Note: Descriptions are shown in the official language in which they were submitted.
CA 02512390 2005-07-12
PILASTER FORM FOR AN INSULATING CONCRETE FORM BUILDING SYSTEM
This invention relates to a pilaster form shaped and arranged for use
with an insulating concrete form building system in which a series of forms
are
stacked wi#h each form defined by two panels of foam defining a central
channel into
which concrete is poured to create a wall in which the structure is defined by
the
concrete layer and the insulation is provided by the inner and outer panels of
foam.
BAGKGR4UND OF THE INVENTION
A construction system for building insulated concrete walls is well-
known and widely used and becoming significantly more popular, This includes
two
panels of insulating foam which are connected by injection molded bridging
members which have ends arranged so that one end is buried within one foam
panel
and the other end buried in the other foam panel to hold the panels parallel
and
spaced. These blocks are commonly of the order of 4 feet in length 1$ inches
in
height and are provided with meshing projections and recesses on the top and
bottom surfaces so that the forms can be assembled in rows each on top of the
next.
This arrangement provides a channel between the two panels which can be filled
with concrete. The bridging members include suitable shaping arrangements to
receive and hold conventional reinforcing bars.
Walls of this type are therefore farmed simply and with minimal labour
with the insulation already in place so that the structure may be finished
simply by
suitable cladding on the inside and outside surface.
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In some cases, particularly when the wall construction is of greater
height which is common used in a commercial building, it is desirable to
provide a
pilaster column integral with the wall structure where there are series of
such pilaster
columns at spaced positions along the length of a wall structure. These are
provided for increased structural strength as is well known and commonly used
in
the industry. Conventionally a pilaster column is formed by providing from
work on
each side of the concrete wall at the required location so as to provide a
column of
increased width at the required location for the pilaster column. Thus when
the
concrete is pours the wall is formed simultaneously with the shaped pilaster
column
90 as an integral structure.
One example of forms of this type is shown in the literature of the
present assignee under the trademark "Logix Icf'. This literature shows
examples of
forms of the above general type.
However up till now there has been no effiective way to form pilasters
7 5 with the insulating forms of the above type. No form nor system appears td
be
currently available in a system of this type which allows the pilaster to be
conveniently and effectively formed as part of the system.
in literature obtained from the Internet by a manufacture of forms of
this type which is Reddiform is shown a type of form known as a "pil2~ster
form",
2o However the technique by which this is used to form pilasters is not clear
and it not
made clear in the literature.
CA 02512390 2005-07-12
SUMMARY OF THE INVENTION
It is one object of the invention to provide an improved apparatus of
this type for forming pilaster columns with the concrete wall structure.
According to one aspect of the invention there is provided an
apparatus for use in constructing an insulated concrete wall comprising:
a plurality of main forms for assembling in stacked rows of side by side
farms;
each main form comprising:
two panels of insulating foam each having a top surface, a bottom
surface, two end surfaces, an inner surface facing toward the other of the
panels
and an outer surface facing away from the other of the panels;
a plurality of bridging members extending between the panels for
holding the panels at a spaced position defining a channel between the inner
surfaces of the panels for receiving a cast concrete layer therebetween;
the top and bottom surface having mating projections and recesses
thereon by which the bottom surface of one form can intermesh with the top
surface
of a next row of forms to hold the forms interconnected;
the main forms being shaped and arranged such that the layer of
concrete can be cast in the space between the panels of the stacked rows of
forms
to define a concrete structural wall insulated on each side by the panels;
and a pilaster form for use with the main forms in defining a pilaster
extending from the concrete structural wall on at (east one side of the wall,
the
CA 02512390 2005-07-12
pilaster form comprising:
4
a pilaster farm body defined from insulating foam to define a generally
channel shape in plan for attachment to the main forms verkically along one of
the
panels of the main forms along a slot in said one of the panels of the main
forms;
the pilaster form body having a web portion arranged to lie generally
parallel to said one of the panels and two leg portions arranged such that the
leg
portions extend from the web portion toward said one of the panels to hold the
web
portion at a position spaced from said one of the panels for receiving a
column of the
cast concrete within the pilaster form and connected to the cast concrete
layer.
