Plastic Stay-In-Place Concrete Forming System

Abstract

A plastic stay-in-place concrete forming system used for one or more sides of a multi-sided form and is based upon a form panel comprised of a thin plastic sheet reinforced on its interior side and capable of bonding to the concrete cast inside the form to create a solid composite structure. In one configuration the form panels are connected to internal bracing that connects to a second form side. The internal bracing is comprised of plastic connecting frames, lateral supports or individual connectors that may further reinforce the form panels or may be used solely for connecting purposes. The second side form may be any type of form including the form panel or a stud supporting foam board. The form panel may also be shaped to form two or more sides of an internally braced, multi-sided form. It may also be externally braced on one or more sides of a form.

Description

CROSS REFERENCE TO RELATED APPLICATIONS

This application is a continuation-in-part of application Ser. No. 12/927,379 filed Nov. 12, 2010 which claims the benefit of the filing date of provisional application Nos. 41/281,166 and 41/281.121 both filed Nov. 13, 2009. This application claims the benefit of copending application Ser. No. 13/374,839 filed Jan. 17, 2012 claiming the benefit of the filing date of provisional application Nos. 61/461,437 filed Jan. 18, 2011 and 61/462,463 filed Feb. 3, 2011. All the above cited applications are incorporated herein by reference.

BACKGROUND OF THE INVENTION

Prior Art

The following is a tabulation of some prior art that presently appears relevant:

U.S. Patents

Patent Number	Kind Code	Issue Date	Patentee
7,146,773	B2	2006 Dec. 12	Wilson
6,247,280	B1	2001 Jun. 19	Grinshpun et al.
6,167,669	B1	2001 Jan. 2	Lane
5,974,751		1999 Nov. 2	De Zen
5,729,944		1998 Mar. 24	De Zen
5,706,620		1998 Jan. 13	De Zen
5,092,093		1992 Mar. 3	Lu
4,876,054		1989 Oct. 24	Goodwin
3,238,684		1963 Jan. 17	Wood

U.S. Patent Application Publications

	Publication No.	Kind Code	Publ. Date	Applicant
	2004/0244321	A1	2004 Dec. 9	Dincel
	2004/0010994	A1	2004 Jan. 22	Piccone

Non-published U.S. Patent Applications

	Application No.	Filing Date	Applicant
	13/373,816	2011 Dec. 1	Kreizinger

Nonpatent Literature Documents

• Octaform Systems, Inc. brochure.
• P2Forms internet downloads.
• Conform internet download.

The invention is a plastic stay-in-place formwork system for cast-in-situ cementicious members such as columns, beams, walls and raised floor/ceilings. Concrete forms have historically been made of wood, metal or fiberglass and are typically removed after the concrete has hardened and reused. Recently foam forms (insulated concrete forms) and plastic stay-in-place forms have been developed which provide insulation and/or a concrete covering, labor savings and faster construction. These features have enabled single use, stay-in-place foam or plastic forms to be competitive with multiple use wood, metal or fiberglass forms.

The foam or insulated concrete forms have a foam exterior that must be covered to protect the foam from deterioration and as a fire safety precaution. The foam forms must also be covered to provide an aesthetically pleasing finished appearance and the foam provides an inadequate base for structural connections between concrete members or to facilitate cladding materials.

Plastic stay-in-place forms have been developed that use plastic sheets as the form panels and thereby provide a solid stay-in-place concrete covering that needs no protection, is fire safe and has a finished appearance. However, these plastic sheets that comprise the forms do not attach or otherwise bond to the concrete cast inside the form. The plastic forms only enclose the concrete and since all concrete shrinks as it cures the concrete pulls away from the plastic form which results in a loose and flimsy plastic covering. Such a loose or flimsy covering is not only unsightly; it also inhibits the attachment of cladding materials to the exterior of the plastic form.

As a concrete form, plastic forms are subjected to high levels of hydrostatic pressure and since plastic has a low modulus of elasticity the form walls must be strengthened to prevent deflection and deformation. To strengthen the form wall and compensate for the plastic material's relative weakness the plastic forms are made of thick plastic sheets and/or have closely spaced lateral connectors/webs which shortens the distance the plastic sheets span. These thicker forms and large number of lateral connectors/webs substantially increases the amount of plastic material needed for a sufficiently strong concrete form.

All of the prior art uses closed connectors/webs to connect the two sides of the form which makes it difficult to place steel reinforcement bars and impractical to use less expensive welded wire fabric sheets as a concrete reinforcement. As such, the horizontal rebars must be laterally fished through the openings of the connectors/webs which is difficult and time consuming, especially for the standard 20′ sections of rebar. Moreover, it is difficult to tie the lapped rebar inside these plastic forms as required by some building codes. Additionally, the closed connectors/webs prevent the use of less expensive welded wire fabric.

Plastic stay-in-place forms are also inflexible is controlling the deflection and deformation of the form that significantly varies from the top to the bottom. The hydrostatic pressure caused by the wet concrete is several times greater at the bottom of a form than at the top. None of the prior art provides any flexibility to strengthen the bottom with additional support or use less support near the top of the form. The support is uniform throughout the form which results in an inefficient and costly use of materials.

SUMMARY OF INVENTION

The invention relates to the construction and the formwork of cast-in-situ concrete members such as columns, beams, walls and floor/ceilings. The concrete forms herein disclosed are stay-in-place forms that are made primarily of plastic materials and intended to remain attached to the concrete for the life of the concrete member.

According to the invention, a unique lightweight plastic stay-in-place form is provided that attaches or otherwise permanently bonds to the wet concrete cast inside. When the concrete cures, the plastic form and the concrete become a solid, composite structure with the plastic covering firmly attached to the concrete.

In accordance with another configuration of the invention, the plastic forms are reinforced to enable the form to be covered by a thin plastic sheet and still withstand the weight and the hydrostatic pressure of the wet concrete cast within. The invention further provides a method by which the connectors used to connect the forms are spaced further apart so that fewer connectors are needed. The invention also provides for separate supports to stiffen and strengthen the form and the plastic sheet covering. These separate supports provide substantial flexibility in their placement so as to vary the relative strength of the form according to the hydrostatic pressures present from the bottom to the top of the form.

In accordance with another configuration of the invention, individual connectors are used to connect the forms for a more efficient use of materials. This also provides greater flexibility in locating the individual connectors throughout the forms. The individual connectors also create an open access to the inside of the form so as to simplify the placement of horizontal and vertical rebar and facilitate the use of welded wire fabric.

The invention also provides a plastic form with a finished exterior texture and appearance so that no other coating or cladding is necessary.

In accordance with another configuration a plastic form panel on the first side of a multi-sided form is connected to a second side form through internal bracing and the second side form may be different from the form panel.

In accordance with another configuration a second side form is comprised of a stud supporting foam board. The stud is connected to internal bracing extending from the form panel on first side and its flanges provide support to a stay-in-place form board.

In accordance with another configuration the plastic form panel is used as a stay-in-place form on one side of a multi-sided form.

The invention also discloses plastic forms used in conjunction with a method of reducing the concrete's hydrostatic pressure in forms. The reduced pressure enables the use of weaker and less expensive plastic forms.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is an exploded view of two form panels to be connected by a connecting frame.

