Note: Descriptions are shown in the official language in which they were submitted.
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CONCRETE FORM SYSTEM AND METHOD
BACKGROUND OF THE INVENTION
S Field of the Invention
The present invention relates generally to a method and system for use in
forming concrete walls, blocks and other components. The invention relates
more
particularly to components of a concrete form system, and methods of using the
same,
including: i) side panels having an improved web member structure embedded
therein;
10 ii) a connector link for joining two or more connectors spanning between
two side
panels of the concrete form system to create a form cavity of extended
incremental
width dimension; iii) a ledge assembly for providing a bearing surface, such
as for
supporting a brick fascia, a flooring system, or other components; iv) a
corner web
member for incorporation into corner side panels of the concrete form system
for
15 attachment of wall cladding; and v) a termite infestation identification
surface
incorporated into a side panel of the concrete from system.
Description of Related Art
Concrete walls in building construction traditionally have been produced by
20 first setting up two spaced apart form panels and pouring concrete into the
space
between the form panels. After the concrete hardens, the builder then removes
the
forms, leaving the cured concrete wall. This technique has been found to
present a
number of drawbacks. For example, formation of concrete walls using the
traditional
technique is inefficient because of the time required to erect the forms, wait
until the
25 concrete cures, and take down the forms. The traditional forming and
fabricating
technique, therefore, is an expensive, labor-intensive process. Moreover, the
provision
of a ledge or other bearing surface using traditional forming techniques
greatly
increases the complexity and expense of a project.
30 Improved techniques have been developed for forming modular concrete walls,
using a foam insulating material for the form panels. The modular form panels
are set
up, typically generally parallel to each other, with connecting components
holding the
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2 -"
two form panels in place relative to each other. Concrete is then poured into
the space
between the foam form panels. Unlike the traditional forming technique,
however, the
foam form panels remain in place after the concrete has cured. That is, the
form panels
become a permanent part of the building after the concrete cures. The concrete
walls
5 made using this technique can be stacked on top of each other many stories
high to
form all of a building's walls. In addition to the efficiency gained by
eliminating the
need for removal of the form panels from the structure, the foam material of
the form
panels provides the finished wall with improved thermal insulation and
acoustical
impedence characteristics, as compared to bare concrete walls.
10
A number of variations of modular insulating concrete forms and methods for
their use have been developed. Concrete form systems utilizing opposed side
panel
forms joined by connectors to define a chamber therebetween are known. For
example,
U.S. Patent Nos. 4,698,947; 4,730,422 and 4,884,382, all incorporated herein
by
15 reference, disclose concrete form systems incorporating connectors for
holding the side
panels in spaced relation; and U.S. Patent No. Des. 378,049, also incorporated
herein
by reference, discloses a connector for such systems. Although the exemplified
prior
art proposed variations to achieve improvements with concrete form systems,
drawbacks still exist for each design. The connecting components used in the
prior art
20 to hold the walls are typically constructed of plastic foam, high density
plastic, or a
metal bridge, which acts as a non-structural support, i.e., once the concrete
cures, the
connecting components serve no function.
A further exemplified embodiment of a prior art connecting component for a
25 concrete form system is disclosed in U.S. Patent No. 5,390,459, which
issued to
Mensen, on February 21, 1995 and which is incorporated herein by reference.
This
patent discloses "bridging members" that comprise end plates connected by a
plurality
of web members. The bridging members also use reinforcing ribs, reinforcing
webs,
reinforcing members extending from the upper edge of the web member to the top
side
30 of the end plates, and reinforcing members extending from the lower edge of
the web
member to the bottom side of the end plates. As one skilled in the art will
appreciate,
this support system is expensive to construct, which, in turn, increases the
cost of the
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3 '
formed wall. It has been found that such concrete form systems may be improved
upon
through the provision of a modified web member in place of the above described
web
member 16.
5 One further disadvantage common to the prior art concrete form systems is
the
limited ability to vary the spacing between side panels of the forms, and
thereby, the
thickness of the finished concrete wall. Typically, connectors or bridging
members are
provided in several standard lengths, often in two-inch increments (i.e., 2",
4", 6" and
8"), to produce standard wall thicknesses. It has been found desirable
however, for
10 certain applications, to produce walls of greater or different thickness
than is permitted
using standard length connectors. For example, desired wall thicknesses of up
to and
possibly exceeding 24" may be encountered. Typically, however, owing in part
to the
dimensions of associated commercially available building materials, walls are
formed
with thicknesses of even two-inch increments. The provision of separate
connectors
15 manufactured in lengths adapted to produce walls of every potential
incremental
thickness (e.g., 4", 6", 8", . . . up to 24" or more) would be prohibitively
expensive.
Known adjustable length connectors are expensive to produce and complicated to
install, thus increasing fabrication costs and potential for incorrect
adjustment and
installation. Thus, it has been found that a need exists for a concrete form
system and
20 method of concrete fabrication enabling the production of walls of various
thicknesses
utilizing standard components.
For certain applications during building of concrete structures, it is also
often
desirable to provide a bearing surface, such as a ledge or shelf, on a
concrete wall or
25 other structure. For example, a brick fascia may be provided on the
exterior surface of
a concrete wall, typically extending upwardly from grade, and/or bearing
surfaces for
floor joists, floor trusses, ceiling joists or other building components may
be required
on the interior surface of a wall. Known insulated concrete form systems have
been
found to present undesirable disadvantages in forming such bearing surfaces.
For
30 example, the brick shelf form described in U.S. Patent No. 5,657,600 has
been found
less than fully satisfactory due to the presence of thick foam partitions
between cut-
away areas of the form panels. These foam partitions present substantial
interruptions
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4
in the concrete bearing surface, potentially weakening the support provided
thereby.
An additional disadvantage to the brick shelf form described in U.S. Patent
No.
5,657,600 results from the inability to vary the thickness of the wall formed
due to the
fixed size of the bridging members embedded into the form panels. Thus, it has
been
5 found that a need exists for an improved concrete form system and method of
concrete
fabrication enabling the production of walls and other components including
bearing
surfaces such a brick ledges and/or floor joists.
In the construction of a building, it is also often desirable, and in some
cases
10 required by local building ordinance, to provide a termite infestation
detection structure
on a concrete wall or other structure having insulated side panels.
Unfortunately, the
various other concrete form systems utilizing opposed side panel forms
enclosing a
core of concrete, exemplified in U.S. Patent Nos. 4,698,947; 4,730,422; and
4,884,382,
may allow the undetected infiltration of termites via the insulated side
panels into
15 vulnerable structures, such as for example wood framed construction,
mounted onto the
concrete form system. Typical detection of termite infestation requires some
form of
visual detection of the presence of the unwanted insects. However, because the
infiltration typically occurs between the concrete in the cavity and the
interior surface
of the side panel or within the material forming the side panel, any damaging
20 infestation may not be detected until significant damage to the vulnerable
structures has
been completed. Thus, it has been found that a need exists for a method of
concrete
fabrication enabling the production of walls incorporating a termite detection
surface
for visual detection of possible termite infestation of the building.
25 It is to the provision of a concrete form system and method of concrete
wall
fabrication meeting these and other needs that the present invention is
primarily
directed.
30 SUMMARY OF THE INVENTION
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Briefly described, the present invention comprises a concrete form system and
a
method of fabrication for the production of concrete walls, blocks, beams,
ledges,
foundations, floor and roof panels that overcomes the disadvantages of the
prior art.
The present invention further includes improved components for the concrete
form
5 system and concrete structures formed by such a system, components, and/or
methods.
Applicant's prior pending U.S. Patent Application, Serial No. 09/008,437,
filed
January 16, 1998, and U.S. Patent No. 5,887,401, which are incorporated in
their
entirety herein by reference, disclose improved concrete form systems and
methods.
10 Referring to Figs. 1 and 2, and as disclosed in the applicant's above-
referenced
application and the '401 patent, an example concrete form system is shown that
is
capable of adaptation and use with the improvements and components of the
present
invention. Opposed longitudinally-extending side panels 10, 12 comprise the
form
panels, defining a cavity 14 therebetween, into which uncured concrete is
poured to
15 fabricate a concrete block, wall, panel or other component. Each side panel
10, 12
incorporates a number of web members 16, partially embedded within or
otherwise
attached to the side panel 10, 12, and having one or more attachment points 17
external
of the side panel 10, 12. Since the web member is an integral part of the side
panel, it
"locks" the side panel to the concrete once the concrete is poured and cures
within the
20 cavity. Each web member preferably has an end plate disposed adjacent the
exterior
surface of the respective side panel. The end plates may be located slightly
below the
exterior surface of, or recessed within, the side panel, preferably at a
distance of one-
quarter ('/4) of an inch from the exterior surface or may abut the exterior
surface of the
panels so that a portion of the end plate is exposed over the exterior
surface. The end
25 plates provide a mounting surface for the allow for secure attachment of,
for example,
exterior fascia such as siding.
Opposed pairs of attachment points 17 of the of web members 16 attached to
each side panel 10, 12 are joined by connectors 18. The attachment points of
each web
30 member are also oriented substantially upright so that one attachment point
is disposed
above another attachment point. As best shown in Fig. 2, the plurality of
attachment
points of each web member are vertically disposed within the cavity in a
substantially
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6
linear relationship. Each connector I 8 includes first and second connector
couplings
that engage opposed attachment points 17 of the side panels 10, 12. One or
more
mounting apertures 24 can be provided on the connectors 18 for receiving re-
bar.
In one aspect, the present invention provides a concrete form system having at
least one longitudinally-extending side panel, and more preferably, a first
longitudinally-extending side panel and a second longitudinally-extending side
panel
having opposed interior faces spaced apart to define a cavity therebetween.