Preferably the pilaster form body has a height equal to the height of the
main forms such that the pilaster form body has top and bottom surfaces co-
planar
with the top and bottom surfaces of the main forms when installed such that
the
pilaster forms can be assembled in a common row with the main forms.
Preferably the leg portions lie at right angles to the web portion to form
a rectangular or square pilaster column. However other shapes are possible
such
as polygonal ar circular.
Preferably an inner surtace of the pilaster form body has a series of
recesses to tie to the concrete column which may comprise longitudinal grooves
on
the web portion and the I~g portions.
Preferably the pilaster farm body includes a buried strip member
extending along the pilaster farm body substantially along the full height of
the
pilaster form body.
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Preferably the buried strip member lies substantially parallel to an
outer surface of the pilaster form body for receiving fastening screws or the
like.
Preferably the buried strip member includes two portions at right
angles such that one portion lies parallel to an outer surface of the leg
portion and
one portion lies parallel to the web portion.
Preferably the pilaster farm body includes longitudinally extending
markings defining a length to be cut off of the leg portions so as to reduce
the
distance of the web portion from said one of the panels.
Preferably the pilaster form body has tap and bottom surface having
mating projections and recesses thereon by which the bottom surtace of one
fom~t
can intermesh with the top surface of a next form to hold the forms
interconnected.
According to a second aspect of the invention there is provided a
method for constructing an insulated concrete wall comprising:
providing a plurality of main forms;
each main form comprising:
two panels of insulating foam each having a top surface, a bottom
surtace, two end surfaces, an inner surface facing toward the other of the
panels
and an outer surface facing away from the other of the panels;
a plurality of bridging members extending between the panels for
holding the panels at a spaced position defining a channel between the inner
surfaces of the panels for receiving a cast concrete layer therebetween;
the top and bottom surface having mating projections and recesses
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.. ~ ..
thereon by which the bottom surface of one form can intermesh with the top
surface
of a next row of forms to hold the forms interconnected;
the main forms being shaped and arranged such that the layer of
concrete can be cast in the space between the panels of the stacked rows of
forms
to define a cancrete structural wall insulated on each side by the panels;
providing a pilaster form for use with the main forms in defining a
pilaster extending from the concrete structural wall on at least one side of
the wall,
the pilaster form comprising:
a pilaster form body defined from insulating foam to define a generally
90 channel Shape in plan for attachment to the main forms vertically along one
of the
panels of the main forms along a slot in said one of the panels of the main
forms;
the pilaster farm body having a web portion arranged to lie generally
parallel to said one of the panels and two leg portions arranged such that the
leg
portions extend from the web portion toward said one of the panels to hold the
web
portion at a position spaced from said one of the panels for receiving a
Column of the
cast concrete within the pilaster form and connected to the cast concrete
layer;
assembling the main forms in taws to define a continuous channel
between the panels thereof with one panel of the forms on one side of the
channel
and the other panel of the forms on the other side of the forms;
forming a vertical slot in the panels on at least one side of the channel;
attaching the pilaster forms such that they are attached to said at least
one side at the slot with the web portion spaced from the channel and the leg
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7 ., . _
portions extending to panels on said at least one side such that the pilaster
forms
define a column inside the web portion and connected to the channel;
~Iling the channel and the column with concrete to form a pilaster
column on the concrete wall;
and leaving the pilaster form body in play covering the pilaster column
as an insulating layer.
BRIEF DESGRIPTIt~N OF THE DRAWINGS
One embodiment of the invention will now be described in conjunction
with the accompanying drawings in which:
Figure 1 is a top plan view of the pilaster form itself separate from the
main forms and the assembled structure.
Figure 2 is a top plan view of the pilaster fom~ of Figure 1 attached to a
wall structure formed by the conventions! main farms.
Figures 3 and 4 show alternative techniques for assembling the
pilaster form of Figure 1 in the wall structure.
