Abstract: A construction form system for forming concrete walls for use as above grade walls, foundations, frost walls, exterior envelopes, and the like, is disclosed. The system includes a plurality of pairs of opposing vertical forming panels spaced from each other to define a forming cavity disposed to receive a hardenable material. Each pair of opposing forming panels comprises an inner panel forming part of an inner wall and an outer panel forming part of an outer wall. The system also includes an outer rail positioned between each adjacent pair of outer forming panels and an inner rail positioned between each adjacent pair of inner forming panels. The inner forming panels comprise support panels configured to be selectively addable and removable from between each adjacent pair of inner rails prior to and subsequent to a pouring of the hardenable material into the cavity.

Abstract: A process for making a panel for supporting the sidewalls of an excavation includes a plate, longitudinal members and vertical members. Each longitudinal member includes a first leg extending along the length, substantially parallel to and spaced laterally from the plate. The first leg of each longitudinal member being located adjacent and secured to the first leg of another member. A second leg, integral with the first leg, extends along the length, away from the first leg and toward the plate, the second leg being secured to the plate. Axially spaced vertical members are welded to the plate and to the longitudinal members.

Abstract: A 3D construction module comprising at least one vertically upstanding panel with first and second mesh layers oriented generally transversely and longitudinally. The first and second mesh layers have at least one rod member mounted to said panel and are vertically spaced from each other. The rod members form a first horizontally projected retention cell to restrict translation of a bar held in said retention cell between said first and second mesh layers. A third mesh can also be provided to form a second retention cell between said second and third mesh layers. The first and second retention cells restrict translation movement longitudinally and transversely of a vertical reinforcement member held in said first and second retention cells, and restrict rotation of the vertical reinforcement member about both a longitudinal axis and a transverse axis of the said 3D construction module. Horizontal reinforcement meshes are features of the invention.

Abstract: A reinforced composite system for constructing insulated concrete structures comprising, panels having a foam plastic core between outside and inside reinforcement layers, reinforcement layers substantially strengthen the panels during material handling and construction, greatly reducing deflection of the panels between studs when placing concrete allowing walls to be filled in one lift. Panels are placed horizontally in an opposing and parallel spaced-apart relation. Opposing panels are placed end to end in rows and stacked vertically, rows of panels being staggered from each other so panel ends in adjacent rows do not line up vertically. Vertical studs are embedded in panels extending the full height of the panels, each stud having a flange for receiving mechanical fasteners and groove for receiving spreaders. A plurality of spreaders at each stud location extend between opposing panels and slidably engaging the studs in opposing panels.

Abstract: A through-insulation connector assembly for use in the construction of insulated concrete sandwich wall. The connector assembly includes a spool-shaped connector body comprised of two, interconnecting pieces and a tie that engages the connector body. The two pieces of the connector body are installed at the place of manufacture in a sheet of foam insulation board that will be used as the insulation layer in the construction of an insulated concrete sandwich wall.

Abstract: An insulated concrete wall structure having a concrete wall with opposing wall surfaces. The concrete wall has several vertically and horizontally spaced wall ties imbedded within the concrete wall and extending between the wall surfaces. Positioned between the vertically spaced wall ties are a series of elongated retaining strips such that the retaining strips are substantially parallel to the wall surface. Insulating panels such as polystyrene foam boards are located between the horizontally spaced wall ties and retained in position by the retaining strips. In one aspect of the invention, each insulating panel has a groove formed along its vertical edge for receiving and engaging the elongated edge of the retaining strips. The present wall system is advantageous in that an insulated concrete wall can be readily formed using conventional wall forms in approximately the same amount of time as conventional uninsulated poured concrete walls.

Abstract: An insulated concrete wall structure having a concrete wall with opposing wall surfaces. The concrete wall has several vertically and horizontally spaced wall ties imbedded within the concrete wall and extending between the wall surfaces. Positioned between the vertically spaced wall ties are a series of elongated retaining strips such that the retaining strips are substantially parallel to the wall surface. Insulating panels such as polystyrene foam boards are located between the horizontally spaced wall ties and retained in position by the retaining strips. In one aspect of the invention, each insulating panel has a groove formed along its vertical edge for receiving and engaging the elongated edge of the retaining strips. The present wall system is advantageous in that an insulated concrete wall can be readily formed using conventional wall forms in approximately the same amount of time as conventional uninsulated poured concrete walls.

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

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

Abstract: Connectors used in manufacturing composite wall structures to substantially prevent forms from being displaced in response to pressure generated by concrete poured between the forms. In a completed composite wall structure, the connectors extend through two structural layers and an insulating layer positioned therebetween. The composite wall structures are formed by positioning the insulating layer between and in a spaced-apart relationship to the two forms. The connectors are subsequently inserted through the insulating layer and the forms. As concrete is then poured into spaces between the forms and the insulating layer, a bearing surface on a form retention segment, which extends beyond the outer surface of the forms, abuts the forms and prevents them from moving away from the insulating layer. The bearing surface is either directly positioned on the form retention segment or on a form locking device attached to the form retention segment.