The side
panels preferably comprise an insulating material, such as expanded
polystyrene (EPS).
10 Each side panel preferably includes at least one web member disposed and
integrally
formed at least partially within the side panel and extending from adjacent
the exterior
surface of the side panel through and out of the interior surface of the side
panel. The
portion of the web member extending from the interior surface of the side
panel forms
at least one upper attachment coupling, at least one lower attachment
coupling, and a
1 S medial attachment coupling. The system preferably further comprises one or
more
connectors for detachable engagement with the attachment couplings of the web
members.
In one preferred embodiment, the improved web member includes an end plate,
20 a plurality of support struts extending from the end plate, and attachment
couplings
connected to each of the support struts, distal the end plate. In a further
preferred
embodiment, the web member has two upper attachment couplings, two lower
attachment couplings, and a medial attachment coupling and five support
struts,
arranged in a generally linear array comprising a first group of two support
struts and
25 two upper attachment couplings, a second group of two support struts and
two lower
attachment couplings, and a medial strut and attachment coupling disposed
between the
first and second groups.
Still further, the web member may have a plurality of bridging members and
30 end struts to add structural rigidity to the web member. The bridging
members
preferably extend between adjacent support struts and the ends of the bridging
members
are preferably connected near the respective distal ends of adjacent support
struts
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7
proximate the connected attachment coupling. Preferably, the web member may
also
have a first end strut and a second end strut, the first end strut extending
from the end
plate near the top edge of the end plate to near the distal end of the closet
adjacent
support strut and the second end strut extending from the end plate near the
bottom end
S of the end plate to near the distal end of the closest adjacent support
strut.
In use, the first and second side panels are first vertically disposed so that
a
portion of the interior surfaces of the side panels are spaced apart from each
other to
form a cavity. When the side panels are disposed in this manner, the
attachment
10 couplings of the web members which extend from, and are spaced apart from,
the
interior surface of each side panel are preferably arranged so that the
attachment
couplings of one web member opposes and is spaced apart a predetermined
distance
from the attachment couplings of the other web member in the other side panel.
At
least one connector is detachably attached to two opposing attachment
couplings to
1 S connect the two erected side panels and the cavity is substantially filled
with concrete
for curing therein.
Another aspect of the present invention provides an insulated concrete slab
structure. In preferred form, the insulated concrete slab structure includes
at least one
20 side panel, at least one web member, and a concrete slab having a surface
in contact
with at least one side panel. In this aspect, it is preferred that the
improved web
member be disposed and integrally formed at least partially within each side
panel and
have at least one upper attachment point, at least one lover attachment point,
and a
medial attachment point that is disposed within said concrete slab.
25
The concrete form system may also include a ledge assembly. The ledge
assembly preferably includes a ledge panel, at least one ledge web member, and
a
plurality of ledge attachment couplings. The ledge panel preferably has a
ledge interior
surface, an opposing ledge exterior surface, a lower edge, an upper edge and a
generally
30 planar panel body extending therebetween. Each ledge v-eb member has an
embedded
portion that is partially disposed and integrally formed within the panel
body, and an
exposed portion extending outward of the ledge interior surface of the panel
body. The
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8 '-
ledge attachment couplings are preferably arranged in a generally linear array
along the
exposed portion of ledge web member, the generally linear array of attachment
couplings preferably forming an acute angle with the generally planar panel
body. The
lower edge of the ledge panel can optionally include a first mounting coupling
for
5 engaging a lower side panel component of the concrete form system, and the
ledge web
member can optionally include a second mounting coupling for engaging an upper
side
panel component of the concrete form system.
In one preferred embodiment of the ledge assembly, a portion of the ledge
10 interior surface of the ledge panel faces, and is spaced apart from, a
portion of the
interior surface of a side panel to form a ledge cavity therebetween. The
attachment
couplings of the web members of the side panel and the ledge attachment
couplings of
the ledge web members are preferably generally disposed in apposition within
the ledge
cavity. Further, it is preferred that the attachment couplings of the side
panel are
1 S generally aligned in a first plane adjacent to, and preferably parallel
to, the interior
surface of the side panel and the ledge attachment couplings of the ledge web
members
are preferably generally disposed parallel to the first plane so that the
attachment
couplings and the opposed ledge attachment couplings are spaced apart a
predetermined
distance. The ledge panel preferably extends at an acute angle from the first
plane in
20 the direction of the ledge exterior surface of the ledge panel. The
concrete form system
preferably further includes a plurality of connectors engaged between the
ledge
attachment couplings of the ledge web members and the attachment couplings of
the
web members.
25 The concrete form system can optionally further include a second ledge
panel
assembly having a second ledge panel and a plurality of second ledge
attachment
couplings. In this embodiment, the second ledge attachment couplings of the
second
ledge panel assembly are generally aligned along a second plane adjacent the
interior
surface of the second side panel to which the second ledge panel assembly is
attached,
30 with the second ledge panel extending at an acute angle from the second
plane in the
direction of the exterior surface of the second side panel. It is preferred
that the second
ledge attachment coupling be spaced apart from and in opposition to one or
more
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9
attachment coupling of an opposing side wall or one or more ledge attachment
couplings of an opposing ledge panel. The connectors can be detachedly engaged
to
any two opposing attachment couplings. Thus, additional bearing surfaces can
be
provided in like manner on either or both surfaces of the wall.
In use, the present invention provides a method of fabricating a concrete wall
or
other component having one or more weight bearing ledge surfaces. In preferred
form,
the method of providing a weight bearing ledge surface comprises the step of
erecting a
first form panel having an interior surface, an exterior surface, and a
plurality of
10 attachment points generally aligned along a first plane adjacent the
interior surface, and
erecting a second form panel having an interior surface, an exterior surface,
and a
plurality of attachment points generally aligned along a second plane adjacent
the
interior surface. The interior surfaces of the first and second form panels
confront one
another and are separated a distance to define a cavity therebetween. The
method
15 further comprises installing a ledge panel assembly having a ledge panel
and a plurality
of attachment couplings onto the top of the first side panel. The ledge
attachment
couplings of the ledge panel assembly are preferably installed to be generally
aligned
with the attachment couplings along the first plane, and the ledge panel
extends at an
acute angle from the first plane in the direction of the exterior surface of
the first side
20 panel and from the interior surface of the second side panel to define a
ledge cavity
therebetween the Iedge panel and the second side panel. The method fiu-ther
comprises
engaging a plurality of connectors between attachment points aligned along the
first
plane and attachment points aligned along the second plane. The method further
comprises substantially filling the cavity between the first and second side
panels and
25 the ledge cavity with concrete.
The concrete form system and method of the present invention may also provide
a corner web member. Here, the concrete form system has a first corner panel
having
two longitudinally-extending side panels connected to form a substantially
vertical
30 corner panel edge in the exterior surface of the corner panel. The corner
panel may be
connected to other longitudinally-extending side panels of the structure
described
above. The corner web member includes a corner flange member, a bridging
member,
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10
and a plurality of support struts. The corner flange member has a
longitudinally-
extending first leg and a longitudinally-extending second leg connected to
form a
corner flange edge in the upper surface of the corner flange member. The
proximal end
of each support strut connected to the lower surface of the corner flange
member and
5 the distal end of each support strut connected to the top edge of the
bridging member to
structurally stabilize the corner web member.
The corner web member is partially disposed and integrally formed within the
first corner panel so that a portion of the corner web member extends through
the
10 interior surface of the first corner panel. The corner flange member and
the proximal
end of each support strut is embedded within the first corner panel. It is
preferred that
the corner flange member be adapted to fi-ictionally hold a metal fastener
therein and be
disposed adjacent the exterior surface of the corner panel. It is further
preferred to
dispose the corner flange member of the corner web member within the first
corner
15 panel so that the corner flange edge of the corner flange member is
substantially
parallel to the corner panel edge of the corner panel. The comer flange member
is
preferably shaped so that the upper surface of the corner flange member is
substantially
parallel to the exterior surface of the corner panel, i. e., if the corner
panel is "L" shaped,
the corner flange member is also preferably "L" shaped.
20
The corner web member may also have a support flange member having an
upper surface which is connected to the bottom edge of the bridging member.
The
support flange member is spaced apart from, and preferably parallel to, the
interior
surface of the corner panel. The support flange member preferably has a shape
that is
25 complementary to the shape of the corner flange member, i.e., if the corner
flange
member is "L" shaped, the support flange member is also preferably "L" shaped.
The present invention may also include a method of fabricating a concrete
structure having a corner web member. In this method of using the concrete
forming
30 system, a first and a second corner panel are exected so that a portion of
the interior
surface of the first corner panel faces, and is spaced apart from, a portion
of the interior
surface of the second corner panel so that a cavity is formed. The first
corner panel has
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a corner web member partially disposed within the first corner panel so that a
portion of
the corner web member extends through the interior surface of the first corner
panel
into the cavity between the first and second corner panels. The first and
second corner
panels preferably each have a plurality of attachment couplings spaced apart
from the
5 interior surfaces of the first and second corner panels. Next, a connector
is attached to
at least one opposing pair of attachment couplings extending from the
respective first
and second side panels. Finally, the cavity formed between the first and
second corner
panels is substantially filed with concrete and allowed to cure.
10 The concrete form system and method of the present invention may also allow
the combination of standard connectors and/or connector links in various
manners to
create a concrete structure of any desired thickness. In this embodiment, the
concrete
forming system preferably includes first and second longitudinally-extending
side
panels having opposed interior faces defining a cavity therebetween. Each of
the side
15 panels has at least one attachment coupling. The concrete form system
preferably
further includes at least two connectors disposed within the cavity between
the side
panels and a connector link disposed within the cavity between two opposing
connectors. Each connector has a first end with a first connector coupling, an
opposing
second end having a second connector coupling, and a first length extending
20 therebetween. Preferably, the first and second connector couplings have the
same
shape. The first connector coupling is adapted to engage one attachment
coupling of
the side panel.