Figure 5 is an isometric view of a portion of a wall structure with the
pilaster column assembled with the concrete wall in an insulated structure.
In the drawings like characters of reference indicate corresponding
parts in the different figures.
DETAILED C~ESGRiPTIaN
In Figure 5 is shown a concrete wall structure including a central Layer
10 of concrete which is coated on one side by a fist panel 1 ? of an
insulating foam
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material and on the other side by a second panel 12 also of similar insulation
foam
material. The wall structure is formed with integral concrete layer created
between a
series of farms generally indicated at 93. Each form 13 as shown in Figure 2
comprises one foam panel '! 1 A and a second foam panel 12A held in spaced
positions by a plurality of injection moulded bridging members 15, The
bridging
members are arranged at spaced positions along the length of the form. Each
bridging member' has a pair of web plates generally at right angles to the
plane of
the bridging member so that the web plates are parallel to the surfaces of the
foam
panels. One of the web plats is located in the plane of the inside surface of
the
respective panel. The other web plate is spaced outwardly and is buried within
the
foam panel. In this way the bridging members locked into the foam panel so
that the
foam panels are held at a predestined space position. In addition the web
plates
buried within the foam panels act as fastening plates into which screw
fasteners can
be applied for attaching the cladding.
As shown in Figure 5, the fam~s are assembled in rows side by side so
that in Figure 5 three rows 18, 17 arid 18 are shown for each row being
created by a
series of the forms end to end. The forms of one row are longitudinally offset
relative to the forms of the next row so that the junctions between the forms
are
offset. The forms each include in the top and bottom surFaces of the panels a
series
of projections and recesses which mesh when the fom~s are placed on top of the
next. The shape and arrangement of the meshing projection and recesses can
vary
of different types as well known to one skilled in the art. The effect is that
the forms
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9 .. ... .
are held against longitudinal transverse movement when placed in the rows by
the
projections with the projections being sufficient t4 maintain the structure
integral until
the reinforcing bars are placed within the rows and the concrete poured, Once
the
concrete is poured and set, the structure is held integral by the concrete
layer itself
a with the foam panels butting each other to provide a complete inserting
layer an both
surfaces of the concrete wall.
The system provides, according to the present invention, a pilaster
form generally indicated at 20 and shown independently in Figure 1. The
pilaster
form comprises a generally channel shape member defining a body of foam with a
web portion 21 and two legs 22 and 23 at right angles to the web portion. The
thickness of the leg portion and the web portions is equal and is generally
approximately equal to the thickness of the foam panels in the conventional
main
forms.
Thus the leg portions have an outside surface 24 and an inside surface
25 where those surfaces are parallel and spaced by the thickness of the fbam
material. The web portion also has an outside surface 26 and an inside surface
27
again spaced by the thickness of the foam material. The web portion connects
to
the leg portions at a right angle and is integrally formed therewith as an
integral foam
structure.
Buried within the form at the junctions between the web portion and the
leg portion is provided a pair of furring strips indicated at 28 and 29. These
furring
strips are arranged to extend substantially on the full height Qf the pilaster
form. The
CA 02512390 2005-07-12
height as shown in Figure 5 of each pilaster farm is substantially equal to
the height
of the main fom~s. In this way each row of main forms can be laid and a
cooperating
pilaster form applied and held in place as discussed hereinafter.
The inside surtace of the feg portions includes a series of longitudinally
extending ribs and recesses 30 at a position adjacent the web portion.
Similarly the
inside surface 27 of the web portion includes ribs and recesses arranged in a
transversely spaced array as indicated at 31. These grooves or ribs act to
engage
into the surface of the concrete when poured into the pilaster form so as to
provide a
keying effect with the concrete surface to hold the foam insulating layer
defined by
1 D the pilaster form in place after the casting is complete and the concrete
set.