FIG. 2 is a plan view of a closed form with two sides connected by a connecting frame.

FIG. 3 is a plan view of one form panel connected to a connecting frame and an exploded view of a second form panel to be connected to the connecting frame in accordance with another embodiment.

FIG. 4 is a perspective view of a form panel comprised of a plastic sheet reinforced with T ribs in accordance with another embodiment.

FIG. 5 is a perspective view of a form panel comprised of a plastic sheet reinforced with a grate in accordance with another embodiment.

FIG. 6 is a perspective view of a form panel comprised of a plastic sheet reinforced with a lattice in accordance with another embodiment.

FIG. 7A is a perspective view of a form panel comprised of a plastic sheet reinforced with T ribs and a lateral support positioned to be attached to the form panel in accordance with another embodiment.

FIG. 7B is a perspective view of FIG. 7A with the lateral support and a stud attached to the T ribs of the form panel in accordance with another embodiment.

FIG. 8A is a section view of a lateral support with a track on top in accordance with another embodiment.

FIG. 8B is a section view of an alternative lateral support with holes in accordance with another embodiment.

FIG. 9A is a section of a double insert, individual connector ready to be snapped into a grate attached to a form panel in accordance with another embodiment.

FIG. 9B is a section of an individual connector with a slider positioned to be attached to a track on a form panel in accordance with another embodiment.

FIG. 10A is an exploded view of a beam form in accordance with another embodiment.

FIG. 10B is an assembled beam form ready for rebar and connectors in accordance with another embodiment.

FIG. 10C is a plan and section view of a corner brace in accordance with another embodiment.

FIG. 10D is a section view of a fully assembled beam form with connectors, rebar and stirrups in accordance with another embodiment.

FIG. 11A is a section view of an inside corner brace with inserts in accordance with another embodiment.

FIG. 11B is a section view of an outside corner brace with inserts in accordance with another embodiment.

FIG. 12 is a section view of a beam form with rebar and stirrups in accordance with another embodiment.

FIG. 13A is a section view of a rebar tie connector positioned to be attached to a grated form panel in accordance with another embodiment.

FIG. 13B is a section view of a rebar tie connector with a slider positioned to be attached to a track on a form panel in accordance with another embodiment.

FIG. 14 is a perspective of a block wall being built with reinforced form panels, connecting frame and foam boards in accordance with another embodiment.

FIG. 15 is a perspective view of a column form being assembled with reinforced form panels and individual connectors with rebar and stirrups positioned inside the form in accordance with another embodiment.

FIG. 16 is a section view of an exterior wall and ceiling/floor comprised of the various components disclosed in the invention in accordance with another embodiment.

FIG. 17 is a plan view of a column form being assembled in accordance with another embodiment.

FIG. 18A is a section view of a T rib reinforced form panel being rolled into a circular shape to create a column form in accordance with another embodiment.

FIG. 18B is a section view of a circular column form with a connecting frame inserted over the T ribs in accordance with another embodiment.

FIG. 18C is a section view of a circular column form with a connecting frame used to position the stirrups in accordance with another embodiment.

FIG. 18D is a plan view of connecting frame used in FIG. 18C.

FIG. 19A is an exploded section view of a wall form being prepared for final assembly in accordance with another embodiment.

FIG. 19B is a plan view of FIG. 19A.

FIG. 20A is a section view of the assembled wall form of FIG. 19A.

FIG. 20B is a plan view of the assembled wall form of FIG. 19B.

FIG. 21 is an exploded plan view of a form ready for assembly in accordance with another embodiment.

FIG. 22 is a plan view of the assembled form of FIG. 21.

FIG. 23 is a section view of a stud in accordance with another embodiment.

FIG. 24A is a plan view of a stud with a track and a connector being positioned to attach to the stud in accordance with another embodiment.

FIG. 24B is a section view of FIG. 24A.

FIG. 25 is a plan view of an alternative design of the stud and a connector being readied to attach to the stud in accordance with another embodiment.

FIG. 26 is a plan view of an alternative design of the stud and a connector being readied to attach to the stud in accordance with another embodiment.

FIG. 27A is a section view of an open wall form into which vertical and horizontal rebar has been placed in accordance with another embodiment.

FIG. 27B is a section view of FIG. 27A showing the stud being slid over the individual connectors to lock them in position in accordance with another embodiment.

FIG. 28 is a plan view of FIG. 27B.

FIG. 29A is a section view of a closed wall form with foam board in accordance with another embodiment.

FIG. 29B is a plan view of FIG. 29A.

DETAILED DESCRIPTION ACCORDING TO THE EMBODIMENTS OF THE PRESENT INVENTION

This invention concerns the use of plastic form panels as stay-in-place forms that may be used to form at least one side of a multi-sided concrete form. The plastic form panels are made from a thin plastic sheet that may be pliable and is reinforced on one or both sides. The term pliable shall mean the plastic sheet can be at least partially rolled up to form at least a quarter circle. As such, the form panels referred to in the invention include the plastic sheet that is at least partially stiffened by reinforcement permanently fabricated onto one or both sides of the plastic sheet. The form panels may have a single sheet of plastic material of any thickness or it may have composite or layered sheets or strips, with or without filler and/or backing materials on the interior and/or the exterior side of the plastic sheet. Such a filler and/or backing material may be for insulation, to achieve fire ratings, to provide a finished appearance or for other reasons that make the form panel more functional in any respect. The form panels may also be of any size and shape and have a smooth or textured finish as well as having either a flat or shaped surface.

In one configuration a multi-sided form is comprised of a form panel on one or more sides of the form and the form panel has a means of connecting to internal bracing that has a means for connecting to a second side of the form. The means for connecting used throughout this disclosure is by any fastener, compound, shape or method that may be used to connect to plastic or connect two or more plastic parts together including snaps, inserts, sliders, tracks, slots, hangers, hooks, hitch, latch, lodge, ties, threads, embed, pressure, prongs, plug, couple, twisting, pins, rivets, clasp, locks, interlocking, molding, adhering, cohering, coatings, adhesives, fusing and welding to name a few. FIG. 1 shows form panels 1A and 1B connected together by a connecting frame 4, which is a horizontally oriented frame used to connect two vertically oriented form panels together. The means for connecting the connecting frame 4 to the form panels 1A and 1B is by inserting the snap inserts 6 into the grate 3 which is a protrusion 15 that reinforces the plastic sheet 2 and is fabricated onto the interior side of the plastic sheet 2 to comprise form panels 1A and 1B respectively in this configuration. FIG. 2 shows the first form panel 1A, as the first side of form 10, and a second form panel 1B, as the second side of form 10, and connected by the connecting frame 4 to create a form 10 into which a cementicious material is cast.

FIG. 3 shows an alternative means for connecting the connecting frame 4 to the form panel 1A and 1B by either snapping or sliding the connecting frame 4 into position on a rib 7 that is a protrusion 15 used to reinforce the plastic sheet 2 and has a round lip 5 attached that functions as a track 8 in this configuration. The lips 5 may be of any size and shape including circular or rectangular. The connecting frame 4 has a slider 9 that snaps or slides onto the track 8 created by the lip 5 that is attached to the rib 7 that is attached to the plastic sheet 2 to create form panels 1A and 1B in FIG. 3. Since the connecting frame 4 attaches perpendicularly to the ribs the combination of the ribs 7 and the connecting frame 4 provide the form panels 1A and 1B with a means for reinforcement in two directions. As such, FIGS. 1 to 3 all show a form panel with protrusions providing both reinforcement means and connecting means across the interior side of the plastic sheet.