Abstract: A system for insulating only the interior surface of a concrete wall to be poured between a pair of interior and exterior wall forms. The system includes horizontally extending elongated tie strips which connect to each of the wall forms to hold the wall forms spaced apart, a single layer of insulation positioned in contact with the interior wall form, and a plurality of connectors for securing the single layer of insulation to only the interior surface of the concrete wall. The connectors include an enlarged head portion which engages the insulation and a web portion of smaller cross section which extends through apertures in the insulation and into the space between the wall forms, the web portion including openings for the passage of concrete therethrough.

Abstract: An insulated concrete wall is constructed by securing at least one tie assembly (14) to a panel (12) of insulative material, securing the tie assembly and panel to a pair of spaced forms (60, 68), and pouring concrete into an open space defined by the forms adjacent the panel. The concrete is then allowed to set, and the forms are removed. The tie assembly (14) includes an elongated tie (16) having a central region (24) adapted to remain in place in the wall subsequent to construction and a pair of opposing end regions (26, 28) adapted to be detached after removal of the forms. In addition, the assembly (14) includes an elongated retainer body (18) formed of heat insulative material and received on the tie (16), and a pair of face plates (20, 22) retained on the body on either side of the panel (12).

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

Abstract: An apparatus for assembling two cement board stay-in-place form panels for aking concrete-filled walls that is cost-effective and forms a uniform precise composite wall construction. The assembly includes a coextensive corrugated spacer panel between the form panels for maintaining a uniform distance there between. The forms and spacer panels are secured in place with a notched tie rod that penetrates the spacer and both wall panels, this assembly allows for rapid form installation. The spacer panel has two embodiments, viz. i) a preformed rigid corrugated panel and ii) a flattened unassembled panel with precut fold lines that are folded at the building site and then secured with a dowel-rod bracing component. The apparatus preferably uses fiber-glass-reinforced cement board for the stay-in-place forms. The final composite wall construction typically is made up of 4 feet wide by 8 feet high by 6.5-inch thick composite wall sections.

Abstract: A wall form system for use in constructing a poured concrete wall includes a plurality of panels aligned in an edge-to-edge configuration to form spaced wall forms. The wall forms are maintained in a spaced relationship by a tie which includes a pair of cutouts which mate with notches in the side edges of each of the panels at the juncture between adjacent panels. A retainer is provided to secure each end of the tie to the outer face of the adjacent panels. After the concrete wall is poured and hardened, the wall forms are easily disassembled by breaking a first frangible section from the tie and removing the wall form panels and then breaking a second frangible section from the tie which is projecting from the concrete wall. The ties and retainers are disposable and easily assembled with the wall forms thereby alleviating the need for collection and retrieval when the wall forms are disassembled.

Abstract: A snap tie for use in maintaining a predetermined spaced relation between opposed forms prior to and during the pouring of a concrete wall therebetween comprises a steel rod of predetermined uniform cylindrical section having at each end an integrally formed head of substantially larger cross sectional dimensions. The rod also includes a portion interconnecting the inner side of each head with the remainder of the rod which has cross sectional dimensions intermediate those of the heads and of the remainder of the rod.

Abstract: An improved snap lock retainer mechanism for insulated wall construction apparatus for pouring a composite wall structure which includes a pair of outer poured concrete layers separated by a high density foam insulating panel mounted between the concrete layers and which includes a number of tying mechanisms for holding the insulated layer in place while the concrete is being poured and hardened wherein the holding means are formed of plastic rods upon which two plastic receivers are directly injection molded onto the rod. One of the receivers has a single notch and the other receiver has multiple notches. One of two snap rings which are identical goes first over the single notch receiver and is locked in place and then the rod is extended through the insulating panel and a second snap ring is attached to the multiple notches in a ratchet effect on the multiple notches plastic receivers so as to lock the board in place so that the concrete can be poured.

Abstract: A compound washer, for use with cylindrical concrete form tie rods having plural spaced flattened portions, that may be positioned by slidable motion along the tie rod and releasably maintained on a particular flattened portion against further lineal displacement. The washer provides a larger truncated conical body that threadedly engages and carries within its forward portion a fastening collar engaged on the flattened portion of a tie rod. The washer provides an elongate shape to create an indentation concrete to allow sub-surface breaking of a tie rod beneath a formed concrete surface.

Abstract: A concrete form self securing tie rod is provided with a cone shaped element having a dowel-like extension slidably mounted on an elongated rod having formed thereon an integrally formed wedge portion. The dowel-like portion of the cone-shaped element has teeth that lockingly engages the element into an aperture formed in the panel making up one side of the concrete form to prevent vertical movement of the tie rod. The wedge shaped portion of the elongated rod lockingly engages the cone element to prevent horizontal movement of the tie rod.

Abstract: Concrete form panels are connected by snap ties to rebars and thereby supported by the rebars. Adaptor plates enable the connection of the snap ties to the rebars.

