Note: Descriptions are shown in the official language in which they were submitted.
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CONCRETE FORM TIE, AND CONCRETE FORMWORK COMPRISING SAME
Field
[0001] The subject application generally relates to forms for
concrete walls
and in particular, to a concrete foull tie and a concrete formwork comprising
the
same.
Backaround
[0002] Conventional forms for forming walls from pourable building
material
such as concrete consists of two opposed panels, typically fabricated of
plywood, that
are connected by a rod, trusswork or other connecting structure. More
recently, it has
become desirable to use insulating material such as expanded polystyrene (EPS)
for
the foun, in order to provide thennal and acoustic insulation to the finished
concrete
wall. In certain applications, particularly those in which it is desired to
utilize the
ability of the concrete to retain heat for themial stabilization, it is
desirable to employ
forms with insulating material on only one side. The other side of the form,
which is
typically a sheet of plywood or other material, may or may not be removed
after full
or partial setting of the concrete.
[0003] Concrete formworks comprising insulating material have been
previously described. For example, U.S. Patent No. 5,701,710 to Tremelling
describes a freestanding fonu module for receiving flowable materials that
includes a
pair of form members, preferably made of styrofoam, joined together by molded
plastic rib members. The rib members may be monolithic or formed from plural
components. Bearing plates and stabilizing plates are employed to support
forces
applied to the form module.
[0004] U.S. Patent No. 5,709,060 to Vaughan et al. describes a fomi
tie for
joining sidewalls of a polymeric concrete fonn that comprises a pair of end
trusses
with an intermediate web truss. Each end truss comprises an interior vertical
strut and
a longer exterior strut with interior and exterior pairs of horizontal struts
extending
therebetween. Upper and lower rectangular trusses and an intermediate truss
are
formed within each truss and rigidified by diagonal struts extending between
the ends
of the exterior vertical strut and interior vertical strut. The exterior
struts of each end
truss are coplanar with the exterior sidewall surface with the interior strut
of each end
Date Recue/Date Received 2022-12-07
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truss being coplanar with the interior sidewall surface. The coplanar
relationship of
the struts serve as a visual gauge that the form with tie has been properly
manufactured and assures that the end trusses extend throughout the width of
each
sidewall. End ties having a height of one-half of the form sidewall are
extended
between the sidewalls at the ends of each form. The end ties of adjacent forms
are
vertically offset to enhance concrete flow therebetween. During transport and
use the
trusses resist the presence of compression, tension, twisting and other forces
acting on
the forms so as to maintain the desired spatial relationship between the
forms. A seat
for horizontal rebar is found with each form tie.
[0005] U.S. Patent No. 6,314,694 to Cooper et al. describes one-
sided,
insulated formwork used in the construction of walls from pourable building
material,
such as concrete, including an insulating panel connectable to a removable
panel by a
connecting structure, which may include a permanent reinforcement embedded in
the
insulating panel. The connecting structure may have a tie removably attachable
to the
reinforcement, or the reinforcement and tie may constitute a monolithic
structure.
The tie may be asymmetric in shape to facilitate distribution of loads across
the
insulating panel, detachment of the removable panel, and enhance the
structural
integrity of the finished wall.
[0006] U.S. Patent No. 7,059,577 to Burgett describes a method and
system
for installing an insulated concrete wall includes insulation panels placed in
an upright
manner. Generally T-shaped wall studs are placed next to the insulation panels
such
that the front section of the wall stud is on the outside of the insulation
panels and an
anchoring section of the wall stud extends beyond the insulation panels into
the gap
into which concrete will later be poured. Concrete pouring forms are placed so
as to
render the gap into which concrete will be poured a desired thickness. The
wall stud
may also include slots for receiving cross-ties that secure the concrete
pouring forms
in proper position and retaining nubs that prevent the insulation panels from
floating
when concrete is poured. Concrete is then poured into the gap, surrounding the
anchoring section the T-shaped wall stud.