The concrete form system preferably further includes a connector link having a
25 proximal end having a first link coupling and a distal end having a second
link
coupling. The first link coupling and the second link coupling are adapted to
engage
the second connector coupling of a connector of the concrete form system. The
connector link preferably includes a substantially rigid body portion
extending between
the proximal and distal ends of the connector link. In a preferred embodiment,
the first
30 and second link couplings have the same shape as the attachment couplings
of the side
panels of the concrete form system so that connector components of the
concrete form
system can engage the attachment couplings or the connector link couplings.
Thus, the
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12
connector link can be directly coupled to any two opposing connector and any
desired
dimensional increments may be achieved through the coupling of one or more
intermediate links and/or connectors.
S In use, the method of constructing a concrete structure for this embodiment
of
the present invention preferably comprises the steps of erecting first and
second form
panels so that opposed interior faces of the first and second form panels
define a cavity
therebetween, engaging a first connector with the first form panel, engaging a
second
connector with the second form panel, attaching a connector link between the
first
10 connector and the second connector, and substantially filling the cavity
with concrete to
be cured therein.
Further, the method of the present invention for constructing a concrete
structure having a termite infestation detection surface comprises the steps
of
15 providing two longitudinally-extending side panels, detachably securing a
longitudinally-extending support panel to the exterior surface of one of the
side panels
so that the interior surface of the support panel overlies the exterior
surface of the side
panel, removing a longitudinally-extending strip of the side panel having the
secured
support panel so that a longitudinally-extending portion of the interior
surface of said
20 side panel is exposed, wherein the strip has a width less than the width of
the support
panel, erecting the side panels so that a portion of the interior surface of
the side panel
having the secured support panel and a portion of the exposed interior surface
of the
secured support panel faces a portion of, and are laterally spaced therefrom,
the interior
surface of the other side panel to form a cavity therebetween, attaching a
connector to
25 the attachment couplings of two opposed web members which are within the
opposed
side panels, pouring concrete into the cavity formed between the side panels
to be cured
therein, and subsequently removing the support panel from the exterior surface
of the
side panel after the concrete has cured to expose the surface of the cured
concrete. The
exposed surface preferably extends the longitudinal length of the side panel
and forms
30 the termite infestation detection surface. Termites are forced to traverse
the exposed
termite infestation detection surface to reach the portion of the concrete
structure above
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13
the detection surface and may be visually detected thereon the detection
surface.
These and other features and advantages of preferred component and methods
of the present invention will become more readily apparent from the following
detailed
5 description of the invention taken in conjunction with the accompanying
drawings.
BRIEF DESCRIPTION OF THE FIGURES OF THE DRAWINGS
Fig. 1 is a perspective view of a concrete form system.
10
Fig. 2 is a front perspective view of one side panel of the concrete form
system
shown in Fig. 1, in which the web members show four attachment couplings
extending
through the interior surface of the side panel, two web members show two
connectors
attached to attachment couplings, and one web member shows two connectors and
15 another web member attached thereto.
Fig. 3 is a perspective view of a connector component of the concrete form
system shown in Fig. 1.
20 Fig. 4 is a perspective view of an improved web member according to a
preferred embodiment of the present invention.
Fig. S is a side view of the improved web member shown in Fig. 4.
25 Fig. 6 is a perspective view of a side panel showing the improved web
member
shown in Fig. 4 partially disposed within the side panel.
Fig. 7 is a cross-sectional view of the side panel shown in Fig. 6, in which a
portion of the side panel is cut away to show the body portion of the web
member
30 partially disposed and integrally formed within the side panel.
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Fig. 8 is a cross-sectional view of a ledge panel assembly of the concrete
form
system used to fabricate a concrete wall having a weight bearing ledge
surface,
showing a re-enforcing re-bar providing additional structural support to the
ledge panel
assembly.
5
Fig. 9 is a perspective view of a ledge panel assembly of the concrete form
system shown in Fig. 8.
Fig. 10 is a side view of the ledge panel assembly shown in Fig. 9.
10
Fig. 11 is a perspective view of a ledge web member of the ledge panel
assembly shown in Fig. 9.
Fig. 12 is a side view of the ledge web member shown in Fig. 11.
15
Fig. 13 is a side, cross-sectional view of two ledge panels assemblies on
opposing sides of a concrete wall structure.
Fig. 14 is a perspective view of a first corner panel having a corner web
member
20 partially disposed and integrally formed within the first corner panel.
Fig. 15 is a perspective view of a first and second corner panel spaced apart
and
connected by a plurality of connectors between opposing attachment couplings
extending from the first and second corner panels.
25
Fig. 16 is a cross-sectional view of a corner panel having a corner web member
disposed therein.
Fig. 17 is a perspective view of a preferred embodiment of a corner web
30 member of the present invention.
Fig. 18 is a top view of the corner web member of Fig. 17.
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IS
Fig. 19 is a side view of the corner web member of Fig. 17.
Fig. 20 is a perspective top view of a connector link component of the
concrete
form system of the present invention.
Fig. 21 is a perspective bottom view of the connector link shown in Fig. 20.
Fig. 22 is a side view of the connector link shown in Fig. 20.
10 Fig. 23 is a bottom view of the connector link shown in Fig. 21.
Fig. 24 is a sectional view of the connector link, taken at line 24-24 of Fig.
22.
Fig. 25 is a sectional view of the connector link, taken at line 25-25 of Fig.
22.
IS
Fig. 26 is a perspective view of the connector link in use within the concrete
form system according to a preferred embodiment of the present invention.
Fig. 27 is a side, cross-sectional view of a termite detection surface of the
20 present invention showing the interior cavity between the respective side
panels filled
with concrete and the exposed surface of the cured concrete.
Fig. 28 is a side, cross-sectional view of a termite detection surface showing
a
support panel affixed. to the exterior surface of one side panel and the
interior cavity
25 between the respective side panels idled with concrete.
DETAILED DESCRIPTION OF THE INVENTION
30 The present invention is more particularly described in the following
examples
that are intended as illustrative only since numerous modifications and
variations
therein will be apparent to those skilled in the art. As used in the
specification and in
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16
the claims, "a" can mean one or more, depending upon the context in which it
is used.
The preferred embodiments are now described with reference to the figures, in
which
like numbers indicate like parts throughout the figures.
5 As described above, Figs. 1 - 3 show an example concrete form system having
first and second side panels 10, 12, each including one or more web members 16
with
attachment coulings 17 extending outward of the side panels 10, 12. One or
more
connectors 18 having first and second coupling elements at opposite ends
thereof
engage the attachment couplings 17 of web members 16, or otherwise retain the
side
10 panels 10, 12 in a spaced apart configuration, to define a cavity 14
between the opposed
interior faces of the panels 10, 12. Concrete is poured into the cavity 14 to
form a
concrete wall, block, beam, foundation, floor or roof panel, or other concrete
component, of a shape and dimension defined by the cavity 14.
15 The depicted embodiment of the present invention, shown in Figs. 1 and 2,
comprises at least two opposed longitudinally-extending side panels 10, 12,
between
which concrete is poured to bond with the form panels. A second embodiment of
the
present invention involves using a single side panel 10 that bonds with the
concrete, for
example to form a concrete slab, instead of using opposed side panels 10, 12
on both
20 sides of the concrete. Each side panel 10, 12 has, a top end, a bottom end,
a first end, a
second end, an exterior surface, 10e, 12e, and an interior surface 10i, 12i.
An example
side panel 10, 12 can be provided having a thickness (separation between the
interior
surface and exterior surface) of approximately two and a half (2%z) inches, a
height
(separation between the bottom end and the top end) of sixteen (16) inches,
and a
25 length (separation between the first end and second end) of forty-eight
(48) inches. In
an alternative example, the side panels 10, 12 may have a thickness of
approximately
two (2) inches, a height of approximately twenty-four (24) inches, and a
length of
approximately forty-eight (4$) inches. As one skilled in the art will
appreciate,
providing a side panel 10, 12 of extended height allows for an increased speed
of
30 construction as fewer layers of the side panels must be constructed to
provide a wall of
a desired height. Also, having a side panel thickness of approximately two
inches
allows the overall wall thickness, in a typical wall construction using a four
inch
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17
connector, to match the existing wall dimensional thickness of conventional
concrete
block/masonry or wood frame construction. By matching the construction
industries
conventional standard dimensions, and therefore not changing usable interior
space
from conventional construction standard, an insulating concrete form ("ICF")
system,
5 such as the present invention, becomes highly advantageous because of the
superior
strength of its monolithic reinforced concrete, sound proofing, and superior
fire rating
when compared to conventional construction methods.
The dimensions can be further altered, if desired, for different building
projects,
10 such as increasing the thickness of the form panels 10, 12 for more
insulation. Half
sections of the form panels 10, 12 can be used for footings. It will also be
understood
that the side panels 10, 12 may take any of a number of configurations,
including for
example: flat panels; curved panels; corner panels of various angular
displacement;
panels comprising indentations, projections or other surface features; door,
window or
15 other opening forms; and/or other configurations.
The interior surface I Oi of one side panel 10 preferably faces the interior
surface
12i of another side panel 12 in the first embodiment and the opposed interior
surfaces
10i, 12i are laterally spaced apart from each other a desired separation
distance so that a
20 cavity 14 of predetermined width is formed therebetween. Concrete-in its
fluid
state-is poured into the cavity 14 and allowed to cure (i.e., harden) therein
to form the
wall. The volume of concrete received within the cavity 14 is defined by the
separation
distance between the interior surfaces 10i, 12i, the height of the side panels
10; 12, and
the length of the side panels 10, 12.
