Note: Descriptions are shown in the official language in which they were submitted.
CA 02202831 1997-04-16
FOUNDATION CONSTRUCTION SYSTEM
BACKGROUND OF THE INVENTION
This invention relates generally to building construction form systems and,
more particularly, to building construction form systems for forming
foundations
and the like.
Concrete foundations have typically been constructed using expensive
reusable forms. These forms have typically been heavy and extremely
labor-intensive to assemble. Various other form systems have been proposed to
reduce construction expense. These systems typically reduce labor costs and
expense through the use of light and inexpensive materials that can be left in
place
after concrete or other building materials are poured into the form system.
Although effective, these alternate systems are not without drawbacks.
Typically, these designs require parts that are formed by injection molding,
which
is an expensive process requiring expensive tooling. Injection molding has
also
limited the practical length of the parts that can be produced to around nine
feet.
These relatively short lengths increase labor costs by increasing the number
of
connections required in the assembly process.
Previous designs have generally required complex shapes and relatively
complex assembly procedures. This complexity increased training costs and
decreased efficiency while workers learned to use the system. Further, this
complexity increased tooling costs.
Leveling the top of the form has also been difficult and labor-intensive with
previous designs. It is critical to have a level foundation upon which to
build, yet
prior art designs have generally not provided a convenient way of achieving a
level
configuration.
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Another important design criterion concerns connection to abutting pieces
and the ability to form corners without requiring complex pieces produced by
labor-intensive operations. Previous designs have necessitated the use of
special
pieces which increase tooling costs and increase the complexity of the design.
Further, appropriate inventories of each of the pieces had to be accurately
established to avoid costly delays midway through the project as more pieces
of a
certain type were purchased and transported to the job site.
It is therefore an object of the present invention to provide a novel building
form system and apparatus.
It is a further object of the present invention to provide an improved form
system and apparatus that provides attachment surfaces to which drywall can be
coupled to meet existing building code requirements.
It is a further object of the invention to provide a form system that is easy
to
use and that reduces training costs by eliminating numerous special use pieces
required by many previous designs.
It is yet another object of the invention to reduce time and effort required
to
set up a building form system by eliminating the need for scaffolding or other
above ground framework for erection of form systems of substantial height.
It is a further object of the invention to provide a novel building form
method and apparatus using substantially vertically oriented support members
that
perform both panel retention and system reinforcement functions.
It is a further object of the invention to eliminate complex exterior bracing
formerly necessary to prevent the form system from bulging as liquid building
material is poured into the system.
It is a further object of another preferred embodiment of the invention to
provide a novel method of erecting a substantially vertically oriented form
system
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and apparatus by installing panels and support members individually from
ground
level along tracks provided by the invention.
It is a further object of another preferred embodiment of the invention to
provide an improved method of installing a component between interior and
exterior panel alignments of the form system, without the need to disassemble
the
form system, by raising an individual panel vertically from the ground level.
SUMMARY OF THE INVENTION
The invention provides a building form system and apparatus including
T-shaped and U-shaped lengths of extruded plastic or steel coupled at their
sides
by rigid links. The links are preferably coupled at ninety degree angles along
the
lengths of the T-shaped and U-shaped elongated members. The T-shaped
members are erected in a substantially vertical orientation and the bottom
edges of
the T-shaped members are inserted into channels of the U-shaped members. The
bottom edges of panels, such as polystyrene boards, are inserted in channels
in the
U-shaped lengths to retain the panels in a spaced-apart relationship and a
vertical
orientation. This spacing enables flow of hardenable liquid building material
(e.g.,
concrete) between the panels and the T-shaped and U-shaped elongated members.
The panels are connected laterally using the T-shaped members, the flanges of
which are inserted into milled slots in the lateral edges of the panels.
In one alternative embodiment of the invention, substantially vertically
oriented H-shaped elongated members are substituted for the T-shaped members.
The panels can be aligned and connected by inserting the flanges of the H-
shaped
member into milled slots in the lateral edges of the panels. The T-shaped or
H-shaped members.and panels are available in (or can be cut to) various
lengths to
create a structure of desired height. The vertical orientation of the T-shaped
or
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H-shaped members also acts as a load bearing system once the liquid building
material has hardened, increasing the load bearing strength of the wall.
Another preferred embodiment of the invention provides a building form
system and apparatus including H-shaped and U-shaped lengths of extruded
plastic
or steel coupled at their sides by rigid links. The links are coupled at
ninety degree
angles along the lengths of the H-shaped and U-shaped elongated members.
Panels, such as polystyrene boards, are received in channels in the H-shaped
and
U-shaped lengths to retain the wall panels in a spaced-apart relationship.
This
spacing enables flow of hardenable liquid building material (~, concrete)
between the panels and the H-shaped and U-shaped elongated members. The
panels and H-shaped lengths can be stacked upon each other to create a
structure
of desired height.
In all the aforementioned embodiments, the T-shaped, H-shaped and
U-shaped lengths enable coupling of drywall and other building materials to
the
assembly formed by the T-shaped, H-shaped and U-shaped elongated members,
the links, the panels and the hardened building material. The links prevent
compression or expansion of the form system so that the resulting structure is
of
the desired dimension.
BRIEF DESCRIPTION OF THE DRAWINGS
The features of the present invention which are believed to be novel are set
forth with particularity in the appended claims. The invention, together with
the
further objects and advantages thereof, may best be understood by reference to
the
following description taken in conjunction with the accompanying drawings,
wherein like reference numerals identify like elements, and wherein:
FIG. 1 is a perspective view of a form system and apparatus constructed in
accordance with one form of the invention.
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FIG. 2 is an exploded perspective view of the form system and apparatus
shown in FIG. 1.
FIG. 3A is a bottom view of U-shaped bottom members connected by links,
and FIG. 3B is an end view of the members and links shown in FIG. 3A.