Another embodiment of the plastic form is its ability to mechanically bond to the concrete and remain attached for the life of the concrete member. This is accomplished by fabricating protrusions 15 onto the interior side of the plastic sheet 2 and when concrete is placed against the interior side of the plastic sheet 2 it flows around or through the protrusions and bonds to them, and thereby to the form panel, during and/or after the concrete hardens. Such a bond may be achieved by becoming lodged, confined, embedded, develop friction or adhesion or otherwise be fastened together. For example, FIG. 4 shows a form panel 1 comprised of a plastic sheet 2 onto which T shaped ribs 12 have been extruded or otherwise fabricated and are protruding from the face of said plastic sheet 2 a distance that enables wet concrete to flow in and around the T ribs 12. When the concrete cures it will be lodged around the shape of the T rib 12 which will prevent the concrete from being pulled away from the T rib 12 and the plastic sheet 2. The shorter the span between the individual protrusions 15, the tighter the bond of the concrete to the form panel 1 and the plastic sheet 2. The protrusions and/or internal bracing may also be fabricated with opening 16 near the interior side of the plastic sheet to enable the concrete to fully surround at least a portion of the protrusion or internal bracing and thereby increase the concrete's effective depth.

FIG. 5 shows another example with a form panel 1 having a grate 3 that has a lip 5 on the end of some protruding members and the grated lip creates the mechanical bond between the plastic sheet 2 and the concrete that is cast inside the grate 3. The lip 5 may be attached to one or both of the cross members used to create the grate 3. As such, only some or part of the protrusion(s) must be capable of bonding to the concrete as may be necessary to obtain the desired bond. In FIG. 6 the form panel 1 is comprised of a lattice 14 fabricated onto the plastic sheet 2 as a means for reinforcement and to bond the form panel to the concrete. The grate 3 has cross members and therefore when either the grate 3 or the lattice 14 are fabricated onto the plastic sheet 2, they provide the form panel 1 with a means for reinforcement in two directions.

The protrusions 15 attached to the plastic sheet may be in any height, shape or design including rectangular, circular, irregular, indented, scratched, under cut or roughened as long as at least some or part of the protrusions have the ability to directly or indirectly bond to the concrete as or after it hardens. The protrusions 15 may also be solid or hollow and of a single or composite material and be relatively large in size such as foam boards. Another embodiment of the invention is for the plastic sheets 2 to provide a means for finishing the exterior side of the form panel and thereby provide a finished appearance to the concrete member. The means for finishing the exterior side of the form panel includes extruding the plastic sheet with a finished appearance, laminating a finished appearance onto the plastic sheet or fabricating a finished material onto the plastic sheet. In addition, the plastic sheet may be all or partially thickened to enable fasteners such as screws to attach to the plastic sheet so that wallboards or panels may be attached. The thickened area may be solid plastic or other material such as rubber, a hollowed area or filled with a filler material. Both the fabrication of a finished material onto the plastic sheet and the thickening of only part of the plastic sheet, such as parallel strips, may also reinforce the plastic sheet which in turn reinforces the form panel.

In another embodiment, the protrusions 15 fabricated onto the interior side of the plastic sheet may also provide a means for reinforcing the plastic sheet, and thereby the form panel, to withstand the hydrostatic and/or other pressures from the wet concrete or otherwise applied against the form. The protrusions 15, from the plastic sheet 2, (the ribs, grate and lattice, etc., in FIGS. 4, 5 and 6 respectively) or other reinforcement such as foam board act to stiffen the plastic sheet in one or more directions across the plastic sheet.

In some applications reinforcement in a single direction is necessary such as when a form panel is rolled and may be provided by parallel ribs or thickened strips. In other applications reinforcement in two or more directions is needed and the means for reinforcement may be by a crossed grate, lattice, a combination of protrusions and internal bracing or by other means as discussed below.

In those instances where the protrusions fabricated onto the plastic sheet provide reinforcement in a single direction, the form panel may be further reinforced by lateral supports perpendicular to the protrusions. FIGS. 7A and 7B shows a lateral support 30 that is slid onto T ribs 12 fabricated onto the plastic sheet 2. FIG. 7A shows the form panel 1 and the lateral support 30 separately. FIG. 7B shows the lateral supports 30 after they have been slid into the form panel 1 to stiffen the form panel 1 in the direction perpendicular to the T ribs 12 and thereby provides the form panel 1 with the means for reinforcement in two direction. The lateral supports 30 may totally enclose the T ribs 12 or only the rib's lip 5.

The lateral supports 30 may also have a means for connecting to a junction bar 31. In FIG. 7B, the lateral supports 30 have a slider 9 that is fabricated onto the lateral supports 30. The sliders 9 facilitate the placement of a junction bar 31 with tracks 8 that allow the junction bar 31 to slide through the sliders 9. In this configuration the junction bar 31 internally braces the form panel 1 and also provides an alternative means for connecting the form panel to other internal bracing. The junction bar 31 in FIG. 7B shows a double track, the first track 8A attaches to the lateral support 30 and the second track 8B attaches to a lateral support of a second form.

The lateral support 30 may be made with a track 8, as shown in FIG. 8A as a means for connecting to other internal bracing. Or the lateral support 30 may also be made with holes 32, as shown in FIG. 8B, to which an individual connector can snap into the holes as another means for connecting to other internal bracing. FIG. 8B also shows how the lateral support 30 may be used to connect to only the lip 5 and a small section of the supporting T rib 12.

The form panels 1 may be frameless around their perimeter, i.e. the plastic sheet perimeter, to enable various internal bracing to be slid onto tracks 8 or T ribs 12 that reinforce the plastic sheet 2. The frameless perimeter also allows the form panel to be folded, rolled or otherwise shaped and further facilitates joining form panels at angles to each other.

In another embodiment the form panels may be connected and held together by internal bracing. Internal bracing is used to build the form by connecting the sides and/or bottom of the form panels and by holding the form together during placement of the form and casting concrete inside the form. Internal bracing may also be used to facilitate and/or provide mechanical bonding the form panels to the concrete. Moreover, internal bracing may also provide lateral rigidity to the protrusions so that the form panel has a means for reinforcement in two or more direction, Internal bracing includes all bracing that supports the form panel from its interior side such as connecting frames, webs, rebar tie connectors, ties, braces, junction bars, lateral supports, prongs, inserts or individual connectors. Some internal bracing may connect directly to the form panel by attaching to the grate, ribs, lattice or other protrusion fabricated onto the plastic sheet. Other internal bracing may indirectly connect to the form panel by connecting to another internal brace that in turn connects to the form panel. Both the connecting means and the internal bracing shall be sufficiently rigid and/or secured and/or positioned to withstand the hydrostatic, vibratory and other pressures exerted inside the form during concrete placement. The internal braces may be individual pieces or may be fabricated onto other internal braces, the form panel or the studs.

