72, and a plurality of corner braces 74 with rivet holes 76. The tabs 70 and corner braces 74 may be located on the rear surface 14 of the wall 12. The tabs 70 may be a metallic component that is configured to help bind the end rails 58 to the rear surface 14 of the wall 10. In one embodiment, the tabs 70 are an integral component of the end rails 58. Alternately, the tabs 70 may be a separate component that is attachable to both the end rail 58 and the rear surface 14 of the wall 12. Whatever, the embodiment, these tabs 70 may be attached with rivets and may be periodically spaced along the length of the top and bottom end rails 58. As shown in the Figures, a single tab may be located at a midpoint between two adjacent vertical studs 22.

Likewise, the corner braces 74 may further be utilized to attach the end rails 58 and the vertical studs 22 to the rear surface 14 of the wall 12. The corner braces 74 are shown located at each corner where a vertical stud 22 or vertical end rail 58 meets the top and bottom end rails 58. The tabs 70 and corner braces 74 may or may not be necessary, and other supporting attachment mechanisms are contemplated. Additional attachments may also be necessary or desirable. Alternate attachments are also contemplated instead of the corner braces 74 and tabs 70.

The entire concrete form 10 may be about two and a half inches thick. In other words, the structure comprising the end rails 54, vertical studs 22, integral walers 24a, 24b, 24c, 26a, 26b, 26c, and angle deflection braces 52 may each be about two inches of the total thickness, while the wall 12 may comprise about a half inch of the total thickness. Because of this thin structure, an entire system of concrete forms 10 may be conveniently carried on a single truck bed. However, the concrete form is not limited to this thickness. For example, in the case that a more resilient structure is required the concrete form 10 may utilize larger structural components, resulting in thicker dimensions. Any concrete form 10 thickness is contemplated.

Referring now to FIG. 6, a perspective view of two concrete forms 10 are shown integrating prior art concrete forms 78 using twisted or bent flat ties 80. As previously described, the prior art concrete forms 78 are much shorter and do not include integral walers or horizontal slots at vertical intervals. Instead a flat tie must be inserted between each of the prior art concrete forms 78 at vertical intervals. The concrete forms 10 of the present invention may be incorporated in a system having prior art forms 78 by twisting flat ties 20 into the twisted flat ties 80. The flat ties may be twisted such that a first end of the flat tie 80 is oriented 90 degrees from a second end of the flat tie 80. Thus, the twisted flat tie 80 is horizontally insertable at one end into the concrete form 10 of the present invention, while simultaneously being vertically insertable at the other end between two prior art concrete forms 78. Alternately, the twisted flat tie 80 may be vertically insertable at the other end between one of the prior art concrete forms 78, and one of the concrete forms 10 of the present invention. Thus, the concrete form system of the present invention allows for greater versatility by structurally integrating with prior art forms during construction. Thus, the irregularly shaped or smaller corners of a concrete foundation may be easily fashioned from a concrete form system that substantially utilizes the concrete forms 10 of the present invention.

In another embodiment, a method of erecting a foundation is contemplated. The method of erecting a foundation may first comprise erecting a first concrete form, such as the concrete form 10. The method may include bracing the first concrete form with one or more catwalk anchors that runs from the top edge of the first concrete form to the ground. The form may then be unhooked. Next, an opposing form may be put into place in the same way as the first concrete form. The method further includes horizontally inserting a flat tie, such as the flat tie 20, through a slot in the concrete form, such as the slot 18. The horizontally inserted flat tie may be inserted through both the first concrete form and the opposing concrete form. The method further includes vertically inserting a wedge bolt, such as the wedge bolt 30, through an opening in a top integral waler of the first concrete form. The opening may be an opening such as the openings 28 described hereinabove, while the top integral waler may be a waler such as the top walers 24a, 24b, 24c described hereinabove. The method may further include inserting the wedge bolt through an opening in the flat tie. Still further, the wedge bolt may be inserted through an opening in a bottom waler of the first concrete form, such as one of the bottom walers 26a, 26b, 26c described hereinabove. The flat tie may also be inserted into an opening in the opposing vertical waler, in addition to one or more retaining wedge bolts through the opposingly inserted side of the flat tie. After this first tie is inserted into both concrete forms and secured, the opposing concrete form may be unhooked and the remainder of the flat ties may be put into place.