FIG. 4A is a top view of H-shaped members connected by links at acute
angles, FIG. 4B is an end view of the members and links shown in FIG. 4A,
FIG. 4C is a top view of H-shaped members connected by links at ninety degree
angles in accordance with a most preferred embodiment of the invention, and
FIG. 4D is an end view of the members and links shown in FIG. 4C.
FIG. 5 is a perspective view of a top cap used to level the top of a panel
structure formed by the invention.
FIG. 6A is a side view of a section splice, FIG. 6B is a top view of the
splice shown in FIG. 6A, and FIG. 6C is an enlarged sectional view of the
splice
shown in FIG. 6B.
FIG. 7 is an enlarged and exploded perspective view of the splice (of two
sections of assembled panel structures) shown in FIG. 6B.
FIG. 8 is a perspective view of a ninety degree outside corner formed using
one form of the present invention.
FIG. 9 is a perspective view of a forty-five degree outside corner formed in
accordance with one form of the present invention.
FIG. 10 is a top view of a wall form system for producing a curved panel.
FIG. 11 is a perspective view of one form of the invention useful for
framing a door or window opening.
FIG. 12 is a perspective view of an alternative embodiment of one form of
the invention useful for framing a door or window opening.
FIG. 13 is an end view of a roof application of one form of the inv+ention.
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FIG. 14 is an exploded perspective view of a vertically oriented building
form system and apparatus constructed in accordance with one form of the
invention.
FIG. 15 is an exploded perspective view of a vertically oriented
ninety degree outside corner assembly constructed in accordance with one form
of
the present invention.
FIGS. 16A- 16E illustrate top views of a method of constructing a ninety
degree outside corner. FIG. 16A illustrates the coupling of an corner post to
a
substantially vertically oriented panel using a substantially vertically
oriented
T-shaped member. FIG. 16B illustrates the coupling of two vertically oriented
T-shaped members coupled using substantially rigid links to the panel. FIG.
16C
illustrates the coupling of a second substantially vertically oriented panel
perpendicular to the first said panel using a T-shaped member. FIG. 16D
illustrates the coupling of a preformed corner panel to the interior T-shaped
member described in FIG. 16B. FIG. 16E illustrates the coupling of the
preformed
corner panel described in FIG. 16D to the panel described in FIG. 16C using
two
substantially vertically oriented T-shaped members coupled with substantially
rigid links.
FIG. 17A is a top view of a vertically oriented building form system for
producing a curved structure. FIG. 17B shows a panel cut and beveled for use
with the exterior alignment of the system represented in FIG. 17A. FIG. 17C
shows a panel cut and beveled for interior alignment of the system illustrated
in
FIG. 17A.
FIG. 18 is a perspective view of a vertically oriented building form system
showing a method by which a panel can be raised and lowered prior to liquid
buildirig material being poured into the system.
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FIG. 19A is an exploded perspective view of a second embodiment of a
vertically oriented ninety degree outside corner assembly constructed in
accordance with the invention. FIG. 19B is a perspective view of the
vertically
oriented ninety degree outside corner assembly of FIG. 19A, showing in
addition a
means of bracing the corner.
FIG. 20 is an exploded perspective view of a third embodiment of a
vertically oriented ninety degree outside corner assembly constructed in
accordance with the invention.
FIGS. 21A and 21B illustrate a portion of a wall and a foundation for a
building, the foundation being constructed in accordance with the invention.
FIG. 22 is a perspective view of an additional embodiment of the invention,
showing how the invention may be applied as a skirting system for
pre-manufactured homes.
FIG. 23 is an exploded perspective view of the embodiment of FIG. 22,
showing the use of T-shaped vertical members.
FIG. 24 is an exploded perspective view of the embodiment of FIG. 22,
showing the use of H-shaped vertical members.
FIG. 25 illustrates the means of adjusting the skirting of FIG. 22 to
compensate for uneven installations.
FIG. 26A is a perspective view of an improved link or crosstie for use in
maintaining spacing between vertically upright elongate members. FIG. 26B is a
side elevation view of the improved link shown in FIG. 26A. FIG. 26C is a top
view of the link of FIG. 26B. FIG. 26D is an end view of the link of FIG. 26B.
FIG. 26E is a cross-sectional view of the link of FIG. 26B, looking to the
left
along the lines 26E-26E in FIG. 26B. FIG. 26F is a cross-sectional view of the
link of FIG. 26B, looking to the left along the lines 26F-26F in FIG. 26B.
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DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
Referring to the drawings, a building form system and apparatus is shown
in FIG. 1 at 10. The form system and apparatus is useful in construction and
provides a form or mold for retaining concrete or other similar building
materials
until they harden to form a structural panel, foundation or the like. The form
system 10 provides two spaced parallel panels 12 between which concrete can be
poured to form a structural member. In one illustrated embodiment, the form
system 10 comprises a bottom assembly 14 set on a footing 16, a plurality of
panel
assemblies 18 stacked thereon, and a top cap 20 placed on the top of a stack
of the
panel assemblies 18 as shown in FIGS. 1 and 2. The panel assemblies 18
preferably include panels 22 formed of a rigid, lightweight, inexpensive
material
such as expanded or extruded polymer foam inserted into H-shaped elongated
members 24 that allow stacking of the panels 22. The panels 22 and the
components in which they are inserted preferably have substantially planar
surfaces. This enables widely available polymer foam materials to be used for
the
panels 22. Furthermore, the components can be easily and inexpensively
extruded
due to this planar design.