The forms of this invention may be cast with any slump of concrete that have different amounts of hydrostatic pressure or they may be cast using a special technique that reduces the concrete's hydrostatic pressure. Applicant has copending applications No. 13/374,839 filed 17 Jan. 2012 entitled the Thixotropic Building System, incorporated by reference, wherein a method of reducing the hydrostatic pressure in concrete forms is described by using the thixotropic properties of low or no-slump concrete.

Thixotropy is a material property that describes a material as being in a solid or semi-solid state when at rest and becoming liquefied when agitated (vibrated). Thixotropy is a property of freshly mixed no-slump or low-slump concrete in that this type of concrete is in a semi-solid state, similar to moist, clumpy dirt, when at rest and becomes liquefied when vibrated. Since hydrostatic pressure is only present when a liquid state exists, limiting the amount of a liquid or semi-liquid concrete present at any one time in a form will limit the amount of hydrostatic pressure present in that form. Moreover, the liquefaction is temporary in that as soon as the vibration ceases, the concrete immediately reverts to its semi-solid state and stops exerting hydrostatic pressure. It is well known in the art that vibration causes the concrete to be consolidated and that concrete can be vibrated several times prior to setting up.

Therefore, the means for reducing hydrostatic pressure in forms is by using low or no-slump concrete and minimizing the amount of concrete being vibrated, and thereby liquefied, at any one time. Specifically, this is accomplished in column and wall forms and deep beam forms by casting one level (lift) of low or no-slump concrete at a time and then vibrating each level before the next level is cast. In those instances were cold joints are to be avoided, it is important to vibrate each subsequent level with the level immediately below. In order to ensure the concrete is sufficiently vibrated to acceptable consolidation, it may be necessary to set at least one side of the forms one level at a time and setting that level of forms after the preceding level has been cast. This enables the vibrator operator to visually observe from close range the vibration of each level, to ensure proper consolidation, before the next level of forms is fully set. Such observance is not possible into fully erected, tall and narrow forms several feet high and containing steel reinforcement.

FIGS. 9A and 9B are examples of means for connecting individual connectors 40 directly to the form panel's ribs, grate or track that are fabricated onto the interior side of the plastic sheet 2 to comprise the form panel 1 as shown in FIGS. 4 through 6. In FIG. 9A an individual connector 40 is fabricated with a double insert 41 that snaps into the lip 5 of a grate 3 that is fabricated onto the plastic sheet 2. Once the double insert 41 is attached to the grate 3, it is connected to the form panel 1 in sufficient strength to prevent pullout.

Also shown in FIG. 9A is a rebar bracket 42 and a gusset 48. The gusset 48 can be fabricated or otherwise attached to secure the individual connector 40 in a perpendicular position to the first form panel 1. By maintaining the individual connector 40 in a perpendicular position, it facilitates and simplifies the attachment of the connector to other internal braces or to the second form panel. The gusset 48 also strengthens the individual connector 40 from the pressure of the concrete being cast into the form.

FIG. 9B shows another means for connecting the individual connector 40 to the form panel 1 whereby a T shaped track 8 is fabricated onto or otherwise attached to the plastic sheet 2 and a slider 9 is attached to the end of the individual connector 40. When the tracks 8 are arranged in close proximity to one another, they act similar to the T ribs shown in FIG. 4 and provide a means of reinforcing the plastic sheet 2. In FIG. 9B the slider 9 simply slides onto one of the tracks 8 and the other tracks serve to reinforce the plastic sheet 2. One alternative embodiment enables the slider 9 to twist or snap onto or otherwise attach to the track 8.

The individual connectors 40 may have both ends the same or may be fabricated with different ends. Both the individual connectors 40 and the respective ends may be designed in a variety of ways through which a means for connecting to the form panel is accomplished. For example, the individual connectors may also have a means for connecting to other internal bracing such as lateral supports, connecting frames, ties, studs, junction bars or braces inside the form which are in turn connected to the form panels. Therefore the means for connecting the internal bracing to the form panels may be directly or indirectly through other internal bracing.

In one embodiment connecting frames 4 are used to connect two form panels together to construct a two sided form as shown in FIGS. 1 through 3. However, a connecting frame 4 may have more functions than to simply connect the form panels. A connecting frame 4 may also be used as a truss to stiffen and thereby provide a means for reinforcing the form panel. In FIG. 3, the connecting frame 4, as attached to the form panels 1A and 1B, substantially stiffens the form panels 1A and 1B in the direction parallel to the frame 4 and perpendicular to the ribs 7 that are fabricated onto the plastic sheet 2. Thereby when a connecting frame 4 is attached to the ribs 7, it provides the form panels 1A and 1B with the means for reinforcement in two directions. Connecting frames 4 may be of different sizes and shapes and may be used parallel or perpendicular or even diagonally to one another.

A multi-sided form can have two sides to form a wall, three sides to form a beam or four or more sides to form a column (to include an infinite number of sides to form a circular column). FIGS. 10A, 10B and 10C demonstrate the assembly of a three sided beam form using three individual form panels. In FIG. 10A the three sides of the beam form 20 are disassembled and the form panels 1A, 1B and 1C, are reinforced in one direction by ribs 7 with a round lip 5. The lateral supports 30 have holes 32 as a means for connecting to the individual connectors 40. The means for connecting the lateral supports 30 to the form panels 1A, 1B and 1C is with the slide 9 that fits over the lip 5. The means for connecting the corner braces 44 is by snapping them into the holes 32 in the lateral supports 30. As such form panels 1A, 1B and 1C each are comprised of a pliable plastic sheet with reinforcement means and connecting means arranged across the interior side of the plastic sheet 2 and each of the form panels is able to mechanically bond to concrete.

In FIG. 10B, the three sides of the beam form 20 have been assembled with the lateral supports 30 bracing each form panel on its interior side which reinforces them in a second direction, perpendicular to the ribs 7. Interlocking corners 47 provide additional internal bracing on the interior side of each form panel and a means for connecting to the interior side of the adjacent form panel. Corner braces 44 are additional internal bracing that connect to the interior side of two adjacent and perpendicular form sides and provide a means for connecting by snapping into the holes 32 of the lateral supports 30. As shown in FIG. 10C, the corner braces have a protruding knob 46 that snaps and locks into the holes 32 of the lateral supports 30.

Of course the three individual lateral supports in FIGS. 10A, 10B and 10D may alternatively have been combined into a single “U” shaped structure (not shown) as internal bracing to which the three form panels each attach.

The beam form 20 is now ready for the steel reinforcement which is placed inside the form 10. After the rebar 45 and stirrups 43 have been placed, the individual connectors 40 are snapped into the lateral supports 30 as the means for connecting the two form panels 1A and 1B together. FIG. 10D shows the form 10 ready for concrete with the rebar 45, stirrups 43 and the individual connectors 40 all in place. In this configuration each of the form panels 1A, 1B and 1C are connected to a second and a third side of the form 10.