Abstract: Apparatus and process for forming or casting poured concrete walls involve form sections, tie bars for tying the form sections together in spaced-apart relation, which tie bars have opposed notches or cut-ins in opposite edges of the tie bars, or like areas or zones of weakness, so located that they are coincident with the interface between the form and the concrete therein, and a device which is adapted to fit over the end portions of the tie bars which are exposed when the form sections have been removed and which is adapted to apply force to the exposed end portion in the plane of the tie bar, one vector of which is applied to one narrow edge of the exposed end portion adjacent the zone of weakness and another like vector of which is applied in the opposite direction to the opposite narrow edge of the exposed end portion at a point remote from the zone of weakness and adjacent or near the free end of the exposed end portion.

Abstract: An improved concrete form and tie rod, the concrete form and tie rod being constructed to facilitate disassembly of concrete form assemblies. The tie rods and concrete forms and structured to permit the ends of the tie rods to be broken off following completion of the concrete casting process to thereby facilitate removal of the aligning pins which hold the concrete forms of a form assembly together.

Abstract: A tie bar for use in positioning forms into which a suitable material such as concrete may be poured comprises a metal bar having a central portion and two end portions. The end portions are intended to be broken away from the central portion at a stress concentrating notch after the concrete has set. A pair of moulded members are moulded directly to the central portion of the bar each of which moulded members comprises at least two flanges extending outwardly from the bar and spaced apart to accommodate a reinforcing rod. The tie is also fitted with two conical spacers which extend axially outwardly from the moulded members and which are conical having the largest diameter facing axially outward to support the form and prevent inward movement of the forms. In one preferred embodiment of the invention the conical spacers are separate from the moulded members. In a second preferred embodiment the conical spacers are integral with the moulded members.

Abstract: A form tie and a method of making the same is provided. The form tie includes an elongated hollow protective sleeve contiguously surrounding a portion of the form tie to facilitate the removal of the form tie portion from a settable casting, such as concrete. The thickness of the sleeve is minimized so that the cross-sectional area of the form tie portion which includes the surrounding sleeve is also minimized.

Abstract: A concrete mold fastening device for use in a concrete mold for holding mold members in a desired spaced relationship which comprises a spacer extending between and passing through said mold members, said spacer having an enlarged diameter stop flange and a pair of annular recesses on the opposite sides of said flange on each end portion thereof, inner holding means positioned on said each end outwardly of the outer one of said recesses, a fastening rod connected to the associated outer end of the spacer and external holding means positioned on the outer end of the associated fastening rod outside of said mold members.

Abstract: A form for poured concrete walls includes a plurality of prefabricated, interconnected form panels which are positioned end to end, in two, spaced apart rows to form a wall cavity therebetween. Each pair of associated, opposed form panels has at least two tie bars extending laterally between the panels in a mutually spaced apart and aligned relationship. A pair of mutually parallel and spaced elongate rods are positioned perpendicularly to each of the tie bars and are fixedly attached thereto, and rigidly align and hold the form panels in a set plumb and straight position. One of the rods is shaped for connecting reinforcing mesh thereto, and accurately and positively positions the mesh along a central, predetermined plane between the form panels for improved wall strength, reduced material usage and labor efficiency.

Abstract: A top rail tie bracket for concrete forms for eliminating the usual additional wooden rail required across the top of the top rail of the form for bracing the wedging element of the top snap tie rod. A reusable T-shaped bracket is provided, one leg of which abuts the top rail and the other leg serves as a back-up support to overcome the tensioning action of the wedge on the top snap tie rod. This eliminates the necessity of the additional top rail.

Abstract: The invention relates to a shuttering system which has a series of connector or distance elements, the elements having formations which receive complemental formations in the shuttering panels, the portions outside of the formations being capable of being broken off or removed when the shuttering panels are removed, leaving the remainder of the element in the wall.

Abstract: A breakback form tie for constructing wallforms to contour concrete in which the form tie has at the end portions thereof engaging means for interfacing with brackets, an enlarged cross section positioned inwardly of the engaging means, plug means preferably in the configuration of truncated conical members positioned between the engaging means and the enlarged cross section with the enlarged, base portion of the conical members oriented outwad from the center of the tie, and a frangible section to facilitate breakback positioned inwardly of the enlarged cross section in order that the end portions of the tie may be severed at the frangible section and the severed section of the tie and plug means concurrently removed from a concrete wall formed around the tie.

Abstract: An elongated form tie bar extends transversely across a concrete receiving space between facing side forms and has opposite end portions thereof each positioned between respective abutting side edge portions of adjacent side forms. The end portions of the tie bar are each adapted to receive respective form holding members for retaining the abutting side edge portions of adjacent side forms in abutting engagement. The tie bar is of carbon steel and has hardened fracture planes positioned relative to the opposite end portions and an intermediate portion thereof whereby after setting of the concrete wall and removal of the forms the end portions are adapted to be separated from the intermediate portion upon being struck a blow as by a hammer and the ends of the remaining intermediate portion are recessed in the concrete wall.