The bottom assembly 14 comprises two substantially U-shaped elongated
members 26 connected by rigid links 28, as shown in FIGS. 2, 3A and 3B. In the
most preferred embodiments, the top cap 20 is identical to the U-shaped
elongated
members 26. The links 28 are illustrated connected at acute angles along
longitudinal axes 30 of the substantially U-shaped elongated members 26 as
shown
in FIG. 3A. However, the links 28 can be connected to the U-shaped elongated
members 26, the H-shaped elongated members 24 (~j., FIG. 4C) and top cap 29 at
ninety degree angles which is a most highly preferred embodiment. The links 28
retain the panels 22 in a spaced-apart relationship to allow flow of the
hardenable
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liquid building material (g.& concrete) between the panels 22 and the U-shaped
elongated members 26. Further, connecting the links 28 at ninety degree or
acute
angles prevents longitudinal shiffing as well as compression or expansion of
the
spaced-apart relationship of the panels 22. This ensures the dimensional
integrity
of the resulting structure.
The panels 22 are received into channels 32 of the U-shaped elongated
members 26 as shown in FIG. 1, 2 and 3B. While various dimensions can be used,
it has been found that a depth of 1.5 inches and a width of 2.5 inches for the
U-shaped elongated members 26 works satisfactorily. An exemplary spacing
between the U-shaped elongated members 26 is 7.62 inches.
After the panels 22 are placed into the channels 32 of the U-shaped
elongated members 26 coupled by the links 28, a substantially H-shaped
elongated
member 24 is placed on top of each of the panels 22 as shown in FIGS. 1, 2,
4A,
4B, 4C and 4D. Next, panels 22 are placed into the channels 32 of the H-shaped
elongated members 24. It will be recognized that slots can be cut into the
panels 22 into which portions (such as the flanges 42) of the H-shaped
elongated
members 24 and U-shaped elongated members 26 can be inserted. Stacking of the
H-shaped elongated members 24 and the panels 22 can be repeated until a
desired
wall height is achieved as shown in FIG. 2. Further, the panels 22 can be
easily
cut to provide virtually any structure height desired. This is a distinct
advantage
over prior art systems which have typically required labor intensive
operations to
produce nonstandard structure heights.
A top cap 20 is placed over the upper edge 34 of the uppermost pane122 as
shown in FIGS. 2 and 5. If the upper edge 34 is not level, the top cap 20 can
be
fixed in place using drywall screws or other conventional means once it has
been
pivoted into a level configuration. In this way, the top surface of the
resulting
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structure can quickly be made perfectly level, without requiring a complicated
and
labor-intensive process.
As shown in FIG. 1, the stacked panel assemblies 18 are braced on one side
by a channe136 connected to the panel assemblies 18 through use of drywall
screws or other conventional means. The channel 36 is maintained in a desired
configuration using a threaded steel rod mechanism 38 having a tumbuckle 40
disposed at its center. One end of the steel rod mechanism 38 is attached to
the
channe136 and the other end of the steel rod mechanism 38 is connected to a
post 42 driven into the ground. The panel assemblies 18 can be aligned at
ninety
degrees (plumb to the footing 16) by adjusting the post 42 and steel rod
mechanism 38 accordingly.
Because the stacked panel assemblies 18 require bracing only on one side,
workers never have to go outside the sections to work on the panel assemblies
18.
This enables substantial reduction of the conventional four-foot working space
which is typically dug outside foundation walls. With the present invention,
this
clearance space can be reduced to one foot or even less. Accordingly, much
less
backfilling is required. Ideally, backfilling is accomplished using sand so
that
drainage around the foundation is enhanced. However, using conventional
systems requiring the four-foot working space, contractors often are reluctant
to
fill this entire space with sand due to the costs of such large quantities of
sand.
The substantially reduced backfilling far required by the present invention
makes
use of sand for backfilling far more cost effective.
The panel assemblies 18 are strong enough to allow the desired sand
backfilling operations of the present invention to take place before concrete
or
other hardenable liquid building materials are poured into the system 10. This
unusual strength enables greater flexibility in scheduling the backfilling
operation,
thereby expediting the construction process and lowering costs. Once all
sections
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have been assembled and the top caps 20 have been leveled, hardenable liquid
building material (preferably concrete) can be poured into the spaces between
the
top caps 20, panels 22, H-shaped elongated members 24 and the U-shaped
elongated members 26. After the concrete hardens, a solid structure is formed.
The invention allows drywall 27 or other building material to be connected to
the
panel assemblies 18 using drywall screws or other conventional means
penetrating
the flanges 42 of the H-shaped elongated members 24, U-shaped elongated
members 26, as shown in FIG. 1. The drywa1127 can also be connected to the top
cap 20 in an identical fashion.
While the members described herein can be formed from a variety of
materials such as steel and plastic, preferably steel or extruded plastic are
used
depending on the availability and material cost of each in a specific region.
The
extruded plastic design allows relatively long members to be formed without
expensive tooling required for injection molded designs. Even with these
longer
members, it may still be desirable to splice sections of assembled wall
assemblies
together as shown in FIGS. 6A-6C and 7.
The present invention does not require special, complex pieces for the
splicing operation. Instead, an H-shaped elongated member 24 is placed
vertically
and abuts the H-shaped elongated members 24, the panels 22 and the U-shaped
elongated members 26 from each section to be joined. The vertical H-shaped
elongated member is connected to the various members using conventional means
such as drywall screws. Next, the top cap 20 is placed over the assembled
sections
as shown in FIGS. 6C and 7. In this way, a secure connection is easily and
quickly obtained.
FIG. 8 shows a method of constructing a ninety degree outside corner. As
illustrated, stacked assemblies are connected using two ninety degree angle
pieces 46 connected to top caps 20, panels 22, H-shaped elongated members 24
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and U-shaped elongated members 26 cut at forty-five degree angles. The angle
pieces 46 are connected to the various members using conventional means such
as
drywall screws as shown in FIG. 8.
FIG. 9 illustrates a forty-five degree outside corner constructed using one
form of the present invention. In this case, the sections are cut at a
twenty-two-and-one-half degree angle, and piano hinge members 48 are coupled
to
the sections to retain them in place.
The invention can also be used to form curved walls as shown in FIG. 10.