When a grate is used to reinforce the plastic sheet and create a form panel, the cross members of the grate provide the form panel with a means for reinforcement in two directions and thereby a lateral support may not be needed. As such the individual connectors and corner braces attach directly to the grate. FIGS. 11A and 11B show the means for connecting inside and outside corner braces to a form panel with a grate and snap inserts 6.

In addition to being used to connect the form panels, the connectors may be used to position the concrete's reinforcement members such as the rebar and the stirrups. FIG. 12 shows a form 10 for a concrete beam wherein the individual connectors 40 connect to the form panel 1 and also connect to the steel stirrups 43 by snapping onto them. When the steel stirrups 43 are attached to the individual connectors 40, they become internal braces comprising a connecting frame that supports the form panels 1 from the pressure of the wet concrete cast inside the form 10. In essence the stirrups are used as a connecting frame to brace the form from the inside.

FIGS. 13A and 13B show two different types of rebar tie connectors 49 being attached to the form panels 1 and used as an internal bracing. Both rebar tie connectors 49 have a plastic or wire tie 33 on one end as a means for connecting to the rebar 45 while the second end of the rebar tie connector 49 has a means for connecting to the form panel 1. In this way the rebar 45 can be used as another type of internal bracing to support the form panel 1 from the concrete's pressure. The means for connecting the rebar tie connector 49 to the form panel 1 is by snapping, clipping or sliding onto one end to the form panel 1 while the second end is tied 33 or uses some type of fastening device to attach to the rebar 45 or stirrup.

The invention may be used in larger sizes such as 4′×8′ or larger form panels or for smaller form panels such as blocks or similar applications. FIG. 14 shows the invention used to build a wall using individual blocks made from the components disclosed herein.

A multi-sided form is shown in FIGS. 14 and 15 comprised of a block. In FIG. 14, the block 70 is two sided with form panels 1A and 1B each providing one side, although not in any particular order. In this configuration both form panels 1A and 1B are comprised of a thin, pliable plastic sheet 2 that has both reinforcement means and connecting means arranged across their respective interior sides. Form panel 1A is reinforced with ribs 7 that have a lip 5 to which the connecting frame 4 is attached. The connecting frame 4, in this configuration, provides both the lateral support (reinforcement means in a second direction) for the form panel 1A and the means for connection to form panel 1B. Form panel 1B is comprised of a thin plastic sheet 2 to which a foam board 65 is bonded to provide both reinforcement in multiple directions and insulation. (The foam used throughout this disclosure may be in board or panel form or may be sprayed or otherwise fabricated onto the plastic sheet.) In addition, form panel 1B has a track 8 fabricated onto its interior side that provides both reinforcement and a means for connecting to the connecting frame 4.

As a result form panels 1A and 1B are on two sides of form 10 and each has reinforcement and connection means arranged across their respective interior sides and are connected to internal bracing that connects to a second side of form 10, which in this configuration can be either form panel 1A or 1B.

The individual blocks 70 may be stacked with one block partially overlapping the other so as to provide some stability and to prevent leakage when the concrete is cast. The blocks slide over the vertical rebar 45 while the horizontal rebar is set in place as the blocks are laid. A wire raceway 60 may be attached to the inside of the form panel for each block in such a location that the raceway from block to block is continuous and extends the entire height or width of the wall.

FIG. 15 is another configuration that shows four sided individual blocks 70 that are stacked to construct a column. In FIG. 15, the blocks 70 are four individual form panels 1 for each of the four sides of the multi-sided form 10 and are locked together at their corners and reinforced with lateral supports 30. The form panels 1 are reinforced on their interior side in one direction with ribs fabricated onto the plastic sheet 2 and in a second direction with lateral supports attached to the ribs 7 and lips 5. Corner braces 44 further connect the form panels 1 together and create a precise 90 degree corner.

The blocks 70 may be set in place before, after or simultaneous with the rebars. In FIG. 15, the blocks 70 are set in place after the rebar 45 and stirrups 43 have been set. The block 70, absent the individual connectors, simply slides over the rebar cage and the bottom section slips into the top of the block 70 immediately below it.

After the block 70 has been placed, the individual connectors 40 are snapped into or otherwise attached to the lateral supports 30 to brace and connect the four sides of the form together from the interior sides of the forms so as to withstand the concrete pressure. The blocks 70 permanently remain in place after the concrete cures. In this configuration the form panel 1 is on four sides of the form 10 and each of the individual form panels 1 are connected by both corner braces 44 and individual connectors 40, as internal bracing, to a second side of the form 10.

The invention may also be used to create moldings, reveals, indentations and other design features to a building's interior or exterior. FIG. 16 shows a section of an exterior wall with window molding and foam board insulation as well as a section of the interior ceiling. From FIG. 16, form panel 1A is the exterior form which has a laminated finish 71 that was fabricated onto the thin plastic sheet 2. The attractive exterior window molding 72 is also made of plastic forms as herein disclosed. The window molding 72 is snapped into or otherwise attached to the form panel 1 and concrete will flow into the inside of the molding so as to make it solid.

In this configuration the form 10 is comprised of form panels 1A and 1B. The exterior form panel 1A reinforced on the interior side by a grate 3 to which individual connectors 40 are attached. Both vertical and horizontal rebar 45 are set in place inside the form panel before the inside form panel 1B is set in position.

The inside form panel 1B has a finished or unfinished interior face 73 and is reinforced and insulated by a foam board 65 bonded to the interior side of the form panel 1B. The form panel 1B also has tracks 8 to which the individual connectors 40 attach. The form panel 1B is attached to the individual connectors 40 by sliding the form panel 1B vertically down the lines of individual connectors 40 from the top connector to the bottom connector. The individual connectors 40 are maintained in their horizontal position by a gusset (not shown) against the interior side of form panel 1A. Not shown is the wire raceway that is concealed by the foam board 65.

In FIG. 16 the exterior form panel 1A extends a distance above the height of the interior wall 74 so as to provide formwork for the floor/ceiling concrete 11. A molded ceiling form panel 51 is used to form the bottom of the floor/ceiling slab and is comprised of a frameless, pliable plastic sheet with ribs (not shown) on the interior side that bonds to the concrete. The ceiling form panels 51 simply interlock to one another and are supported by shoring (not shown) prior to the concrete curing. After the concrete cures and the shoring is removed, the ceiling form panels 51 remain in place to expose an aesthetically pleasing and fully finished ceiling.

FIG. 17 shows another configuration comprising a connecting frame 4 used to connect the four sides of the form 10 to construct a rectangular column form. In this configuration a single form panel 1 is used to form all four sides of the form 10 and the connecting frame 4 acts as to secure the rebar 45 as well as provide the framework for the form 10. The form panel 1 is composed of a pliable plastic sheet 2 to which a grate 3 is fabricated to provide reinforcement means and the connection means on the plastic sheet's 2 interior side. The form panel 1 is creased to allow it to be folded as a means for shaping a single form panel to form more than one side of a multi-sided form. The connecting frame 4 provides the internal bracing with the attached pronged inserts 41 providing the means for connecting to the other three sides of the form 10, which in this configuration are all provided by the folded form panel 1.