[00071 U.S. Patent No. 9,121,166 to Amend describes a panel for a
building
form made of insulating material such as polystyrene that is integrated with a
reinforcing member for enabling the panel to resist deformation due to forces
applied
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against its concrete-facing surface. The reinforcing member may be made of a
plastic
material such as polypropylene or high-impact polystyrene.
[0008] U.S. Patent Application Publication No. 2001/029717 to
Spakousky
describes a composite modular building block with a connective structure
between the
outer and inner wall. The inner and outer walls of the composite modular block
units
may be made of cement, clay brick, or similar materials. The connective
structure is
made of a different material than the walls of the composite block and may be
formed
per the requirements of each block. In one embodiment, the connective
structure may
comprise two or more individual connective struts connecting an outer and an
inner
wall of a modular block. A panel member cooperating with the struts may be
inserted
between the outer and inner walls to form two separate cavities between the
blocks
when these are assembled into a wall.
[0009] Improvements are generally desired. It is therefore at
least an object to
provide a novel concrete form tie and a novel concrete formwork comprising the
same
same.
Summary
100101 It should be appreciated that this summary is provided to
introduce a
selection of concepts in a simplified form that are further described below in
the
detailed description. This summary is not intended to be used to limit the
scope of the
claimed subject matter.
100111 Accordingly, in one aspect, there is provided a tie for a
concrete
formwork, the tie comprising: a tie anchor configured to be embedded in a
block of
insulating material, the tie anchor having a first connecting feature
accessible from a
concrete-facing surface of the block; and a tie member having a second
connecting
feature configured to connect to the first connecting feature of the tie
anchor, the tie
member having at least one connector for connecting to an abutting tie member.
[0012] The first connector may comprise features defining a
channel that is
sized to receive the second connector. The features may comprise a base plate
and a
plurality of angled tabs extending therefrom and defining the channel. The
second
connector may comprise features configured to be received in the first
connector. The
features may comprise a rail including one or more longitudinal tabs.
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100131 The first connector may comprise a longitudinal rib having
features
defining a channel that is sized to receive the second connector. The features
may
comprise a base plate and a plurality of angled tabs extending therefrom and
defining
the channel. The second connector may comprise features configured to
accommodate at least a portion of the first connector. These features may
comprise a
longitudinal guide defining a longitudinal channel that is sized to
accommodate at
least a portion of the first connector. The longitudinal guide may have a
generally "C-
shaped" section along its length, defining the channel. The longitudinal guide
may
comprise a series of angled tabs extending from a longitudinal baseplate,
defining the
channel.
[0014] The tie member may further comprise a panel fastening plate
defining
an elongate panel fastening surface; and a central web connecting the panel
fastening
plate and the second connecting feature. The tie may further comprise flanges
extending laterally from the panel fastening plate and defining a portion of
the panel
fastening surface. The panel fastening surface may extend the length of the
panel
fastening plate. The web may have a linking feature formed in an edge thereof,
the
linking feature being sized to engage a connecting rod for linking the tie
member to
an adjacent tie member. The linking feature may be a notch formed in the edge
of the
web, the notch being sized to receive the connecting rod. The linking feature
may be
a pin formed in the edge of the web, the pin being sized to engage a bore
formed in
the connecting rod. The at least one connector may comprise a connector at
each
longitudinal end of the panel fastening plate. The at least one connector may
be
configured to prevent relative lateral movement of the abutting tie members.
The at
least one connector may comprise a connector at each end of the second
connecting
feature. The at least one connector may be configured to prevent separation of
the
abutting tie members in a longitudinal direction.
[0015] In another aspect, there is provided a concrete formwork,
comprising: a
plurality of blocks of insulating material arranged to define a side of the
formwork,
each block comprising at least two tie anchors embedded therein, each tie
anchor
having a first connecting feature accessible from a concrete-facing surface of
the
block; a plurality of tie members, each tie member having a second connecting
feature
connected to the first connecting feature of the tie anchor; a connecting rod
seated
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horizontally on two or more adjacent tie members, the connecting rod linking
the two
or more tie members; and a panel fastened to the tie members, the panel and
the
blocks defining a volume into which concrete is to be poured.