In this embodiment, the beginning of the curved wall is connected to a
standard
section using piano hinge members 48 connected using conventional means such
as drywall screws to a section abutting the curved section. The curved section
comprises substantially H-shaped elongated members 24 in vertical orientation,
similar to the splicing method described hereinbefore, along with narrower
wall
panels 22 for the inner portion of the curve section and wider panels 22 for
the
outer section. The entire assembly can be held together using conventional
perforated metal strapping 50 or other conventional retention means as shown
in
FIG. 10.
FIGS. 11-13 show alternative embodiments of the invention, wherein
lumber 52 can be held in place by conventional metal perforated strapping 50
to
form an end seal, or top or bottom seal for various sections as described
hereinbefore. FIG. 13 illustrates how the form system 10 can be braced for
forming sections other than those that are strictly vertical merely by using
sufficient bracing 54 to hold the system in place. In this way, an entire
building
structure can be produced using the present invention.
A building form system and apparatus constructed in accordance with
another preferred embodiment of the invention is shown in FIG. 14. The form
system 10 provides two spaced, substantially parallel and substantially
vertically
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oriented panels 60 between which concrete or other building material can be
poured to form a structural member, in virtually the same manner as the curved
wall construction shown in FIG. 10. The form system 10 preferably comprises a
bottom assembly 62 set on a footing 64, a plurality of vertically oriented
panels 60
aligned thereon, and a top cap 66 placed on the top of a line of panel
assemblies 68 as shown in FIG. 14. The panel assemblies 68 preferably include
panels 60 formed of a rigid, lightweight, inexpensive material such as
expanded or
extruded polymer foam connected by T-shaped elongated members 70 that can
align the panels 60. The panels 60 can include one or more slots 72, sawn,
milled
or otherwise formed in the pane160, such that a flange 71 of the T-shaped
member 70 fits into the slot 72 in the lateral edge of the panel 60.
The bottom assembly 62 comprises two substantially U-shaped elongated
members 74 connected by rigid links 76. In the most preferred embodiments, the
top cap 66 is identical to the bottom assembly 62 but is installed in an
inverted
orientation. The links 76 can be connected at acute angles along the
longitudinal
axes of the substantially U-shaped elongated members 74. However, as
illustrated,
the links 76 are preferably connected to the U-shaped elongated members 74 and
the T-shaped elongated members 70 at ninety degree angles. The links 76 retain
the panels 60 in a spaced-apart relationship to allow flow of the hardenable
liquid
building material (g.&. concrete) between the panels 60 and the U-shaped
elongated members 74. Further, connecting the links 76 at ninety degree or
acute
angles prevent longitudinal shifting as well as compression or expansion of
the
spaced-apart relationship of the panels 60. This ensures the dimensional
integrity
of the resulting structure.
After the panels 60 are placed into the channels of the U-shaped elongated
members 74 coupled by the links 76, a substantially T-shaped elongated
member 70 is placed into the slot 72 located on a lateral edge 61 of each of
the
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panels 60 as shown in FIG. 14. The bottom edge of the T-shaped member 70 is
placed into the channel 75 of the U-shaped member 74. The next pane160 is
aligned with the pane160 already in place and attached to the panel 60 by
inserting
the flanges 71 of the T-shaped member 70 into the slot 72 in the lateral edge
61 of
the panel 60. This construction method can be repeated, as shown in FIG. 14,
until a desired structure length is achieved. Further, the panels 60 can be
easily
cut to provide virtually any structure height desired. This is a distinct
advantage
over prior art systems which have typically required labor-intensive
operations to
produce nonstandard structure heights. The panels 60 can be easily raised and
lowered along the tracks created by the flanges 71 of the T-shaped members 70
in
order to install fixtures or other components between the interior and
exterior
panel assembles 86 as shown in FIG. 18.
The top cap 66 is placed over the top edge of the aligned panels 60 as
shown in FIG. 14. If the aligned top edges are not level, the top cap 66 can
be
fixed in place using drywall screws or other conventional means once it has
been
pivoted into a level configuration. In this way, the top surface of the
resulting
structure can quickly be made perfectly level, without requiring a complicated
and
labor-intensive process. In this embodiment, the U-shaped channel members 74
that form the top cap 66 are interconnected by rigid members 76. However, the
U-shaped members 74 that form the bottom assembly 62, as well as the U-shaped
members that form the top cap 66, do not have to be coupled together by links
76.
However, the members 74 which form the inner and outer channels 75 of the
bottom assembly 62 are secured individually to the footing 64, and the U-
shaped
members that form the inner and outer channels for the top cap 66, although
independent of one another, are fixed in place using drywall screws or other
conventional fasteners.
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The building form system can be braced as shown in FIG. 18. Because the
aligned panel assemblies 68 require bracing 80 only at the corners of the form
system and the bracing 80 runs parallel to the form system, a significant
amount of
work effort and material is saved compared to prior art form systems which
require
vertical bracing at regular intervals to keep the panel assemblies 68 plumb
and to
prevent horizontal bulging. In addition, workers have limited functions to
perform
outside the panel assembly 68. This enables a substantial reduction in the
conventional four-foot working space typically dug outside foundation walls.
Accordingly, much less backfilling is required. The panel assemblies 68 are
strong
enough to allow the desired backfilling operations of the present invention to
take
place before concrete or other hardenable liquid building materials are poured
into
the system. This unusual strength enables greater flexibility in scheduling
the
backfilling operation, thereby expediting the construction process and
lowering
costs.
Once all sections have been assembled as shown in FIG. 14 and the top
caps 66 have been leveled, hardenable liquid building material (preferably
concrete) can be poured into the spaces between the top caps 66, panels 60,
T-shaped elongated members 70 and the U-shaped elongated members 74. After
the concrete hardens, a solid structure is formed. The invention allows
drywall or
other building material to be connected to the panel assemblies 68 using
drywall
screws or other conventional means penetrating the flanges of the T-shaped
elongated members 70 or U-shaped elongated members 74. The drywall can also
be connected to the top cap 66 in an identical fashion.