FIG. 18A is another configuration that shows a circular form 75 comprised of a single form panel 1 with ribs 7 and lips 5 as reinforcement and connection means fabricated onto and across the interior side of the pliable plastic sheet 2 to create the form panel 1. The form panel 1 may be rolled, extruded, or otherwise molded into said circular shape, or into any other shape as additional means for shaping the form panel to form more than one side of a multi-sided form. Several circular connecting frames 4 with sliders 9 as a means for connecting are slid into the circular form 75, attaching to the ribs 7 and lips 5 as shown in FIG. 18B to provide the form panel 1 with a means for reinforcement in a second direction. After all of the connecting frames 4 are in place, the circular form 75 is then slid down over the rebar to its final position. In this configuration a single form panel 1 is on an infinite number of sides of the form 10 to shape a circular form. The circular connecting frame 4 provides the internal bracing and has a means connecting to some of the infinite number of sides of circular form 10.

In an alternative configuration, FIG. 18C shows circular form 75 reinforced with a connecting frame 4 that has a rebar support area 76 that secures the rebar 45 and stirrups 43 in their respective positions. In this configuration the stirrups 43 are attached to the connecting frame 4 which is then slid into position on the inside of the circular form 75. After this, the vertical rebar 45 is slid through the rebar support area 76 which secures the rebar in place next to the stirrups 43. In another configuration, FIGS. 19A through 20B are side or top views of the form panel on two sides of form 10 that is used to build a wall. FIG. 19A is a section view with form panel 1A comprising a plastic sheet 2 to which a grate 3 is fabricated onto as the reinforcement and connections means. The individual connectors 40, rebar tie connectors 49 and lateral supports 30 all of which are internal bracing, have been snapped into the grate 3 as a means for connecting to form panel 1A.

Also shown in FIG. 19A is the second form panel 1B comprised of a plastic sheet 2 reinforced with a foam board 65 across the interior side of the plastic sheet 2. In addition a “T” shaped slider 9B may be either individual or a spaced apart means for connecting or it may be a continuous, track-like slider extending the full height of the plastic sheet 2 and providing both reinforcement and connections means across the interior side of the plastic sheet 2 to comprise form panel 1B. For purposes of this disclosure the term “across” shall mean from side to side in at least one direction, but not necessarily continuously from side to side nor extending all the way to a side. It shall also mean more than the perimeter. For example in FIG. 19B the foam board 65 is not continuous across the plastic sheet 2 because it is interrupted in several places by the slider 9B. In those interrupted areas, the slider 9B is connected to internal bracing which supports and thereby reinforces the plastic sheet 2 in that immediate area. Likewise a reinforcing means may end near a side of the plastic sheet that has other reinforcement such as in FIG. 25 wherein the stud's flange supports the edge of a plastic sheet/form panel.

In FIG. 19B both the slider 9B and the foam board are protrusions and both provide a means for reinforcing the plastic sheet 2 and thereby the form panel 1B. In addition both the slider 9B and the foam board 65 will also bond to the concrete when it is hardened. In the slider's 9B case the concrete will lodge under the “T” shape whereas in the foam board's 65 case the concrete on the side of the foam board 65 where it is interrupted by the slider 9B will develop friction with the foam board 65. In addition, the concrete may also adhere to the foam board 65 as the concrete cures and/or it may partially embed into the foam board during placement. Moreover, the foam board may be undercut on its side and/or have dove tails into which the concrete will flow and thereby enabling it to bond to the foam board 65.

After form panel 1A with the internal bracing is set in place, the horizontal and vertical rebar 45 are positioned with the horizontal rebar 45 placed in the rebar bracket 42. One function of the rebar bracket 42 is to secure the rebar 45 a set distance from the form panel 1A. Rebar tie connectors 49 are then tied to the rebar 45 and snapped into the grate 3 so as to provide additional internal bracing to the form panel 1A by the rebar 45 and to stabilize the form panel 1A in the upright position.

As the rebar tie connector 49 is tightened, it pulls the form panel 1A toward the rebar while the rebar bracket 42 holds the form panel a set distance. In this way the rebar 45 is used as an internal bracing to support the form panel 1A from the pressure of the wet concrete.

After the steel rebars 45 have been placed, a junction bar 31 is slid down the sliders 9A attached to the individual connectors 40 as a means for connecting, and as can be better understood by FIG. 19B, which is a plan view of FIG. 19A. The junction bars 31 in FIG. 19B has a double track 8 as a means for connecting with the first track 8A to be slid over the slider 9A attached to the individual connectors 40 and the second track 8B to accept the “T” shaped slider 9B that is fabricated onto the interior side of the second form panel 1B. Slider 9B will be slid down the second track 8B of junction bar 31 to position form panel 1B and close the form 10.

Also shown in FIG. 19B is the raceway 60 into which wires and cables from switches and outlets may be located. The raceway 60 is attached to the form panel 1B and the area between the plastic sheet 2 and the raceway is filled with foam or other filler material.

FIG. 20A shows the section view of the components of FIG. 19A as assembled and

FIG. 20B shows the plan view of FIG. 20A. FIGS. 20A and 20B also shows one configuration of the internal bracing on the interior side of either form panel as it connects to the interior side of the second side form. The form 10 is now ready for concrete 11 cast between the panel 1A and the foam board 65. FIG. 20B also shows how the junction bar 31 is attached to both the individual connectors 40 and the track 8. The lateral pressure of the concrete pushes the two form panels 1A and 1B away from each so as to create a firm and solid wall section.

As a result of this configuration a form panel 1A in on one side and form panel 1B is on a second side (or vice versa) of form 10 and each form panel has reinforcement and connection means arranged across their respective interior sides and are connected to internal bracing that connects to a second side of form 10, which can be either form panel 1A or 1B.

FIGS. 21 and 22 shows another configuration disclosed herein as applied to forming a concrete wall. In FIG. 21 the individual form components “A” thru “G” are shown and FIG. 22 shows the form's components assembled.

FIG. 21A is a plastic sheet 2 extruded with ribs 7 as reinforcement means and lips 5 as connection means. FIG. 21B shows the plastic sheet 2 with foam board 65 bonded for additional reinforcement and insulation and comprises form panel 1A, which is one side of the form 10 as depicted in FIG. 22. There is an optional housing 77 that surrounds the lip 5 to keep this area clear of foam that may be sprayed or otherwise liquid applied to the plastic sheet 2. The form panel 1A also has a wire raceway 60 attached which is supported by a rib 7.

FIG. 21C shows one of two lateral supports 30A as internal bracing with connection means as used in this form 10. This lateral support 30A connects to the lip 5 of form panel 1A to provide both support from the pressure of the wet concrete and a means for connecting form panel 1A to a second side of form 10, which in this configuration is form panel 1B. The lateral support 30A when attached to the form panel 1A acts as a truss to strengthen form panel 1A to withstand the pressure of the wet concrete. While the ribs 7 may be in close proximity to reinforce the plastic sheet 2, the sliders 9B on the second side of the lateral support 30A may be spaced much further apart since they only provide a means for connecting.

FIG. 21D shows the junction bars 31 as internal braces that run the full length (height) of the form panels 1A and 1B. The junction bars 31 provide vertical tracks 8A and 8B as a means for connecting to other internal bracing shown such as the lateral supports 30A and/or the individual connectors 40 that are inserted (on either side) and slid to their final position. The sliders 9, as the means for connecting on the ends of the individual connectors 40 may be deformed or otherwise altered after they are positioned so that they remain fixed at set locations.