[0016] The panel may be spaced from ends of the tie members by a
plurality
of spacers. The panel may be fastened to the tie members by fasteners
extending
through the spacers.
[0017] In another aspect, there is provided a method of constructing
a concrete
wall and a concrete floor slab of a building, comprising: arranging a
plurality of
blocks of insulating material, each block comprising at least two tie anchors
embedded therein, each tie anchor having a first connecting feature on a
concrete-
facing surface of the block; connecting tie members to the tie anchors, each
tie
member having second connecting feature matingly engaging the first connecting
feature of a respective one of the tie anchors; fastening an insulating panel
to the tie
members, the insulating panel being fabricated of insulating material; pouring
concrete into a volume defined by the blocks and the insulating panel to foini
the
concrete wall; removing the panel from the concrete wall after the concrete
has set;
laying the insulating panel on ground; and pouring concrete onto the
insulating panel
to foHn the concrete floor slab.
[0018] The concrete wall may be formed on a concrete footing.
[0019] The laying may further comprise: laying a vapour barrier on
the
ground; and laying the insulating panel on the vapour barrier.
[0019a] In another aspect, there is provided a tie for a concrete
formwork, the
tie comprising: a tie anchor configured to be embedded in a block of
insulating
material, the tie anchor having a first connecting feature accessible from a
concrete-
facing surface of the block; and a tie member fabricated of a single piece of
material,
comprising: a second connecting feature shaped to slidably engage the first
connecting feature in a direction along a length of the tie anchor to connect
to the first
connecting feature of the tie anchor, a panel fastening plate defining an
elongate panel
fastening surface, a central web connecting the second connecting feature and
the
panel fastening plate, and at least one connector for connecting to an
abutting tie
member.
Date Recue/Date Received 2022-12-07
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10019b] In still another aspect, there is provided a concrete
formwork,
comprising: a plurality of blocks of insulating material arranged to define a
side of the
formwork, each block comprising at least two tie anchors embedded therein,
each tie
anchor having a first connecting feature accessible from a concrete-facing
surface of
the block; a plurality of tie members, each tie member being connected to a
respective
tie anchor, each tie member having: a second connecting feature slidably
engaging the
first connecting feature in a direction along a length of the respective tie
anchor,
thereby connecting to the first connecting feature of the respective tie
anchor, a panel
fastening plate defining an elongate panel fastening surface, a central web
connecting
the second connecting feature and the panel fastening plate, and at least one
connector
for connecting to a vertically abutting tie member; a connecting rod seated
horizontally on two or more adjacent tie members, the connecting rod linking
the two
or more tie members; and a panel fastened to the tie members, the panel and
the
blocks defining a volume into which concrete is to be poured.