While the members described herein can be formed from a variety of
materials such as steel and plastic, preferably steel or extruded plastic are
used
depending on the availability and material cost of each in a specific region.
The
extruded plastic design allows relatively long members to be formed without
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expensive tooling required for injection molded designs. Although vertical
members are available in lengths of up to sixteen feet or more, it may still
be
desirable to splice sections of assembled wall assemblies together to create
assemblies of greater height.
The present invention does not require special, complex pieces for the
splicing operation. Instead, an H-shaped elongated member 24 can be placed
horizontally across the top ends of the vertical panels 60 and T-shaped
members 70. The horizontal H-shaped elongated member 24 is connected to the
various members using conventional means such as drywall screws. The next
level of vertically aligned panels 60 and T-shaped members 70 are inserted
into the
upwardly directed channel of the H-shaped member 24. Finally, the top cap 66
is
placed over the assembled sections. In this way, a secure connection is easily
and
quickly obtained.
FIGS. 15 and 16A - 16E show a method for constructing a ninety degree
outside corner. U-shaped members 74 coupled by substantially rigid links 76
are
cut at forty-five degree angles at the ends and coupled to a footing 64 at a
right
angle to similar U-shaped members 74. To form the outer alignment of the comer
assembly 82, the bottom edge of a corner post 86 is inserted in a
substantially
vertical orientation into the channel 75 of the outer U-shaped member 74. The
bottom edge of a T-shaped member 70 in a substantially vertical orientation is
inserted into the channel 75 of the outer U-shaped member 74 and the flange 71
of
the T-shaped member is inserted into a slot in the lateral edge of the corner
post 86. The bottom edge of a substantially vertically oriented panel 60 is
inserted
into the channel 75 of the outer U-shaped member 74 and the panel 60 is
coupled
to the corner post 86 by inserting the flange 71 of the T-shaped member 70
into a
slot 72 in the lateral edge 61 of the panel 60. The corner post 86 preferably
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includes a built in drain tile to accept down spout run off from the roof of
the
structure and deliver it to a conventional tile in a foundation footing 64.
To form the inner alignment of the corner assembly 84, the bottom edge of
a preformed panel 88 in the form of a ninety degree corner is inserted into
the
channel 75 of the inner U-shaped members 74. The bottom edge of a
substantially
vertically oriented T-shaped member 70, coupled to an opposite T-shaped
member 70 by substantially rigid links 76, is inserted into the channe175 of
the
inner U-shaped member 74 and the flange 71 of the T-shaped member is inserted
into a slot in the lateral edge of the preformed panel 88. The bottom edge of
a
substantially vertical panel 60 is inserted into the channel 75 of the inner U-
shaped
member and coupled to the preformed panel 88 by inserting the flange 71 of the
T-shaped member 70 into a slot 72 in the lateral edge 61 of the panel 60.
Panels 60 and T-shaped members 70 alternately are inserted into the inner and
outer U-shaped members 74 until a structure of the desired length is obtained.
While in the exemplary embodiment the invention is described with reference to
forming a ninety degree outside corner, it is apparent that corner assemblies
can be
provided to form corners for wall sections that extend at angles less than
ninety
degrees and at angles greater than ninety degrees by suitable shaping of the
corner
elements 86 and 88.
The invention can also be used to form curved walls as shown in FIG. 17A.
In this embodiment, the curved section comprises standard T-shaped elongated
members 70 in a substantially vertical orientation. The T-shaped elongated
members 70 are coupled by rigid links 76 that connect narrower panels 60 (as
shown in FIG. 17C) in the inner arc of the curve 90 and wider panels 60 (as
shown
in FIG. 17B) in the outer arc of the curve 92. The panels 60 are beveled at an
angle sufficient to allow the lateral edges 61 of said panels 60 to fit
tightly together
and prevent liquid building material leakage.
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In another alternative embodiment of the invention, substanrially vertically
oriented H-shaped elongated members 24 are substituted for the T-shaped
members 70. The bottom edge of the H-shaped member 24 is inserted into and
contained within the channel of the U-shaped member 74. Alternatively, the
panels 60 are aligned and connected by inserting the flanges of the H-shaped
members 24 into slots in the lateral edges 61 of the panels 60 on either side
of said
member. In another embodiment, the panels are aligned and connected by
inserting the lateral edges 61 of the panels 60 on either side of the H-shaped
member 24 into the corresponding channel in the H-shaped member.
Accordingly, the present invention provides the ability to anchor drywall to
the resulting structure. This is required by building codes in many areas of
the
country. Previous systems have typically not provided for this criterion,
typically
necessitating the use of masonry anchors which are expensive and time-
consuming
to install. The system of the present invention is simple to use, thereby
reducing
training costs and enhancing efficiency. Further, a smooth flat surface at the
top
of the form enables quick and easy cleanup of concrete which spills over the
side
while pouring from conventional supply means such as a concrete truck. Because
this spillover is very common, substantial labor savings can be realized by
providing the easy to clean top surface of the present invention.
The invention provides a form system and apparatus that allows the upper
surface of the resulting structure to be adjusted to level without complex
and/or
labor-intensive operations. The present invention also provides a form system
and
apparatus that utilizes simple corner components that are strong and easy to
install,
and that requires no special pieces for connecting abutting pieces of the
system to
one another.
Further, the present invention provides the ability to level the top of a
foundation, without requiring special pieces or cutting to attain a level
upper
MW2\10679GLF:LJK 04/08/97 18
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surface of the foundation. It also provides a fully adjustable form system and
apparatus that can be produced by extruding to increase the length of the
components that can be produced over previous injection molded designs and
reduces tooling and labor costs accordingly. Finally, the inventors have
discovered that a form system and apparatus can be constructed to be strong
enough to allow backfilling operations to take place before concrete or other
hardenable liquid building material is poured into the form. This enables
easier
access to the form for filling, and allows the backfilling operation to be
scheduled
when time and weather permits. This flexibility of operation can further
expedite
the building process.