25
The side panels I 0, 12 are preferably constructed of polystyrene,
specifically
expanded polystyrene ("EPS"), which provides thermal insulation and sufficient
strength to hold the poured concrete until it substantially cures. The formed
concrete
wall using polystyrene with the poured concrete has a high insulating value so
that no
30 additional insulation is usually required. In addition, the formed walls
have a high
impedance to sound transmission.
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18
As described in greater detail in U.S. Patent Serial No. 090/008,437,
incorporated in its entirety herein by reference, the interior surfaces 1 Oi,
12i of the side
panels 10, 12 preferably includes a series of indentations therein that
enhance the bond
between the side panels 10, 12 and concrete. To improve further the bond
between the
5 side panels 10, 12 and the concrete poured in the cavity 14, a portion of
each of the web
members 16 formed in the side panels 10, 12 extends through the interior
surface of the
side panels 10, 12 into the cavity 14. Since at least a portion of each web
member 16 is
integrally formed within its respective side panel 10, 12, and the portion of
the web
member 16 that extends into the cavity 14 is also cured within the concrete,
the web
10 member 16 acts to strengthen the connection between the side panel 10, 12
and the
concrete. That is, since the web member 16 is an integral part of the side
panel 10, 12,
it "locks" the side panel 10, 12 to the concrete once the concrete is poured
and cures
within the cavity 14 around exposed portions of the web member 16.
15 Each side panel 10, 12 has at least one web member 16 formed into it.
Preferably, adjacent web members 16 formed within a side panel 10, 12 are
separated a
predetermined longitudinal distance, which is typically eight (8) inches.
Based on the
preferred length of the side panel 10, 12 of forty-eight inches, approximately
six web
members 16 may be disposed within each side panel 10, 12.
20
The portions of each web member 16 that extend through the interior surface of
the side panels 10, 12 form attachment couplings 17. The attachment couplings
17 are
disposed within the cavity 14 and are spaced apart from the interior surface
of the side
panels 10, 12. One or more connectors 18 detachably engage attachment
couplings 17
25 on opposed web members 16, which position the interior surfaces 10i, 12i of
the side
panels 10, 12 at a desired, predetermined, separation distance. The connectors
18,
when operatively connected to the attachment couplings 17 of the respective
side
panels 10, 12, provide support to the side panels 10, 12 when the concrete is
poured
into the cavity 14. The ends of the connector 18 are of a shape to
complementarily and
30 removably engage the attachment coupling 17 of two respective web members
16
within opposed panels 10, 12. The attachment couplings 17 may take any of a
number
of alternate forms, including for example: slots, channels, grooves,
projections or
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19
recesses formed in the form panels 10, 12; hooks or eyelets projecting from or
formed
in the form panels 10, 12; twist, compression or snap couplings; or other
coupling
means for engaging cooperating coupling portions of the connectors 18.
Preferably,
however, the attachment coupling 17 is substantially rectangular and flat and
each end
5 of the connector 12 has a channel and slot forming a connector coupling 20
into which
the rectangular shaped attachment coupling 17 is slidably received.
As best shown in Fig. 3, the connector 18 preferably also has at least one
aperture 24 of a size to complementarily receive a re-bar (not shown) therein.
The re-
10 bar provides reinforcing strength to the formed wall. Alternatively, and as
described in
greater detail below, a first connector 18 can be engaged with an attachment
couplings
17 on first panel 10, a second connector 18 engaged with an attachment point
on second
panel 12, and a connector link engaged between the first and second connectors
18,
thereby enabling the formation of concrete components of selected incremental
I S thicknesses.
Referring now to Figs. 4-7, the present invention provides an improved web
member 90 for use in place of the web member i 6 described above shown above
in
Figs. I - 3. The web members 90 are provided within the side panels 10, 12 in
20 substantially the same manner and arrangement as the web members 16, and
serve to
engage the connectors 18 in substantially like manner as well.
The improved web member 90 preferably comprises an end plate 92, a plurality
of attachment couplings 100, and a plurality of support struts 94 extending
from the end
25 plate 92 the attachment couplings 100. The web member 90 is partially
disposed and
integrally formed within each side panel 10, 12 so that a portion of each of
the web
members 90 extends through the respective interior surface 10i, 12i of the
side panels
10, 12.
30 The end plate 92 has a top surface 91 and an opposing bottom surface 93 and
preferably has a substantially planar, rectangular shape. When a portion of
the web
member 90 is embedded within a side panel 10, 12, the end plate 92 is
preferably
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20
substantially completely disposed within a portion of the side panel 10, 12.
That is, the
end plate 92 is located slightly below the exterior surface of, or recessed
within, the
side panel 10, 12, preferably at a distance of approximately one-quarter ('/<)
of an inch
from the exterior surface. This position allows for easily smoothing the
surface of the
5 side panels 10, 12 without cutting the end plate 92 should the concrete,
when poured,
create a slight bulge in the exterior surface of the side panels 10, 12.
Recessing the end
plate 92 also provides the additional benefit of providing a uniform exterior
surface;
which allows external surfacing, such as stucco for example, to be readily
applied.
Alternatively, the end plate 92 can abut the exterior surface of the side
panels 10, 12. It
10 is also preferred in the first embodiment that each end plate 92 is
oriented substantially
upright and disposed substantially parallel to the exterior surface of the
side panels 10,
12. The end plate 92 is preferably adapted to receive and frictionally hold a
metal
fastener, such as a nail or screw, therein, thus providing "strapping" for a
wall system
that allows attachment of gypsum board (not shown), interior or exterior wall
cladding
15 (not shown), or other interior or exterior siding or wall treatment (not
shown). Thus,
the web members 90 function to align the side panels 10, 12, hold the side
panels 10,
12 in place during a concrete pour, structurally support the side panels 10,
12 while the
concrete cures, enhance the bond between the panels 10, 12 and the cured
concrete, and
pravide strapping to connect siding and the like to the formed concrete wall
structure.
20
The plurality of support struts 94 of the web member 90 preferably extend
generally perpendicularly from the end plate 92. Each support strut 94 has a
proximal
end 95, a distal end 96, and a first longitudinal-length therebetween. The
proximal end
95 of each support strut 94 is connected to the top surface 91 of the end
plate 92 and the
25 distal end 96 of each support strut 94 is connected to one attachment
coupling 100 or
other panel coupling. The proximal end 95 of each support strut 94 is
integrally formed
within the side panel 10, 20 to be embedded therein. The generally
perpendicular
arrangement of the struts 94 with respect to the end plate 92, and the co-
axial alignment
of one of the struts 94 with each attachment point 100, provides increased
strength and
30 resistance to forces encountered as concrete is poured into the cavity 14.
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21
End struts 97 and a plurality of bridging members 110 can also be provided in
the improved web member 90 for added strength. The end struts 97 preferably
comprise a first end strut 98 and a second end strut 99. The first end strut
98 preferably
extends from the top surface 91 of the end plate 92 near the top edge of the
end plate 92
S to near the distal end 96 of the closest adjacent support strut 94.
Similarly, the second
end strut 99 preferably extends from the top surface 91 of the end plate 92
near the
bottom edge of the end plate 92 to near the distal end 96 of the closest
adjacent support
strut 94.
10 Each bridging member 110 has a first end 112 and a second end 114 and
extends from one support strut 94 to one adjacent support strut 94. A portion
of the
bridging member 110 may be partially disposed and integrally formed within the
side
panel 10, 12 to enhance the structural support provided by the web member 90.
That is,
the bridging members 110 are located slightly below the interior surface 10i,
12i, of, or
15 recessed within, the side panel 10, 12, or may abut the interior surface
10i, 12i of the
side panels 10, 12 so that a portion of the bridging member 110 is exposed,
and/or
extends above, the interior surface 10i, 12i of the side panels 10, 12.
Preferably, the
first end 112 of one bridging member 110 is connected near the distal end 96
of one
support strut 94 and the second end 114 of the bridging member 110 is
connected near
20 the distal end 96 of one other adjacent support strut 94. The bridging
member 110
preferably extends generally perpendicular to the respective support struts 94
to which
it is connected. As one skilled in the art will appreciate, the addition of
the bridging
members 110 significantly enhances the structural rigidity of the web member
90. This
desired structural rigidity is further enhanced by the addition of the first
and second end
25 struts 98, 99.
The modified web member 90 is preferably formed as an integral component,
preferably constructed of plastic, and more preferably a high density plastic
such as
high-density polyethylene, although polypropylene or other suitable polymers
may be
30 used. Factors used in choosing the material include the desired strength of
the web
member 90 and the compatibility of the material of web member 90 with the
material
used to fabricate side panels 10, 12. As best shown in Fig. S, the points of
connection
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22
between the end plate 92, the struts 94, the attachment couplings 100, the end
struts 97,
and the bridging members 110 of the web member 90 are preferably chamfered or
radiused to eliminate any sharp corners or transitions, and thereby reduce or
eliminate
any resultant stress concentrations.
S
Each of the attachment couplings 100 preferably comprises a generally
rectangular element adapted to be slidably or otherwise engaged within a
corresponding
channel or connector coupling 20 of the connector 18. Recesses 102 or other
engagement means can be provided on or adjacent the attachment couplings 100
for
10 engagement with cooperating retaining shoulders provided on the connectors
18, in
order to provide more secure attachment. In preferred form, a recess 102 is
provided in
each face of each strut 94 proximate the attachment couplings 100 of the web
member
90. As seen best with reference to Figs. 4 and 5, it is preferred that the
recesses 102 do
not penetrate through the entire thickness of the strut 94 of the web member
90, as such
1 S complete penetration may weaken the connection of the attachment point 100
to its
respective support strut 94 and may provide a point of mechanical failure.