The method of erecting a foundation of claim 21 may further comprise twisting the flat tie so that a first end of the flat tie is oriented 90 degrees from a second end of the flat tie. In other words, the flat tie may be twisted into one of the twisted flat ties 80. In this embodiment, the method may comprise vertically inserting an end of the flat tie between a vertical slot located between two adjacent concrete forms that oppose the first concrete form.

Still further, the method may include pouring a hardenable material between the first concrete form and the opposing concrete form or forms. The hardenable material may be concrete, or another material such as as geopolymers, hemperete, mudcrete, papercrete and Portland cement.

The present invention offers several advantages over the prior art concrete forms, systems and methods. First, the integrated walers 24a, 24b, 24c, 26a, 26b, 26c provide a robust structure that keeps the walls 12 of the concrete form 10 straight when used for the erection of a plurality of structures. The structure of the forms 10 is also fairly thin so that more square feet of the forms 10 may be included on the bed of a truck for transportation between jobs. Furthermore, using the present forms, the form ends on the inside of the foundation need not align with the form ends on the outside of the foundation. This is because of the several openings 28 along the walers 24a, 24b, 24c, 26a, 26b, 26c through which the flat ties may be inserted. The versatility of tie locations of the present invention also make special fillers in many places, such as T walls and outside fillers unnecessary. Moreover, if more ties are necessary, the tie spacing may be easily decreased in the case of heavy concrete, or other hardenable material. Even further, the present invention reduces the number of wedge bolts needed at each connection by 50%. This is because a single wedge bolt may be inserted into each hole because it is vertically inserted. Still further, the concrete forms 10 are compatible with prior art forms 78, as described hereinabove.

Elements of the embodiments have been introduced with either the articles “a” or “an.” The articles are intended to mean that there are one or more of the elements. The terms “including” and “having” and their derivatives are intended to be inclusive such that there may be additional elements other than the elements listed. The conjunction “or” when used with a list of at least two terms is intended to mean any term or combination of terms. The terms “first” and “second” are used to distinguish elements and are not used to denote a particular order.

While the invention has been described in detail in connection with only a limited number of embodiments, it should be readily understood that the invention is not limited to such disclosed embodiments. Rather, the invention can be modified to incorporate any number of variations, alterations, substitutions or equivalent arrangements not heretofore described, but which are commensurate with the spirit and scope of the invention. Additionally, while various embodiments of the invention have been described, it is to be understood that aspects of the invention may include only some of the described embodiments. Accordingly, the invention is not to be seen as limited by the foregoing description, but is only limited by the scope of the appended claims.

Claims

1. A form comprising:

a wall having a first surface and a second, opposing, material-receiving surface;

a slot extending substantially across the wall and between the first surface and the second surface; and

a first waler attached to the first side of the wall directly above or directly below the slot, the first waler including a plurality of openings spaced across the length of the first waler, wherein the openings are each configured to receive an inserted wedge bolt.

2. The form of claim 1, wherein the openings in the first waler are spaced at about two inches apart from each other across the length of the first waler.

3. The form of claim 1, further comprising a second waler integrally attached to the first side of the wall directly on the other side of the slot from the first waler.

4. The form of claim 3, wherein the second waler further includes a plurality of openings spaced across the length of the second waler, and wherein the openings of the first waler and the second waler are aligned such that a wedge bolt is vertically insertable simultaneously into an opening of each of the first waler and the second waler.

5. The form of claim 1, wherein the slot has a thickness of about 5/16 inches.

6. The form of claim 1, further comprising a plurality of vertical studs attached to the first surface of the wall and spaced across the width of the wall, wherein a pair of walers are integrally attached to the first surface of the wall extending between each adjacent vertical steel stud.

7. The form of claim 6, wherein the vertical studs are spaced about two feet apart.

8. The form of claim 1, wherein the first waler is an L-beam having a first leg attached to the first surface of the wall, and a second leg extending perpendicular from the first surface of the wall, wherein the openings are located on the second leg.