FIGS. 19A and 20 show two alternate forms of construction of a
ninety degree outside corner. As in FIG. 14, FIG. 19A shows U-shaped members
74 coupled by substantially rigid links 76. In forming the corner in
accordance
with a preferred embodiment, inner and outer U-shaped members 74' are cut and
bent at ninety degree angle, forming portions which extend at a right angle to
one
another at the corner. The members 74' are coupled to a footing 64 in a manner
similar to that in which U-shaped members 74 are coupled to the footing,
forming
inner and outer channels with channel portions that extend at an angle
relative to
one another. Alternatively, the ends of two U-shaped members can be cut at
forty-
five degree angle allowing the ends of the members to be butted against one
another to form the ninety degree joint at the corner. A right angled member
73 is
provided to form the outside corner and is preferably made of steel or
extruded
plastic or other material similar to that used for the T-shaped members 70.
T-shaped members 70' and 70" are attached to the right angled member 73 with
drywall screws for example, and cooperate with member 73 when so assembled to
form the outside corner element of the form as shown in FIG. 19B. The bottom
edges of the corner element formed by 73, 70' and 70" are inserted in a
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substantially vertical orientation into the channel 75 of the outer U-shaped
member 74. The bottom edges of substantially vertically oriented panels 60 are
then inserted into the channel 75 of the outer U-shaped member 74 and the
panels 60 are coupled to the corner element by inserting the flange 71 of the
T-shaped members 70' and 70" into slots 72 in the lateral edge 61 of the
panels 60.
FIG. 20 illustrates a preferred embodiment of a ninety degree outside
coraer. In this embodiment, the outside corner consists of an one-piece, full
height
corner panel 63 of high density polystyrene material, or any other suitable
material, preformed in the shape of an angled corner, with panel portions 63'
and
63" extending at an angle to one another, and in the exemplary embodiment, the
panel portions 63' and 63" extend at a relative angle of ninety degrees. The
corner
panel can be eight feet in vertical length, for example. Embedded within the
preformed corner piece 63 at or just below the outside surface as shown are
two
T-shaped strengthening members 70', 70" which provide additional strength to
the
corner panel 63 as well as provide anchor points for drywall screws.
As in the embodiment of FIG. 15, in each of the embodiments shown in
FIGS. 19A and 20, a preformed panel 88 in the form of a ninety degree corner
is
inserted into the channel 75 of the inner shaped members 74 to form the
interior of
the corner assembly. The bottom edge of a substantially vertically oriented
T-shaped member 70, coupled to an opposite T-shaped member 70 by
substantially rigid links 76, is inserted into the channel 75 of the inner U-
shaped
member 74 and the flange 71 of the T-shaped member is inserted into a slot 72
in
the lateral edge of the preformed panel 88. The bottom edge of a substantially
vertical pane160 is inserted into the channel 75 of the inner U-shaped member
and
coupled to the preformed panel 88 by inserting the flange 71 of the T-shaped
member 70 into a slot 72 in the lateral edge 61 of the panel 60. Panels 60 and
T-shaped members 70 alternately are inserted into the inner and outer U-shaped
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members 74 until a structure of the desired length is obtained. As in the
embodiment of FIG 15, in each of the embodiments shown in FIGS. 19A and 20, a
top cap 66 is placed on the top of a line of panel assemblies 68. Also, as has
been
pointed out above, the U-shaped members 74 that form the bottom assembly 62,
as
well as the U-shaped members that form the top cap 66, do not have to be
coupled
together by links 76, the members 74 of which form the inner and outer
channels
75 of the bottom assembly 62 being secured to the footing, and the U-shaped
members that form the inner and outer channels for the top cap 66 being
independent of one another.
While in the exemplary embodiments, illustrated in FIGS. 19A and 20, the
invention is described with reference to forming a ninety degree outside
corner, it
is apparent that corner assemblies can be provided to form corners for wall
sections that extend at angles less than ninety degrees and at angles greater
than
ninety degrees by suitable shaping of the corner elements 73 and 88 for the
wall
structure of FIG. 19A or the preformed corner piece 63 and preformed panel 88
for
the wall structure of FIG. 20.
FIG. 19B illustrates the vertically oriented ninety degree outside corner
assembly of FIG. 19A in assembled form, and further illustrates a means of
bracing the corner. Right-angled triangular shaped pieces 100 of reinforcing
material of the same height or a substantial portion of the height of the wall
to be
reinforced are attached to the corner assembly as shown. The bottom edges 101
of
each triangular piece are aligned with the bottom U-shaped members 74, and the
vertical edges 102 are aligned adjacent the vertical right angled member 73.
They
are affixed to the wall along the horizontal bottom and vertical side by
attaching
them to the adjacent U-shaped member 74 and vertical T-shaped member by any
convenient means, such as drywall screws.
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The reinforcing material may be made of any suitable material, such as
metal, plywood or heavy plastic. When installed in the fashion described, the
reinforcements protect the corner during construction, and lend additional
support
to the structure while the concrete or other material to be set in the forms
is being
poured or during curing.
Referring now to FIGS. 21A and 21B, there is illustrated a portion of a wall
140 and a foundation 142 for a building. The foundation 142 is constructed in
accordance with the invention and, as shown in FIG. 21B, includes spaced,
substantially parallel, vertically oriented inner and outer panels 160 and 162
of a
polymer foam material, such as polystyrene, between which concrete 144 or
other
building material has been poured and allowed to harden, forming a structural
member. Panels 160 and 162 correspond to panels 60 shown in FIGS. 14, 15, 19
and 20, for example, and extend in a side-by-side relationship along planar
inner
and outer surfaces 145 and 146, respectively, of the concrete 144 and from the
top
or upper edge 147 to the bottom or lower edge 149 of the foundation wall
portion
formed by the concrete 144.