As seen best with reference to Figs. 4 - 6, the web member 90 of the present
invention preferably comprises a substantially linear array of attachment
couplings 100,
20 comprising at least one upper attachment coupling 104, at least one lower
attachment
coupling 106, and a medial attachment coupling 108. The attachment couplings
100
are also oriented substantially upright so that one attachment coupling 100 is
disposed
above another attachment coupling 100. The attachment couplings 100 are
preferably
oriented substantially parallel to the interior surface 10i, 12i of the
respective side panel
25 10, 12 and are thus spaced a predetermined distance from the interior
surface 10i, 12i.
In a more preferred embodiment, the web member 90 comprises five attachment
couplings 100, each supported by a respective strut 94. In this embodiment the
upper
attachment coupling 104 comprises two attachment couplings 100 spaced a first
distance apart from each other, the lower attachment coupling 106 comprises
two
30 attachment couplings 100 spaced the first distance apart, and the medial
attachment
coupling 108 comprises one attachment coupling 100. The closest attachment
coupling
100 of the upper attachment coupling 104 is spaced apart from the singular
medial
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23
attachment coupling 108 a second distance, which is greater than the first
distance that
separates the couplings 100 forming the upper and lower attachment couplings
104,
106. Similarly, the closest attachment coupling 100 of the lower attachment
coupling
106 is spaced apart from the singular medial attachment coupling 108 by the
second
S distance. Thus, the web member 90 advantageously comprises a first group of
two
struts 94 and attachment couplings 100 (the upper attachment couplings 104); a
second
group of two struts 94 and attachment couplings 100 (the lower attachment
couplings
106}; and a medial strut 94 and medial attachment coupling 108 between the
first and
second groups.
10
In an alternative embodiment of the web member 90, as shown in Figs. ,the web
member 90 of the present invention comprises a substantially linear array of
seven
attachment couplings 100, each supported by a respective strut 94. In this
embodiment,
the upper attachment coupling 104 comprises three attachment couplings 100
spaced a
15 longitudinal distance apart, the lower attachment coupling 106 comprises
three
attachment couplings 100 spaced the longitudinal distance apart, and the
medial
attachment coupling 108 comprises one attachment coupling 100. The closest
attachment coupling 100 of the upper and lower attachment couplings 104, 106
is
spaced apart from the singular medial attachment coupling 108 by a distance
greater
20 than, or approximately equal to, the longitudinal distance. Thus, the web
member 90
advantageously comprises a first group of three struts 94 and attachment
couplings 100
(the upper attachment couplings 104); a second group of two struts 94 and
attachment
couplings 100 (the lower attachment couplings 106; and a medial strut 94 and
medial
attachment coupling 108 between the first and second group, wherein the
attachment
25 couplings 100 of the web member 90 are preferably equally spaced apart from
each
other.
The provision of a medial attachment coupling 108 advantageously enables side
panels 10, 12 to be cut horizontally to produce concrete components of
selected
30 heights, while still providing sufficient bracing and support for the side
panels 10, 12
during the concrete pour. For example, the side panels 10, 12 can be cut
horizontally,
just above the medial attachment coupling 108 of the web members 90 within the
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24
panels 10, 12, and the panels 10, 12 will be adequately supported during the
subsequent
concrete pour by installing connectors 18 that engage the remaining attachment
couplings 100. The spacing and use of the upper, lower, and medial attachment
couplings 104, 106, 108 allow wide flexibility in the horizontal cutting of
the side
5 panels 10, 12 and web members 90 over a wide variety of heights to satisfy
desired or
requisite architectural requirements, without the necessity of providing
extensive
bracing to resist collapsing when concrete is poured into the cavity 14. The
improved
web member 90 of the present invention provides at least two attachment
couplings 100
on the affected web member 90 after a requisite horizontal cut of the side
panel Z 0, 12
10 and web members 90 which is sufficient to maintain the structural integrity
of the
formed wall.
Although Figs. 1, 2 and 6, depict linear side panels 10, 12, the web member 90
of the present invention is also applicable to use with corner side panel
sections of
1 S various angular offsets, as well as non-linear side panels for producing
curved
components.
As described above, the concrete system of the present invention comprises one
or more side panels 10, 12, each comprising one or more web members 90
disposed
20 therein. Attachment couplings 100 of the web members 90 are engaged with
corresponding connector couplings 20 of connectors 18 for retaining the
relative
positions of the side panels I 0, 20 during pouring of the concrete into the
cavity 14. In
this manner, an insulated concrete structure is provided. The resulting
insulated
concrete structure preferably includes at least one side panel 10, 12; at
least one web
25 member 90 disposed at least partially within each side panel 10, 12, having
at least one
upper attachment coupling 104, at least one lower attachment coupling 106, and
a
medial attachment coupling 108; and a concrete slab having a surface in
contact with
the interior surface 10i, 12i of at least one side panel 10, 12. As one
skilled in the art
will appreciate, the portions of the web member 90 that extend from the
interior surface
30 10i, 12i of the panel 10, 12, which includes the attachment couplings 100,
are cured
within the concrete so that the web member 90 strengthens the connection
between the
side panel 10, 12 and the concrete. That is, since the exposed portions of the
web
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25
member 90 extend into the cavity 14 and a portion of the web member 90 is an
integral
part of the side panel 10, 12, the side panel 10, 12 is "locked" to the
concrete once the
concrete is poured and cures within the cavity 14.
5 The present invention further enables a method of constructing a concrete
structure. In preferred form, the method of the present invention comprises
providing
at least one side panel 10, 12 comprising a web member 90 having attachment
points
100 for engaging connectors 18. The method of the present invention preferably
further comprises erecting the side panels 10, 12 to define a cavity 14, and
pouring
10 concrete into the cavity 14 to form a concrete slab or other component.
With reference to Figs. 8-13, the present invention provides for the
fabrication
of a concrete structure having one or more bearing surfaces such as for
example, a
brickledge 150 for supporting a brick fascia 152, a shelf 154 for supporting a
floor
15 system 156 or other structure. One or more ledge panel assemblies 200 are
installed on
a form panel 10, 12 according to the method described below, to form a ledge
cavity
208, which is filled with concrete to form the bearing surface. Figures 9 and
10 show a
preferred form of the ledge panel assembly 200 of the present invention in
greater
detail. In preferred form, the ledge panel assembly 200 generally comprises a
ledge
20 panel 208 having a lower edge 210, an upper edge 212, and a generally
planar panel
body 214 extending therebetween. The ledge assembly 200 is preferably
constructed of
high-density plastic. A first mounting coupling can be provided on the lower
edge 210,
for alignment and for more securely retaining the ledge panel assembly 200 on
an
underlying lower side panel 10,12. For example, the preferred embodiment of
the first
25 mounting coupling, as depicted in the figures, comprises a slot 213, for
engaging a
corresponding key 13, shown in Figs. 2 and 8, provided on the top edge of the
underlying lower side panel 10, 12. The key 13 and slot 213 can be provided
with
cooperating projections and recesses for more secure engagement.
30 The ledge panel 208 further comprises an interior face 216 and an exterior
face
218. Similar to the side panels 10, 12 discussed above, the interior face 216
is
preferably slotted or provided with other surface features to increase the
available
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26
surface area on the interior face 216 to provide more secure bonding between
the ledge
panel 208 and the concrete. The exterior face 218 of the ledge panel 208
adjacent the
upper edge 212 is preferably mitered with a plumb cut 220, whereby the upper
edge
212 has a reduced thickness t, preferably of approximately %2 inches. In this
manner,
5 the apparent thickness of the panel 208 is minimized for improved
aesthetics, while
maintaining substantially the full thickness, strength and insulative capacity
of the
panel 208 throughout substantially the remainder of its length.
The ledge panel assembly 200 preferably further comprises one or more ledge
10 web members 230, shown in greater detail in Figs. 10 - 12. Each ledge web
member
230 preferably comprises an embedded portion 232 which is embedded or
otherwise
integrally formed within the panel body 214, and an exposed portion 234
extending
outward of the panel body 214. The embedded portion preferably comprises an
end
plate 236, which is preferably embedded adjacent the exterior face 218 of the
panel
15 body 214. The ledge memberend plate 236 provides structural strength to the
panel
body 214, and provides strapping for attachment of siding, wallboard, or other
wall
treatment. A plurality of struts 238, preferably approximately six, extend
from the end
plate 236, to support a medial flange 240, which is preferably embedded or
otherwise
integrally formed within the panel body 214 adjacent the interior face 216 of
the panel
20 body 214.
The exposed portion 234 of each ledge web member 230 preferably further
comprises a plurality of support ribs 242 extending from the medial flange 240
to
support an attachment flange 244. The attachment flange 244 preferably carries
a
25 generally linear array of ledge attachment couplings 250 formed from the
portion of the
ledge web member 230 that extends outward of the ledge panel 208 into the
ledge
cavity 206. The ledge attachment couplings 250 are preferably substantially
similar to
the attachment points 17 or 100 of the web members 16 or 90, respectively,
described
above and are capable of engagement with the connector couplings 20 of
standard
30 connectors 18. In the preferred embodiment depicted, the ledge panel
assembly 200
has three spaced-apart ledge attachment couplings 250. It is also preferred
that the
ledge attachment couplings 250 of one ledge web member 230 be disposed in a
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27
substantially linear relationship with each other. That is, one ledge
attachment coupling
250 is disposed above an adjacent ledge attachment coupling 250. Further, it
is
preferred that the ledge attachment couplings 250 of a ledge web member 230
are
equally spaced apart.