FIG. 21E shows individual connectors 40 that attach to the lateral supports 30A and 30B that support form panels 1A and 1B respectively. The individual connectors 40 connect the two sides together and, in this configuration, are simply a straight bar with a slider 9 as a means for connecting on both ends.

FIG. 21F shows the second lateral support 30B used in this configuration. The lateral supports may be of different configurations as required by the application and the means by which the form panels are reinforced. The lateral support 30B in FIG. 21F is used to support form panel 1B, which is reinforced with ribs 7 of a different configuration than used in form panel 1A. Sliders 9 are fabricated onto one side of the lateral support 30B and a slot 78 is on the other side and the slider 9 of the individual connectors 40 snaps or slides into said slot 78 so as to attach to the lateral support 30B as a means for connecting. The second side of this lateral support 30B has slider 9 that snaps or slides onto the lip 5 on form panel 1B as a means for connecting.

FIG. 21G shows form panel 1B, which consists of a plastic sheet 2 to which ribs 7 and a lip 5 are attached. The lip 5 provides a track as a means for connecting to the lateral support 30B through its sliders 9. The ribs 7 support the form panel 1B in one direction while the lateral support 30B provides support in the direction perpendicular to the ribs 7. FIG. 22 shows the components of FIG. 21 assembled and the form 10 is complete and ready for concrete (rebar not shown).

To assemble the form in FIGS. 21 and 22, the form panels 1A and 1B are each assembled with their respective lateral supports attached. The individual connectors 40 are then placed in the slots 78 of lateral support 30B and form panel 1B is set in place. The rebar (not shown) is then set in place inside form 10 and the form 10 is ready to be closed

To close the form 10 the junction bar 31 with its track 8B is slid vertically down the open ends of the individual connectors 40 to align, brace and connect the individual connectors 40 and to create a truss. The junction bar 31 runs the full vertical length (height) of the form panel 1B and said truss is created by the junction bar 31, the individual connectors 40 and the form panel 1B.

Form panel 1A is then slid vertically down the opposite and open side of the track 8A of junction bar 31 as a means for connecting. Form panel 1A is easily slid into its final position because of the limited number of connection points between the junction bar 31 and the lateral support 30A. For example while the form panel 1A may have ribs 7 in close proximity that attach to the lateral support 30A, the lateral support 30A may have a connection point to the junction bar 31 much further apart. As such, a 4′×8′ form panel 1A may have very few connection points to the junction bar 31.

As a result of this configuration shown in FIGS. 21A-G and FIG. 22, a form panel 1A in on one side and form panel 1B is on a second side (or vice versa) of form 10 and each form panel has reinforcement and connection means arranged across their respective interior sides and are connected to internal bracing that has a means for connecting to a second side of form 10, which can be either form panel 1A or 1B.

In another configuration the form is comprised of a form panel on one side of a multi-sided form and is connected to a stud that is supporting foam boards or other panels in predetermined positions on a second side of the form. In this configuration the backside of the stud connects to the internal bracing while the stud's front side may provide a nailable and/or screwable surface to which claddings such as drywall or other wall surface sheets may be attached on the second side of the form. The stud may also facilitate externally bracing the form.

FIG. 23 shows a section view of an elongated rigid stud 80 that is made of any materials including plastic, metal, wood or a combination thereof. FIGS. 24 to 26 shows several means for connecting the backside of the stud to the internal bracing. FIG. 24A shows a plan view of one configuration of stud 80 into which a track 8 has be molded or fabricated as a means for connecting to internal bracing. The sliders 9 connected to the individual connectors 40 are inserted or otherwise attached to the track 8 that provides the means for connecting to the stud 80. Also shown in FIG. 24A is a flange 13 attached to the stud 80 that enables the stud 80 to support foam boards, or other insulation boards on the backside of the flange 13 and to support wall board, panels or other materials that may be attached to the front side of the stud. FIG. 24B shows the section view of FIG. 24A and the extended length of the slider 9 that may be on the end of the individual connector 40.

FIG. 25 shows another configuration of the stud 80 wherein the stud's 80 means for connecting to the individual connector 40 is by snapping them together. In FIG. 25, the snap insert 6 of the individual connector 40 is shaped such that it will slip into and snap open behind a lip 5 fabricated on the stud 80

FIG. 26 shows another configuration by which the slider 9 on the individual connector 40 is connected to the stud 80 by either snapping over or sliding down the lip 5 on the end of rib 7 protruding from the backside of the stud 80 as a means for connecting. The ribs 7 or other element extending inward from the flange 13 may be short or may extend beyond the thickness of the insulation boards or panels.

The stud enables the plastic form panel to be economically used in conjunction with various wallboards, siding and panels that are commonly used in the construction of a wall. One advantage of the stud is that it allows for open access into the area between the forms where the concrete is to be cast to facilitate the placement and securing of the concrete reinforcement materials (rebars). For example, FIG. 27A shows a partially completed form 10 with one side closed with a form panel 1A and the second side open through which the horizontal rebar 45A and the vertical rebar 45B can easily be set in place. FIG. 27B also shows the stud 80 being slid down a track on the end members 82 of the individual connectors 40 as a means for connecting the stud to the internal bracing which in turn are connected to the form panel 1A. In this embodiment the stud 80 ties together or locks the individual connectors 40 into a rigid alignment.

FIG. 28 shows the plan view of FIG. 27B with stud 80 that has flanges 13. Although the stud 80 is shown as “T: shaped with a flange 13 on two opposite sides, the stud 80 may also have a single flange on only one side, such as a “L” shape, and may be used for corners or other conditions. Also shown in FIG. 28 is an optional connector support 84 as a means for connecting the studs 80 so as to secure them in a set vertical alignment to facilitate sliding the stud 80 down the individual connectors 40. The optional connector support 84 attaches horizontally from individual connector 40 to connector and may also be used a horizontal support for the form board. Or, as an alternative, the individual connectors 40 may also have flanges on both sides (not shown) a set distance from the stud so as to secure the backside of the foam board in place.

FIG. 29A is a section view of the closed form 10 showing the addition of a foam board 65 having been slid down between the flanges 13 and the connector supports 84 as shown in FIG. 29B. The foam board 65 is supported by the stud's flanges and closes the form 10 so as to be ready for concrete. In this configuration the stud 80 and foam board 65 comprise the second side form of the multi-sided form and by connecting the internal bracing to the backside of the stud the second side form is being connected on its interior side. The connector supports 84 acts to hold the foam board 65 in position before and during the casting of the concrete into the form 10.

FIG. 29B is a plan view of FIG. 29A showing the foam board 65 in position between and supported by the flanges 13 that are part of the studs 80, and also by the connector supports 84. When concrete is cast inside form 10, the foam board 65 or other such board or panel is of such strength that it can withstand the hydrostatic pressure from the wet concrete as supported by the stud 80 and its flanges 13 and the individual connectors 40.

The stud 80 may be made of a nailable/screwable material to which drywall or other materials may be attached to the stud's front side. The stud may be used in either a vertical or a horizontal direction and may also be shaped as an angle for corners.