Referring to FIG. 21A, as has been described above with reference to FIGS.
14, 15, 19 and 20, for example, adjacent panels 160 are connected by
vertically
extending, T-shaped elongated members 70 which extend the vertical length of
the
panels 160 and 162. The T-shaped members 70 have their bottom ends mounted
in the U-shaped channel members 74, represented by dashed lines in FIG. 21A,
and interconnected by links 76 (FIG. 14) in the manner described above. Top
caps
166 and 168, which correspond to top caps 66 (FIG. 14) are placed over the
tops
of the outer panels 160 and the inner panels 162. In this embodiment, the top
caps
166 and the U-shaped members (not shown) which support the T-shaped members
70 are not interconnected by links, such as links 76.
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The bottom edge 148 of the wall 140 rests on a sill plate 150 that extends
the length of the foundation in the conventional manner. The outer surface 152
of
the wall 140 has to be substantially flush with the outer surface 154 of the
foundation and so approximately one-half of the sill plate 150 overlies the
polystyrene panel, as is illustrated in FIG. 21B.
As is known, the load of the wall 140 on the sill plate 150 produces a down
pressure on the polystyrene panels 160. The upright T-shaped members 70 act as
studs or supports which substantially prevent the sill plate 150 from bowing
or
cracking as would allow crushing of the polystyrene panels 160 located beneath
the sill plate 150. The top cap 166 on the polystyrene panels 160 distributes
the
wall load along the length of the foundation. In contrast, known polystyrene
concrete forming systems, do not provide such support so that the load
presented
by a wall on the sill plate on which the wall is supported is applied through
the sill
plate to the underlying polystyrene, crushing the polystyrene in time, and
causing
the sill plate to bend or crack. This would allow the building to settle,
causing
damage to the structure.
FIG. 22 illustrates a modification of the previously described construction
form systems for use with pre-fabricated homes for forming a wall upon a
footing.
Instead of a double-sided form being constructed as previously described, the
invention may be used in a single-sided form in association with pre-
fabricated
houses which do not require a full foundation.
In the case of many pre-manufactured houses, a poured foundation is not
required or is not possible, and the houses are instead set on the ground on
supporting pillars. In these cases, a skirting must be applied around the
bottom of
the house to comply with local building codes, as well as to provide
insulation of
the house and to keep animals and children from underneath the structure.
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The present invention provides an ideal means of forming a wall between
the bottom of a pre-fabricated house and a concrete slab footing. In a normal
pre-fabricated installation, as seen in FIG. 22, a poured concrete slab 200 is
provided as a level base or footing for the siting of the pre-fabricated house
201.
Pillars or supports 202 (made from cinder blocks for example in the example
shown) are built in the appropriate locations on the slab 200 in order to
support the
weight of the house when installed upon the supports.
Once the house has been installed onto the supports, the wall of the
invention may be formed on the slab between the slab and the house. This is
done
by securing U-shaped channels 274 to the concrete slab 200 adjacent the
perimeter
of the house 201 where it is desired to form the wall. The U-shaped channels
274
may be secured to the concrete slab 200 in any convenient fashion such as by
means of masonry fasteners for example.
A U-shaped top cap 266 is secured by screws to the rim joist on the
underside 267 of the house around its perimeter as shown, and located
vertically
above the bottom U-shaped channel 274. In the example depicted in FIG. 22, the
top cap 266 and bottom U-shaped channel 274 are shown only partially installed
on the house. When fully installed, the U-shaped top cap 266 and U-shaped
bottom channel 274 would both extend fully along the entire length of the wall
or
walls to be constructed.
Vertically oriented side panels 260 cut to the correct height to fit are then
slid between the U-shaped top cap 266 and bottom channe1274, thereby forming a
solid vertical surface between the top cap and the bottom channel. In the
example
shown, the side panels 260 are made of approximately 21/z-inch thick high
density
material such as expanded or extruded polymer foam or polystyrene. The
U-shaped top cap 266 and bottom channel 274 are sized so as to permit the
vertical
MW2\10679GLF:LJK 04/08/97 24
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panels to be slid snugly in to the top and bottom channels from an open end,
as
shown by the arrows "A" and "B" in FIG. 22.
The vertical panels 260 include slots 272 formed in each vertical edge,
adapted to receive flanges 271 of T-shaped members 270, pennitting the T-
shaped
members 270 to be fit between adjacent vertical panels 260, providing a
reinforced
connection between panels and sealing air gaps. The T-shaped members are sized
so that they will fit between the U-shaped top cap 266 and bottom channel 274,
and are thin enough that they may fit between opposite sides of the channel,
thereby permitting the T-shaped members to be fully seated within the U-shaped
top cap 266 and bottom channe1274, respectively.
In the example shown, corners are formed by simply leaving a slight gap
276 between the U-shaped channels 274 as shown. The polystyrene panels 260
may then simply be slid together to form a butt joint.
Once in position, the vertical polystyrene panels may then be fixed in place
with screws through the sides of the U-shaped top cap 266 and bottom
channel 274. Additionally, adjacent vertical panels 260 may be held in place
by
means of screws into the vertical flanges 271 of vertical T-shaped members
270.
FIG. 23 illustrates in exploded perspective fashion the construction of a
side wall in the manner just described, utilizing T-shaped members 270.
Alternatively, H-shaped members 224 may be utilized, as shown in FIG. 24.
Once all vertical panels have been positioned and fixed, a structural skin
coating 280, shown in FIG. 23 for only one of the panels 260 of a hardenable
material is then back plastered over the vertical polystyrene panels in order
to give
the assembled wall the uniform appearance of a poured foundation. By applying
parging to the wall in this fashion, it is possible to provide a fuushed
skirting wall
indistinguishable to the eye from a normal poured foundation.