As seen best with reference to Figs. 8 and 10, the substantially linear array
of
ledge attachment couplings 250 are parallel to first plane F of the interior
surface of the
first side panel 10. Further, it is preferred that the attachment couplings of
the side
panel upon which the ledge assembly 200 is mounted and the ledge attachment
I 0 couplings of the ledge assembly 200 are generally disposed in the same
plane. This
allows the attachment couplings of opposed side panels 10, 12 and the ledge
attachment
couplings 250 and attachment coupling of opposed side panels) 10, 12 to be
spaced a
predetermined distance apart. As one skilled in the art will appreciate, by
spacing the
respective attachment couplings and ledge attachment couplings the
predetermined
15 distance apart, a selected length connector, and/or connector link, may be
used to
bridge the gap between the respective opposing attachment couplings and ledge
attachment couplings.
The generally linear array of the ledge attachment couplings 250 of the ledge
20 web members 230 preferably forms an acute angle a with the panel body 170.
The
exposed portion 234 of the ledge web member 230 preferably further comprises
one or
more ledge apertures 260 for engaging a generally horizontal, longitudinally
extending,
span of re-bar. It is preferred that the ledge aperture 260 is formed in the
upper surface
of the uppermost support rib 242 of the ledge assembly 200. In use, the span
of re-bar
25 is extended through the aperture 260 of each of the ledge web members 230
of the
ledge assembly 200. As shown in Figure 8, the present invention contemplates
reinforcing the ledge assembly with re-bar for increased structural strength
of the
formed ledge surface. Here, a second longitudinally extending span of re-bar
is place is
a connector aperture 24 of a connector 18 so that the respective spans of
rebar are
30 parallel to each other and are co-planer. Subsequently, at least one hook
shaped re-bar
form 29 is set onto both the spans of re-bar so that the hook shaped re-bar
form is
disposed and secured within the ledge cavity 206. The re-bar is "locked" to
the
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28
structure of the present invention within the ledge cavity 206 when the
concrete sets
within the cavity 206.
The ledge assembly 200 also preferably has a second mounting coupling for
5 engaging an upper side panel 10, 12 of the concrete form system stacked
above the
ledge assembly 200. Preferably the second mounting coupling is formed on the
exposed portion 234 of the ledge web member 230. The second mounting coupling
preferably has a key shape 272 that is adapted to be complementarily mated
into a slot
within the lower edge of the side panel 10, 12 for alignment and more secure
10 attachment between the ledge assembly 200 and the upper side panel 10, 12.
As seen best with reference to Figs. 8 and 12, one or more ledge assemblies
200
are installed within the concrete form system by mounting the lower edge 210
of the
ledge panel 208 onto the top of an underlying lower side panel 10, 12. For
clarity, the
1 S arrangement of a single ledge assembly 200 installed onto the second side
panel 12, in
opposition to the side panel 10, will be described. It will be understood,
however, that
this arrangement can be repeated at various positions on the second side panel
12 to
form multiple bearing surfaces. Also, one or more ledge assemblies 200 can be
installed on the first side panel 10, in mirror image fashion. In this manner,
opposed
20 bearing surfaces can be formed at the same level, and or staggered at
different levels,
on both side panels 10, 12. If provided, the first mounting coupling of the
ledge panel
is engaged between the ledge assembly 200 and the side panel 12, for example,
by
engaging the slot 213 with a cooperating projection or key 13 provided on the
top edge
of the lower side panel 12 as shown in Fig. 1. The ledge attachment couplings
250 of
25 the ledge assembly 200 are generally parallel to the first plane F of the
first side panel
10, which is erected in opposition to the ledge assembly 100 (or generally
parallel to
the second plane S of the second side panel 12 if the ledge assembly is
erected on the
first side panel). More particularly, the ledge attachment points of the ledge
assembly
are generally aligned in the same plane A as the attachment points of the
underlying
30 second side panels 12 ( or generally in plane B for ledge assemblies 200
installed on
underlying first side panel 10). In this position, the ledge panel 208 will
extend at the
acute angle a, shown in Figs. 8 and 10, outward from the plane A, or B, of the
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attachment points 17 or 100 in the direction of the exterior surface 12e of
the side panel
12.
In the installed configuration of the ledge assembly 200, the struts 238 and
the
5 ribs 242 are preferably generally horizontally aligned, and the attachment
flange 244 is
generally vertical. The outward extension of the ledge panel 208, in
opposition to the
opposing side panel 10, forms the ledge cavity 206, which is filled with
concrete to
form the brickledge bearing surface or other bearing surface. One or more
connectors
18 are engaged between ledge attachment couplings 250 of the ledge assembly
200, and
10 the attachment points 17 or 100 of the opposed side panel 10.
In the arrangement wherein first and second ledge panel assemblies 200 are
installed opposite one another in each side panel 10, 12, respectively, as
shown in Fig.
I3, the connectors 18 are engaged between opposed ledge attachment points 250
of the
15 first and second ledge panel assemblies 200 within the ledge cavity between
the
opposing first and second ledge panels 208. A single connector can directly
engage
attachment points 250 and attachment points 17 or 100 (or attachment points
250 of
opposed first and second ledge assemblies 200), or if a thicker wall is
desired, a first
connector 18 can be attached to a first attachment coupling 250, a second
connector 18
20 attached to a second attachment coupling 17 or 100 (or ledge attachment
coupling
250), and one or more connector links (not shown) installed to couple the
connectors
18.
One or more upper side panels 12 can be stacked above the ledge assembly 200
25 on the second mounting coupling of the ledge assembly 200. If provided, the
ledge
panel assembly 200 and the upper side panel 12 are engaged, for example, by
engaging
the key 272 in the cooperating slot provided in the bottom edge of the upper
side panel
12, as shown in Figs. 8 and 13. The key and slot configuration of the second
mounting
coupling of the ledge assembly can optionally be provided with interlocking
projections
30 and recesses for more secure attachment.
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Thus described, the system of the present invention enables a method of
fabricating a concrete structure having a ledge support surface. In preferred
form, and
described with reference to Fig. 8, the method of the present invention
generally
comprises the steps of erecting a first form panel 10 comprising an interior
surface 10i,
5 an exterior surface 10e, and a plurality of attachment points 17 (or 100)
generally
aligned along a plane A adjacent the interior surface 10i. The method
preferably further
comprises erecting a second form panel 12 comprising an interior surface 12i,
an
exterior surface 12e, and a plurality of attachment points 17 (or 100)
generally aligned
along a plane B adjacent the interior surface 12i, the interior surfaces 10i,
12i of the
10 first and second form panels 10, 12 confronting one another and separated a
distance to
define a cavity 14 therebetween. The method preferably further comprises
installing a
ledge assembly 200 onto the upper surface of the lower second side panel 12,
whereby
the ledge attachment couplings 250 of the ledge assembly 200 are installed to
be
generally aligned along the plane B, and whereby the ledge panel 208 extends
at an
15 acute angle a from plane B in the direction of the exterior surface 12e of
the second
side panel 12 to define a ledge cavity 206 therebetween the ledge panel 208
and the
opposing first side panel 10. The method preferably further comprises engaging
a
plurality of connectors 18 between the ledge attachment couplings 250 of the
ledge
assembly 200 and the attachment couplings 17 (or 100) aligned along plane B
and the
20 attachment points 17 (or 100) aligned along plane A. The method preferably
further
comprises substantially filling the cavity 14 between the first and second
side panels
10, 12 and the ledge cavity 208 with concrete, and allowing the concrete to
cure. The
method may optionally also include the formation of additional ledge
assemblies 200 or
other bearing surfaces on the same or other surfaces of the concrete
structure, in like
25 manner. In this fashion, multiple brickledges or other bearing surfaces can
be provided
on either or both surfaces of the wall in like manner. A brick fascia 152,
floor system
156, or other structures or materials can be installed on and supported by the
ledge
assembly 200.
30 The method and system of the present invention is advantageous, as the
ledge
assembly 200 or other bearing surface thereby provided is not interrupted by
any
portion of the EPS material typically used to construct the side panels 10,
12, and the
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31
ledge panel 208. Only the thin plastic support ribs 242 of the ledge web
members 230
present interruptions in the concrete of the ledge assembly 200, and the cross-
sectional
area of these interruptions is minimal. Thus, a stronger bearing surface may
be
achieved. The system and method of the present invention are further
advantageous as
5 a majority of the forming components utilized are standard components, and
need not
be specially manufactured for the provision of brickledges or other bearing
surfaces.
This results in reduced cost and complexity. A further advantage of the
present
invention is the versatility provided by enabling fabrication of a wall having
a bearing
surface of virtually any desired incremental thickness, through the use of
different
10 length connectors, and/or the use of connector links coupling two or more
connectors.
Refernng now to Figs. 14 - 19, the present invention may also provide a corner
web member. As noted above, the side panels 10, 12 may be provided as corner
panels
of various angular displacements. For clarity in describing this embodiment of
the
15 invention, and as shown in Figs. 14 and 15, the side panels 10, 12 will be
called a first
corner panel 310 and a second corner panel 312. It will be understood that the
first
comer panel 310 and the second corner panel 312 have the same properties as
the side
panels 10, 12 described above. That is, the first corner panel 310 has a first
exterior
surface 310e, an opposing first interior surface 310i. The two longitudinally-
extending
20 first side panels that form the first corner panel connect to form a
substantially vertical
corner panel edge 311 in the first exterior surface 310e of the first corner
panel.
Similarly, the second corner panel 312 has a second exterior surface 312e, an
opposing
second interior surface 312i, and is formed from two longitudinally-extending
second
side panels. As one skilled in the art will appreciate, and as shown in Fig.