The stud, foam boards and/or form panels can be set in levels on one or more sides of a multi-sided form, to utilize the means for reducing hydrostatic pressure on the form as disclosed above. In this instance the stud, form boards and/or form panels one at least one side of the form are in shorter sections that are vertically stacked for each level until the full height of the structure is reached. The low or no-slump concrete is placed into each level prior to setting the next level of studs, foam boards and/or form panels to enable visual observation of the concrete being placed (cast and vibrated) in each level. Such a process greatly reduces the hydrostatic pressure on the form and thereby allows for less bracing.

Another configuration of the plastic form panel is its use as a stay-in-place form on one or more sides of a multi-sided form and at least a second side of the form is comprised of a different type of form that has the ability to connect to the internal bracing. For example the form panel may be on one side of a two sided form and internally braced and connected to a one-sided insulated concrete form (ICF) on the second side of the form. Or the second side form may be a removable form that has the means for connecting to the internal bracing. Any type of form that is capable of having a means for connecting to the internal bracing may be used in this configuration.

Another configuration is of the form panel reinforced on its interior side but is externally braced. For example the ceiling form shown in FIG. 16 is one such application wherein the form panel forms the bottom side of a ceiling/floor form and is externally braced from below. Beyond the ceiling form application, the form panels are all internally braced in relatively close proximity to withstand the wet concrete's hydrostatic pressure.

On Jan. 17, 2012, applicant filed copending application Ser. No. 13/374,839 filed 17 Jan. 2012 entitled the Thixotropic Building System, incorporated herein by reference. This application disclosed a new method for reducing the hydrostatic pressure in concrete wall forms to such a degree that form ties may be eliminated and external bracing may be solely used to brace wall or other vertically oriented forms. Also disclosed in this application were plastic, stay-in-place forms that have ridges that embed into the wet concrete and may be externally braced.

The significant reduction in hydrostatic pressure and the resulting elimination of form ties, makes it possible for the plastic form panel disclosed herein to still bond to the concrete and have reinforcement means on its interior side but replace the connecting means for internal bracing with external bracing. This was disclosed in the above referenced copending application. In addition, with adequate reinforcement and external bracing (to include a removable form) or other support, such a plastic form panel may be used in all casting methods.

As such, FIGS. 4 through 7A show a form panel 1 comprising a plastic sheet 2 with reinforcement means attached to the interior side of the plastic sheet 2 and the lips 5 enable the form panel to bond to the concrete. In this configuration the form panel 1 may be used to form one or more sides of a multi-sided concrete form and be externally braced and/or supported by removable forms. The form panel 1 may also have a finished appearance or a cladding attached to its exterior side such as siding, boards, panels or provide a backing for all types of claddings and/or coatings.

From the description above, a number of advantages of some embodiments of my plastic stay-in-place forming system become evident:

(a) A thin plastic sheet is reinforced with protrusions to create a rigid form panel capable of forming wet concrete despite high levels of hydrostatic pressure.

(b) The protrusions attached to the interior side of the thin plastic sheet act to bond the form's thin plastic sheet to the cured concrete such that the plastic form provides a firm, sturdy and solid covering to the concrete member.

(c) The forms are internally braced with connecting frames, lateral supports and individual connectors which provide substantial flexibility and efficiency in their placement. This results in the use of fewer connecting frames, supports and connectors and thinner plastic sheets.

(d) The individual connectors create an open access form into which concrete reinforcement, including welded wire fabric can easily be placed.

(e) A special stud that supports foam boards as one side of a form and uses individual connectors to connect to a second form.

(f) A means wherein the rebar is used to support the form panels.

(g) The plastic forms are lightweight, easy to handle, simple to assemble, highly flexible. and use less plastic materials. They may be used for columns, walls, beams and floor/ceilings.

(h) Since the plastic covering is firmly attached to the concrete, it provides a suitable surface to which attractive exterior claddings may be attached.

Accordingly the reader will see that thin plastic sheets may be used as concrete forms when they are reinforced with ribs, grates and the like and further supported by lateral supports or connecting frames. These thin plastic sheets provide an attractive and permanent covering because they are firmly bonded to the concrete. The individual connectors provide a flexible and inexpensive approach to connecting one or more plastic forms.

Although the description above contains many specifications, these should not be construed as limiting the scope of the embodiments but as merely providing illustrations of some of several embodiments. Thus the scope of the embodiments should be determined by the appended claims and their legal equivalents, rather than by the examples given.

Claims

1. A stay-in-place, plastic concrete form comprising:

a. a form panel on one or more sides of a multi-sided concrete form and said form panel comprised of a pliable plastic sheet with reinforcement means and connecting means arranged across the interior side of said plastic sheet and said form panel mechanically bonds to the concrete,

b. one or more internal bracing having a means for connecting to said form panel and extending inward with a means for connecting to at least a second side of said concrete form.

2. A concrete form of claim 1 further including a means for shaping a single said form panel to form at least two sides of said concrete form.

3. A concrete form of claim 1 wherein said form panel on at least one side of said concrete form further includes foam bonded to at least a portion of said interior side.

4. A concrete form of claim 1 wherein said second side comprises at least one foam board secured in a predetermined position by elongated rigid studs adjoining said foam board on two or more sides and said stud having one or more flange and means for connecting to said internal bracing.

5. A concrete form of claim 1 wherein said reinforcement comprises a multitude of ribs fabricated onto said interior side.

6. A concrete form of claim 1 wherein said internal bracing comprises a connecting frame with a means for connecting perpendicular to said form panel.

7. A concrete form of claim 1 wherein said internal bracing comprises individual connectors.

8. A concrete form of claim 1 wherein said internal bracing comprises rebar tie connectors.

9. A concrete form of claim 1 wherein said reinforcement means comprises protrusions.

10. A concrete form of claim 1 further including a means for reducing the hydrostatic pressure in said concrete form.

11. A concrete form of claim 1 wherein said internal bracing has a means for connecting to other internal bracing.

12. A concrete form of claim 1 wherein one or more said form panels includes a filler and/or backing material.

13. A concrete form of claim 1 wherein said second side comprises one or more foam boards supported by one or more studs.

14. A concrete form of claim 1 wherein said second side comprises said form panel.

15. A concrete form of claim 1 further including a means for finishing the exterior side of said form panel.

16. A stay-in-place concrete form panel comprising a plastic sheet reinforced by protrusions arranged across the interior side of said plastic sheet and said protrusions mechanically bond to the concrete placed against said interior side and said form panel is externally braced.

17. A concrete form of claim 16 further including a means for reducing the hydrostatic pressure from said concrete placed.

18. A concrete form of claim 16 further including a means for finishing the exterior side of said form panel.

19. A method of constructing a multi-sided concrete form with a stay-in-place form panel on one or more sides, said method comprising:

a. fabricating said form panel by reinforcing a plastic sheet across its interior side with protrusions capable of bonding to concrete and connecting to internal bracing,

b. arranging said form panel to form one or more sides of said concrete form,

c. attaching internal bracing to said form panel,

d. connecting said internal bracing to at least a second side of said concrete form, whereby a multi-sided concrete form is constructed with a stay-in-place form panel on one or more sides.