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FIG. 25 illustrates a means of adjusting the installation of the wall to
compensate for concrete slabs which are not completely level. Because it is
not
necessary for the vertical panels to be fully seated in the U-shaped top cap
266 so
long as they engage the sides of the U-shaped channel adequately, there is
some
latitude for adjustnient of the top cap 266. In the example shown, there is
approximately one inch of height adjustment possible between the sides of the
wall, as indicated at "d".
In addition, because of the nature of the materials from which they are
made, the vertical panels may be easily and quickly custom cut to fit, as may
the
vertical T-shaped members 270. Accordingly, with the system described by the
present invention, it is possible to quickly and cheaply fashion a wall to fit
any
dimensions, without requiring any special tools.
By utilizing the const.ruction form system of the present invention in this
single-sided manner for the construction of side walls, numerous advantages
are
obtained. The resulting wall (when parged) is indistinguishable to the eye
from a
normal poured foundation. The wall has sufficient strength to permit
backfilling to
be done against the wall. The polystyrene panels provide insulation up to an R-
I 1
level, thereby possibly eliminating the need for further insulation. The walls
are
water resistant, rodent-resistant, wind resistant and child resistant.
The walls may be made adjustable to any height, including uneven heights.
For example, it is no more difficult to build a wall 22 inches high at one end
and
30 inches high at the other than it is to build a wall the same height
throughout.
Windows and vents may be easily positioned in the walls simply by cutting the
polystyrene panels to the right size to permit them. Automatic venting may be
easily installed with vents supplied by third party suppliers.
- FIGS. 26A, 26B, 26C, 26D, 26E and 26F illustrate an improved link or
cross tie 300 which.can be used in place of or in addition to the links 76
previously
MW2\10679GLF:LJK 04/08/97 26
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described for maintaining forms, such as panels 60 shown in FIGS. 14, 15, 18,
19A and 20, for example, in a desired spaced relationship until hardenable
liquid
building material is poured and hardens between the forms. The link 300
includes
an elongated body portion 301 having a wing or flange 302 formed on the top
edge
303 of the link 300, as viewed in the side elevation view of FIG. 26B, and a
flange
304 formed on the bottom edge 305 of the link 300. The flanges 302 and 304 are
bent outwardly and rearwardly relative to the plane of the body portion 301 to
provide a stiffening effect by giving the link 300 a generally U-shaped
profile as
shown in FIGS. 26E and 26F, for example. In one embodiment, the flanges were
bent at an angle a(FIG. 26F) of approximately of 20 relative to the plane of
the
body portion 301. However, the flanges can be bent at other angles.
The link 300 further includes connecting end portions 306 and 307 at
opposite ends of the body portion 301 which facilitate connection of the link
300
to the leg portions 77 of the vertically oriented T-shaped members 70, shown
in
FIG. 19A, for example. The connecting end portions are defined by extensions
308 and 309 of the body portion at opposite ends thereof and by the opposite
end
portions 310 and 311 of the flanges 302 and 303. The flange end portions 310
and
311 are detached from the body portion 301 and lie in a plane that extends
parallel
to the plane of the body portion 301, spaced rearwardly of the plane of the
extensions 308 and 309 of the body portion, as shown in FIG. 26C, defining
slots
312. The slots 312 are adapted to receive the vertical leg portion 77 of the T-
shaped mounting member 76 (FIG. 19A). The opposing, spaced-apart portions of
the link, defmed by the extension 308 and the flange end portions 310 at one
connecting end portion 306 of the link, are adapted to engage the leg of the T-
shaped member on opposite sides thereof. Similarly, the opposing, spaced-apart
portions of the link, defmed by the extension 309 and the flange end portions
311
at the opposite connecting end portion 307 of the link, are adapted to engage
the
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leg of a further T-shaped member on opposite sides thereof. The flanges 302
and
304 are twisted in the transition regions 314 between the flange end portions
310
and 311 and the flange portion intermediate the end portions to provide the
change
in orientation between the intermediate portion of the flange and the flange
end
portions 310 and 311.
Each of the flanges 302 and 304 includes a rib 316 that extends along the
flange for providing additional stiffening to the link 300. The length of the
rib 316
corresponds approximately to the length of the body portion 301. The link 300
includes further stiffening ribs 318 which extend along the body portion 301
of the
link 300 and which converge at the connecting end portions of the link.
Instead of a relatively heavy gauge U-shaped link 76, the link 300 of
FIG. 26 can be stamped out of a lightweight metal (24 gauge sheet metal, for
example) which is formed to defme the outwardly extending flanges 302 and 304
and the end portions 310 and 312 which are connected to the flanges by the
twisted regions at both sides, and including strengthening ribs, resulting in
a link
that is characterized by increased rigidity for a given material thickness.
Cuts
provided in the twisted regions or pleats near each end, detach the flange
ends 310
and 311 from the body portion 310, forming the slots 314 at each end into
which
the legs 77 of a pair of T-shaped members 76 (FIG. 19A) can be inserted and
spot
welded at weld projections 320. By way of example, the link 300 can be between
about 6.5 inches to 18.5 inches in length and preferably is about 12.5 inches
in
length. The link can be about 1.75 inches in width between its top and bottom
edges and approximately .5 inch thick.
As will be apparent to those skilled, with suitable modification of the
configuration of the connecting end portions of the link 300, the link 300 can
also
be used to interconnect the bottom and/or top U-shaped members 74, and can be
used in place of the links 28 which interconnect the U-shaped members 26, the
H-
MW2110679GLF:LJK 04/08/97 28
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shaped members 24 to the top cap 29, which are shown in FIGS. 1-13, for
example.
While particular embodiments of the invention has been shown and
described, it will be obvious to those skilled in the art that changes and
modifications may be made without departing from the invention in its broader
aspects, and, therefore, the aim in the appended claims is to cover all such
changes
and modifications as fall within the true spirit and scope of the invention.
MW2\10679GLF:LJK 04/08/97 29