9. The form of claim 1, further comprising a plurality of substantially parallel slots each extending substantially across the wall, the plurality of substantially parallel slots spaced vertically across the wall.

10. The form of claim 1, further comprising a cat walk anchor attached to the first surface of the wall.

11. A concrete form comprising:

a wall having a rear surface and an opposing concrete receiving surface;

a plurality of vertical studs attached to the rear surface of the wall and spaced across the width of the wall;

a pair of walers attached to the rear surface of the wall and extending substantially between at least one pair of adjacent vertical studs; and

a slot extending substantially horizontally across the wall, the slot located between each of the pairs of walers, the slot configured to receive a horizontally inserted flat tie.

12. The concrete form of claim 11, wherein the pair of walers each include a plurality of openings spaced across the length of the pair of walers, wherein the plurality of openings are aligned such that a wedge bolt is vertically insertable simultaneously into an opening of each of the pair of walers.

13. The concrete form of claim 12, wherein the plurality of openings are spaced about two inches apart from each other across the length of the plurality of walers.

14. The concrete form of claim 11, wherein the slot has a thickness of about 5/16 inches.

15. The concrete form of claim 11, wherein each of the plurality of vertical studs are horizontally spaced about two feet apart.

16. The concrete form of claim 12, wherein each of the walers of the pair of walers is an L-beam having a first leg attached to the rear surface of the wall, and a second leg extending perpendicular from the rear surface of the wall.

17. The concrete form of claim 16, wherein the plurality of openings are located on the second leg.

18. The concrete form of claim 16, wherein the first leg of a first waler of the pair of walers extends away from the slot, and wherein the first leg of a second waler of the pair of walers extends away from the slot.

19. The concrete form of claim 1, further comprising a plurality of substantially parallel slots each extending substantially across the wall, the plurality of substantially parallel slots spaced vertically across the wall, wherein a pair of walers extends along each of the plurality of substantially parallel slots.

20. A concrete form system comprising:

a first form, the first form including: a wall having a first surface and a second opposing concrete-receiving surface; a slot extending substantially across the wall; and a waler integrally attached to the first side of the wall adjacent the slot, the waler including a plurality of openings spaced across the length of the waler;

a second form, the second form including: a wall having a first surface and a second opposing concrete-receiving surface; a slot extending substantially across the width of the wall; and a waler integrally attached to the first side of the wall directly adjacent the slot, the waler including a plurality of openings spaced across the length of the waler;

wherein the first form and the second form are positioned such that the second opposing concrete-receiving surface of the first form and the second opposing concrete-receiving surface of the second form are facing each other;

a flat tie having a first opening at a first end and a second opening at a second end, the flat tie inserted horizontally into the slots of both the first form and the second form;

a first wedge bolt inserted vertically through both an opening of the waler of the first form and the first opening of the flat tie; and

a second wedge bolt inserted vertically through both an opening in the waler of the second form and the second opening of the flat tie.

21. A method of erecting a foundation comprising:

erecting a first concrete form;

horizontally inserting a flat tie through a slot in the first concrete form; and

vertically inserting a wedge bolt through each of: an opening in a top integral waler of the first concrete form; and an opening in the flat tie.

22. The method of erecting a foundation of claim 21, further comprising vertically inserting the wedge bolt through an opening in a bottom integral waler of the first concrete form.

23. The method of erecting a foundation of claim 21, further comprising erecting a second opposing concrete form and horizontally inserting the flat tie through a slot in the second opposing concrete form.

24. The method of erecting a foundation of claim 21, further comprising bending the flat tie so that a first end of the flat tie is oriented 90 degrees from a second end of the flat tie.

25. The method of erecting a foundation of claim 24, further comprising vertically inserting an end of the flat tie between a vertical slot, the vertical slot located between a third and a fourth adjacent concrete form.

26. The method of erecting a foundation of claim 23, further comprising pouring a hardenable material between the first concrete form and second concrete form.

27. The method of erecting a foundation of claim 25, further comprising pouring a hardenable material between the first concrete forms and the third and fourth concrete forms.