The pilaster from has markings 32 an the leg portions parallel ta~ the
web portion sa as to define a position at which the leg portion can be cut to
reduce
the length of the leg portion away from the web portion. It will be
appreciated that the
length of the leg portion varies the spacing of the web portion from the
outside
surface of the main form when attached so that this changes the dimensions
of~the
pilaster column cast within the pilaster fom~. The markings 32 are provided at
suitable positions for conventionally dimensioned pilaster columns.
In assembling the pilaster form with the main forms as shown in
Figures 2, 3 and 4, the main form is cut at a position indicated at 4Q and 41
to define
a slot 42. This slat is located at a position spaced from a bridging .member
15 or the
bridging member 15 can be cut also if required depending upon the dimensions
of
the slat cut. As shown in Figures 2, 3, and 4, the slot can be cut in only one
of the
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11 .. .
panels sa that the intention is the pilaster only be defined on only one side
of the
layered concrete when cast,
In Figure 5 a slot 42 is cut in one panel 11 and a second slot 42A is cut
in the other panel 92 so that a pilaster column can be defined an bath sides
df the
central layer 10.
In Figures 2, 3 and 4, the width of the slot is equal to the intended
width of the pilaster column. In this way, the pilaster form is atkached onto
the
outside surface of the existing foam panel 11A. As shown at the top of Figure
5, it is
also possible to cut the slot 41A so that the end edges 40 and 41 are outside
the leg
portions 22 and 23 so that the leg portions insert into the slot. For this
purpose of
course the leg portions must be longer than when butted on the outside as
shown in
Figures 2, 3 and 4. It is preferred far more effective assembly that the slots
be
alternated wider and narrower with alternating pilaster forms of shatter and
longer
legs in each of the rows 16, 11 and 1$. This provides an improved intem~eshing
of
the foam pieces of the panels and the leg portions of the pilaster forms.
As shown in Figures 2, 3 and 4, suitable form work is applied onto the
outside surface of the pilaster form to hold the pilaster farm in place during
the
casting of the pilaster column. In Figure 2 this form work comprises an outer
plate
50 and two pieces plumber 51 and 52. These are fastened together with nails 53
and bridging fasteners 54 can be applied through the whole structure from the
outside of the pilaster form through to the opposite panel 12A and a panel 55
applied
on that panel. This therefore transfers loads through the structure so that
forces on
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. 12
the pilaster form tending to push it away from the panel 11A are resisted by
the
forces from the plate 55 against the panel 12A.
In Figure 3 is shown an alternative arraignment in which additional
transverse tying members 58 are provided between the lumber pieces 51 and 52.
In the arrangement of Figure 4, additional plates 57 and 5$ are
provided on either side of the pilaster from which are fastened to narrower
lumber
pieces 51A and 52A again to provide improved holding forces. In this
arrangement
the transverse member 5~ can be omitted.
Thus in the assembly of the system, the pilaster forms are selected
9 p and cut to the required dimensions so that they fit into or on the outside
of the slots
42 as described above. The slots 42 are then formed in the panels, either one
of the
panels or in both of the panels as required. The slots are preferably formed
out the
position spaced from the ends of the forms. With the pilaster forms in place
and
interconnected each from the top of one to the bottom of the next by the
intermeshing praje~ctians t30, the form work is applied to hold the pilaster
forms in
place during the casting of the pilaster column and the layer of concrete
between the
fomns.
Suitable reinforcing bars are laid in place as is known to one skilled in
the art within the space between the main forms and also into the columns
within the
pilaster farm. These reinforcing bars can include horizontal bars and also
vertical
bars along the length of the column.
With the form work in place holding the pilaster form attached to the
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main form, the concrete can be poured into place thus integrally forming the
concrete wall and the pilaster column. Once the concrete is set, the form work
can
be removed leaving the pilaster form in place so that the concrete and the
pilaster
column is covered on both the outer surface and the inner surface by the foam
layer.
Since various modifications can be made in my invention as herein
above described, and many apparently widely different embodiments of same made
within the spirit and scope of the claims without department from such spirit
and
scope, it is intended that all matter contained in the accompanying
specification shall
be interpreted as illustrative only and not in a limiting sense.