15, a portion
25 of the first interior surface 310i of the first corner panel 310 faces a
portion of the
second interior surface 312i of the second corner panel 312. Further, the
first and
second interior surface 310i, 3121 are spaced apart a predetermined distance
so that a
cavity 314 of predetermined width is formed therebetween the interior surfaces
310i,
3121. As one skilled in the art will further appreciate, the corner panels
310, 312 may
30 be connect to other longitudinally-extending side panels 10, 12 of the
structure
described above.
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32
The corner panels 310, 312 are connected to each other by a bridging means.
As shown in Figs. 14 and 15, the bridging means preferably comprises the
engaged
combination of web members 16 or 90, and connectors 18, as described above.
That is,
the bridging means may comprise at least one web member 16 or 90 and at least
one
5 connector. Here, at least one web member 16 or 90 is partially disposed and
integrally
formed within each of the first and second corner panels 310, 312 and extends
through
the respective first and second interior surfaces 310i, 3121 to form an
attachment
coupling 17 or 100 that is disposed within the cavity 314 between the first
and second
corner panels 310, 312. The connector is disposed within the cavity 14 in
operative
10 engagement with opposing attachment couplings 17 or 100 extending from the
respective interior surfaces 31 Oi, 312i of the corner panels 310, 312.
A corner web member 320 may be provided within the first corner panel 310 to
provide additional structural support of the outside corner of the formed
insulated wall
15 structure as well as to provide a strapping surface to connect siding and
the like to the
formed concrete wall. Referring now to Figs. 16 - 18, the corner web member
320 is
partially disposed and integrally formed within the first corner panel. To
enhance the
bond between the first side panel 310 and the concrete poured within the
cavity 314, a
portion of the corner web member extends through the first interior surface
310i of the
20 first corner panel into the cavity 314. That is, since the corner web
member 320 is both
an integral part of the first corner panel 310 and extends into the cavity
314, it allows
the first corner panel 310 to "lock" to the concrete once the concrete is
poured and
cures within the cavity 314.
25 The corner web member 320 preferably comprises a corner flange member 330,
a bridging member 340, and a plurality of spaced-apart support struts 350
connecting
the corner flange member 330 to the bridging member 340. Preferably, the
corner
flange member 330 has an upper surface 332, an opposed lower surface 334 and
is
formed from a longitudinally-extending first leg 336 connected to a
longitudinally
30 extending second leg 338. The connected first and second legs 336, 338 form
a corner
flange edge 339 in the upper surface 332 of the corner flange member 330. The
bridging member 340 has a top edge 342 and an opposed bottom edge 344. Each
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33
support strut 350 has a proximal end 352, an opposed distal end 354 and a
longitudinaly-length therebetween. For structural support of the corner web
member
320, the proximal end 352 of each support strut 350 is connected to the lower
surface
334 of the corner flange member 330 and the distal end 354is connected to the
top edge
5 342 of the bridging member 340. It is preferred that the support struts 530
are spaced a
predetermined distance apart from each other.
When a portion of the corner web member 320 is embedded within the first
corner panel 310, as best shown in Fig. 16, the corner flange member 330 and
the
10 proximal end 352 of each support strut 350 is preferably completely
disposed within
the first corner panel 310. That is, as best shown in Fig. 16, the corner
flange member
330 is located slightly below the exterior surface of, or recessed within, the
first corner
panel 310, preferably at a distance of approximately one-quarter (%<) on an
inch from
the exterior surface 310e. Alternatively, the corner flange member 330 may
abut the
15 exterior surface 3 l0e of the first corner panel 310. It is also preferred
that the corner
flange member 330 is oriented substantially upright and disposed substantially
parallel
to the exterior surface 310e of the first corner panel 310. In this
orientation, the corner
flange edge 339 of the corner flange member 330 is disposed substantially
parallel to
the corner panel 311 edge of the first corner panel 310. For example, the
first corner
20 panel 310 and the corner flange member 330 may both have an "L" shape in
cross-
section, which allows the upper surface 332 of the corner flange member 330 to
be
substantially parallel to the exterior surface 312e of the first corner panel
310 when the
corner flange edge 339 of the corner flange member 330 is disposed
substantially
parallel to the corner panel edge 311 of the first corner panel 310. The
corner flange
25 member 330 is thus preferably adapted to receive and fractionally hold a
metal fastener,
such as a nail or screw, therein, thus providing "strapping" for a wall system
that allows
attachment of gypsum board (not shown), interior or exterior wall cladding
(not
shown), or other interior or exterior siding or wall treatment (not shown).
30 Refernng now to Figs. 17 - 19, the plurality of support struts 350 of the
corner
web member 320 preferably extends generally perpendicular to the corner flange
member 330 and the bridging member 340. This generally perpendicular
arrangement
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34
of the support struts 350 with respect to both the corner flange member 330
and the
bridging member provides increased strength and resistance to outward
pressures as
concrete is poured within the cavity 314. As best seen in Fig. 18, the corner
flange
member 330 preferably has a first width W and the bridging member 340 has a
second
5 width w that is less than the first width. The proximal end 352 of each
support strut
350 preferably has a width approximately equal to the first width of the comer
flange
member 330 and the distal end 354 of each support strut 350 has a width
approximately
equal to the second width of the of the bridging member 340. Thus, each
support strut
350 preferably tapers from the proximal end 352 to the distal end 354.
10
A support flange member 360 can also be provided in the corner web member
320 for additional surface area for locking the set concrete to the first
corner panel 310
and for providing structural support for the corner web member 320. Referring
to Figs.
16- 19, the support flange member 360 preferably comprises a top surface 362
that is
15 connected to the bottom edge 344 of the bridging member 340. As one skilled
in the
art will appreciate, the support flange member is spaced apart from the
interior surface
310i of the first corner panel 310 and is thus disposed within the cavity 314.
It is
preferred that the top surface of the support flange member 360 is oriented
substantially
parallel to the first interior surface 310i of the first corner panel 310. It
is also preferred
20 that the support flange member 360 have a cross-sectional shape similar to
the corner
flange member 330. That is, if the corner flange member has an "L" shape cross-
section, the support flange member should also have an "L" shape cross-
section. As
best shown in Figs. 16 and 18, the support flange member 360 is preferably
smaller
than the corner flange member 330.
25
Referring back to Figs. 14 and 15, the support flange member 360 preferably
also has a bottom surface 364 that forms at least one attachment point 366.
The
attachment point 366 is adapted to connect a support line 368, such as a tie
wire or a
plastic strap for example, to one attachment coupling 17 or 100 of the closest
web
30 member 16 or 90 in the second corner panel 312. By connecting the corner
web
member 320 to the attachment couplings 17 or 100 within the opposing second
corner
panel, the corner structure of the concrete form system is advantageously
structurally
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35
reinforced. Preferably, an as shown in Fig. 14, the corner web member 320 has
an
attachment point 366 formed in the bottom surface 364 of the support flange
member
360 proximate the distal end 354 of each of the support struts 350. Thus, in
the
example shown, the corner web member 320 comprises four attachment points 366.
5
The corner web member 320 is preferably formed as an integral component,
preferably constructed of plastic, and more preferably high-density plastic
such as
polyethylene, although polypropylene or other suitable polymers may be used.
Factors
used in choosing the material include the desired strength of the corner web
member
10 320 and the compatibility of the material of corner web member 320 with the
material
used to fabricate the first side panel 310.
The present invention may also include a method of fabricating a concrete
structure having corner portions having a corner web member 320 disposed in
the outer
15 wall of the concrete structure . In this method of using the concrete form
system, a first
and a second corner panel 310, 312 are erected so that a portion of the
interior surface
310i of the first corner panel 310 faces, and is spaced apart from, a portion
of the
interior surface 3121 of the second corner panel 312 so that a cavity 314 is
formed
therebetween. The first corner panel 310 has a corner web member 320 partially
20 disposed and integrally formed within the first corner panel 310 so that a
portion of the
corner web member 320 extends through the interior surface 310i of the first
corner
panel 310 into the cavity 314 between the first and second corner panels 310,
312. The
first and second corner panels 310, 312 preferably each have a plurality of
attachment
couplings 17 or 100 spaced apart from the interior surfaces 310i, 312i of the
first and
25 second corner panels 310, 312. Next, a connector 18 is attached to at least
one
opposing pair of attachment couplings 17 or 100 extending from the respective
first and
second side panels 310, 312. Finally, the cavity 314 therebetween the first
and second
corner panels is substantially filed with concrete and allowed to cure.
30 Referring again to Figs. 1 - 3, each attachment coupling 17 (or 100 if the
web
member 90 is used) independently engages a cooperating connector coupling of a
connector 18. In the embodiment depicted in the figure 3, the connector 18
includes
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36
connector couplings 20, 21 formed in the respective first and second ends of
the
connector 18. Each connector coupling 20, 2lcomprises a generally rectangular
channel track forming a notch 22, 23, arranged at the opposite first and
second ends
thereof, and separated by a longitudinally-extending body 25 having a length
L.
5 Connectors 18 are preferably provided in standard lengths of two inch
increments, such
as for example, two inches (2"), four inches (4"), six inches (6"), and eight
inches (8").
The notches 22, 23 of the couplings 20, 21 of the connector 18 are of a size
and shape
to complementarily and removably engage the attachment couplings I7 or 100 of
the
side panels 10, 12 by slidably receiving the substantially rectangular and
flat
10 attachment points 17 or 100 therein. Channel shaped slots 26 formed in each
end of the
connector 18 allow clearance of the portion of the web member 16 or 90 that
connects
the web member 16 or 90 to the attachment coupling 17 or 100. One or more
retaining
shoulders 28 can be provided within the slots 26 of the connector 18 for
engaging
cooperating recesses 102 in the web members 16 or 90 for more secure
attachment of
15 the connector 18 to the respective attachment coupling 17 or 100. As one
skilled in the
art will appreciate, the connector couplings can take any of a number of
alternate
embodiments to provide cooperating engagement with the attachment couplings 17
or
100. For example, the connector couplings can comprise slots, channels,
grooves,
recesses, hooks, eyelets, twist couplings, compression couplings, snap
couplings, or
20 other coupling means for engaging the attachment couplings 17 or 100.
The present invention preferably further provides one or more connector links
400, or splicers, shown in preferred form in Figs. 20 - 26. Each connector
link 400
preferably comprises a proximal end 410, comprising a first link coupling 412,
an
25 opposed distal end 420, comprising a second link coupling 422, and a
substantially
rigid body portion 430 extending between the distal end 420 and the proximal
end 410.
The first and second link couplings 412, 422, are shaped similarly and
preferably
substantially match the configuration of the attachment couplings 17 or 100,
so that the
connector couplings of connectors 18 can interchangeably engage attachment
couplings
30 17 or 100 and/or the connector link couplings 412, 422, depending upon the
desired
application.
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In the depicted embodiment, each link coupling 412, 422 comprises a generally
rectangular element 440 adapted for sliding engagement within notches 22, 23
of the
connector 18. A rib 432 preferably extends between the opposing rectangular
elements
440 to form the body portion 50, and is preferably adapted for sliding
engagement
5 within the slot 26 of the connector 18. The generally rectangular elements
440 of the
connector link 400 are generally parallel to one another, with the rib 432
extending
generally perpendicularly therebetween and connecting the approximate
midpoints
thereof. In this manner, as seen best in Figs. 21 and 23, each link coupling
412, 422
can be described as generally "T" shaped in cross-section. As seen best with
reference
10 to Figs. 20 - 23, the rib 432 preferably has a first face 434 and an
opposite second face
436. Each face of the rib 432 is preferably provided with a recess 438
adjacent the
rectangular element 440 of each link coupling 412, 422 to engage the
corresponding
retaining lug 28 of the connector 18 with a snap fit, to provide a positive
locking action
and prevent disengagement during the concrete pour.
15
The depicted embodiment of the connector link 400 preferably further
comprises a base flange 460, comprising a generally rectangular panel lying in
a plane
generally perpendicular to the rectangular elements 440 and the rib 432 of the
body
portion 430. The base flange 460 lends additional strength and rigidity to the
connector
20 link 400.
The length of the connector link 40 is selected to cooperate with the length
of
standard connectors 18 and the extent of projection of the panel couplings
from the
internal face of the form panels, to result in a cavity width (and thereby a
finished wall
25 thickness) of standard dimension (i.e., two inch increments).
The connectors 18 and the connector links 400 are preferably constructed of
plastic, and more preferably of high-density plastic such as polyethylene.
Polypropylene or other plastics, as well as metals, and other natural and
synthetic
30 materials of construction providing suitable strength and rigidity may
alternatively be
utilized.
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The present invention provides a concrete form system enabling the formation
of concrete walls or other components of various selected incremental
thicknesses.
With reference to Fig. 26, a preferred embodiment of the concrete form system
of the
present invention preferably comprises first and second side panels 10, 12,
substantially
5 as described above. Each of the first and second side panels 10, 12
comprises one or
more attachment couplings substantially as described above, such as attachment
points
17 or 100. A connector coupling 20 of the first end 27 of the one connector
18a
engages one attachment coupling 17 or 100 of the first side panel 10, and a
connector
coupling 20 of the first end 27 of a second connector 18b engages one
attachment
10 coupling 17 or 100 of the second side panel 12. A connector link 40 is
engaged
between the first and second connectors, with its first and second link
couplings
engaging the connector couplings of the second ends 29 of the first and second
connectors 18a, 18b. By combining connectors 18 and connector links 400 of
selected
lengths, a cavity 14 of any desired incremental width can be achieved.
15
Thus described, the system of the present invention enables a method of
constructing a concrete structure. In preferred form, and described with
reference to
Fig. 26, the method of the present invention generally comprises the steps of
erecting
first and second form panels 10, 12, substantially as described above, whereby
opposed
20 interior faces of the first and second form panels 10, 12 form a cavity 14
therebetween.
The method preferably further comprises engaging a first connector 18a with
the first
form panel 10, engaging a second connector 18b with the second form panel 12,
and
engaging a connector link 400 between the first connector 18a and the second
connector 18b. By appropriate selection of the sizes of the first and second
connectors
25 18a, 18b and the connector link 400, a cavity 14 of any desired incremental
width can
be achieved, thereby enabling the production of a wall or other component of
any
desired incremental thickness.
While the invention has been described in its preferred forms, it will be
readily
30 apparent to those of ordinary skill in the art that many additions,
modifications and
deletions can be made thereto without departing from the spirit and scope of
the
invention. For example, although the invention is described with reference to
a
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39
preferred embodiment depicted in the figures, wherein a connector link 400 is
engaged
between two connectors 18a, 18b, with the connectors engaging the panel
couplings,
the present invention also comprehends systems and methods similarly
incorporating a
chain of three or more connectors 18 coupled by two or more connector links.
Thus,
5 using three connectors 18 that are eight inches in length, coupled with two
connector
links 400, the width of the cavity 14 would be approximately twenty-four
inches.
Further, the present invention provides for a method for constructing a
concrete
structure having a termite infestation detection surface 500. A termite
detection surface
10 is often required in construction of buildings because termites and other
burrowing
insects may burrow through the insulation material, such as the preferred EPS
side
panels 10, 12 of the present invention, or between the insulation material and
the
underlying structure to reach vulnerable construction materials above. To
preclude the
destruction of vulnerable materials, building code often requires the
inclusion of a
1 S means of detecting the presence of termites or other such destructive
pests. With
reference to Fig. 27, a preferred embodiment of the concrete form system of
the present
invention preferably comprises first and second side panels 10, 12,
substantially as
described above. Each of the first and second side panels 10, 12 comprises one
or more
attachment couplings substantially as described above, such as attachment
points 17 or
20 100. A connector 18, or any combination of connectors 18 and connector
links 400
(not shown), operatively connects the first and second side panel 10, 12. One
side
panel 10 has a longitudinally extending length of set concrete that extends
therethrough
the side panel 10, and abuts the exterior surface l0e of the side panel 10.
The exposed
exterior surface 502 of the concrete preferably extends the entire
longitudinal length of
25 the side panel 10, and any abutting side panels 10, to form the termite
infestation
detection surface 500. As one skilled in the art will appreciate, because the
cured
concrete extends to and abuts the exterior surface l0e of the side panel 10, a
crawling
or burrowing insect is forced to traverse the exposed exterior surface, i.e.,
the termite
infestation detection surface 500, in order to reach the portion of the
concrete structure
30 above the detection surface 500 and may thus be visually detected on the
detection
surface.
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Thus described, the system of the present invention enables a method of
constructing a concrete structure with a termite infestation detection surface
500. In
preferred form, and described with reference to Figs. 27 and 28, the method of
the
present invention generally comprises the steps of: providing a first and
second side
5 panels 10, 12, substantially as described above; providing a longitudinally-
extending
support panel 504 having support panel interior surface 506 and having a first
width
that is less than the width of the first side panel 10; detachably securing
the support
panel 504 to the exterior surface l0e of the side panel 10 so that the
interior surface 506
of the support panel 504 overlies the exterior surface l0e of the side panel
10. The
10 method further comprises the steps of removing a longitudinally-extending
strip of the
side panel lOs, the strip having a width that is less than the first width of
the support
panel 504, to thus expose a portion of the interior surface 506 of the support
panel 504,
which allows the support panel 504 to be retained in contact with the exterior
surface
l0e of the side panel 10 during a concrete pour into the cavity 14.
15
Still further, the method comprises the steps of erecting the first and second
side
panels 10, 12, substantially as described above, whereby the interior surface
1 Oi of the
first side panels 10 and the exposed portion of the interior surface 506 of
the support
panel 504 oppose the interior surface 12i of the second side panels 12 to form
a cavity
20 14 therebetween; detachably engaging a connector 18 to the opposing
attachment
couplings I7 or 100 within the opposed side panels 10, 12, and pouring
concrete into
the cavity 14 formed between the side panels 10-12 to be cured therein. As one
skilled
in the art will appreciate, the poured concrete will fill the cut out portion
of the side
panel 10 and will abut the exposed portion of the interior surface of the
support panel
25 504 so that the poured concrete will be constrained substantially flush
with the exterior
surface l0e of the side panel 10. The method preferably further comprises
removing
the support panel 504 from the exterior surface l0e of the side panel 10 after
the
concrete has cured to expose the exterior surface 502 of the cured concrete.
Thus, a
longitudinally-extending termite infestation detection surface 500 is formed.
30
Although the present invention has been described with reference to specific
details of certain embodiments thereof, it is not intended that such details
should be
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41
regarded as limitations upon the scope of the invention except as and to the
extent that
they are included in the accompanying claims. For example, although the
present
invention is described with reference to a preferred embodiment incorporating
the
depicted concrete form system, it will be understood by those of ordinary
skill in the art
5 that the present invention is applicable to other types of concrete form
systems utilizing
one or more form panels or other concrete retaining and/or molding elements
retained
in position by one or more connectors or other relative position-fixing
elements. Also,
although the present invention is described with reference to a system, method
and
components thereof for use in the forming of concrete building components, the
present
10 invention may also find application in the formation of various other types
of products
of concrete and/or other moldable and curable materials such as, for example,
structural
and non-structural building components and consumer products of concrete,
plastics,
and other synthetic and natural materials.