Brief Description of the Drawings
[0020] Embodiments will now be described more frilly with reference
to the
accompanying drawings in which:
[0021] Figure 1 is a perspective view of a concrete foiniwork;
[0022] Figure 2 is a perspective view of a tie founing part of the
concrete
formwork of Figure 1;
[0023] Figure 3 is a perspective view of a tie anchor forming part of
the tie of
Figure 2;
[0024] Figure 4 is an end view of the tie anchor of Figure 3;
[0025] Figure 5 is a side view of the tie anchor of Figure 3;
Date Recue/Date Received 2022-12-07
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100261 Figure 6 is a sectional view of the tie anchor of Figure 5,
taken along
the indicated section line;
[0027] Figure 7 is a front view of the tie anchor of Figure 3;
100281 Figure 8 is a perspective view of a tie member forming part
of the tie
of Figure 2;
[0029] Figure 9 is another perspective view of the tie member of
Figure 8;
[0030] Figure 10 is a side view of the tie member of Figure 8;
[0031] Figure 11 is an end view of the tie member of Figure 8;
[0032] Figure 12 is a rear view of the tie member of Figure 8;
[0033] Figure 13 is a front view of the tie member of Figure 8;
100341 Figures 14 and 15 are enlarged fragmentary views of the tie
member of
Figure 8 identified by reference numerals 14 and 15;
100351 Figure 16 is an enlarged fragmentary view of the tie member
of Figure
9 identified by reference numeral 16;
[0036] Figure 17 is a perspective view of a connecting rod forming
part of the
concrete formwork of Figure 1;
[0037] Figure 18 is a top view of the connecting rod of Figure 17;
[0038] Figure 19 is a front view of the connecting rod of Figure
17;
[0039] Figure 20 is a perspective view of a spacer forming part of
the concrete
foiinwork of Figure 1;
[0040] Figure 21 is a side view of the spacer of Figure 20;
[0041] Figures 22A to 22C are views of the concrete formwork of
Figure 1, at
various stages of assembly;
[0042] Figure 23 is a perspective view of a concrete wall formed
using the
concrete formwork of Figure 1;
[0043] Figures 24A to 24D are elevational views of a concrete
floor slab, at
various stages of assembly;
[0044] Figure 25 is a side view another embodiment of a tie member
forming
part of the concrete formwork of Figure 1;
[0045] Figure 26 is a perspective view of another embodiment of a
connecting
rod forming part of the concrete formwork of Figure 1;
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100461 Figures 27A and 27B are perspective views of another
embodiment of
a concrete formwork, at various stages of partial assembly;
100471 Figure 28 is a perspective view of another embodiment of a
tie anchor,
forming part of the concrete formwork of Figures 27A and 27B; and
[0048] Figure 29 is a perspective view of another embodiment of a
tie
member, forming part of the concrete fon-nwork of Figures 27A and 27B.
Detailed Description of Embodiments
100491 The foregoing summary, as well as the following detailed
description
of certain examples will be better understood when read in conjunction with
the
appended drawings. As used herein, an element or feature introduced in the
singular
and preceded by the word "a" or "an" should be understood as not necessarily
excluding the plural of the elements or features. Further, references to "one
example"
or "one embodiment" are not intended to be interpreted as excluding the
existence of
additional examples or embodiments that also incorporate the described
elements or
features. Moreover, unless explicitly stated to the contrary, examples or
embodiments
"comprising" or "having" or "including" an element or feature or a plurality
of
elements or features having a particular property may include additional
elements or
features not having that property. Also, it will be appreciated that the
teinis
"comprises", "has", "includes" means "including by not limited to" and the
terms
"comprising", "having" and "including" have equivalent meanings.
100501 As used herein, the term "and/or" can include any and all
combinations
of one or more of the associated listed elements or features.
100511 It will be understood that when an element or feature is
referred to as
being "on", "attached" to, "connected" to, "coupled" with, "contacting", etc.
another
element or feature, that element or feature can be directly on, attached to,
connected
to, coupled with or contacting the other element or feature or intervening
elements
may also be present. In contrast, when an element or feature is referred to as
being,
for example, "directly on", "directly attached" to, "directly connected" to,
"directly
coupled" with or "directly contacting" another element of feature, there are
no
intervening elements or features present.
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100521 It will be understood that spatially relative terms, such
as "under",
"below", "lower", "over", "above", "upper", "front", "back" and the like, may
be
used herein for ease of description to describe the relationship of an element
or feature
to another element or feature as illustrated in the figures. The spatially
relative terms
can however, encompass different orientations in use or operation in addition
to the
orientation depicted in the figures.
100531 Turning now to Figure 1, a portion of an assembled concrete
formwork
is shown and is generally indicated by reference numeral 30. Concrete
folinwork 30
is configured to serve as a mold into which concrete (not shown) is poured to
form a
concrete wall during construction of a building. The building may be a
residential
building, such as a house, and the concrete wall may be a concrete foundation
wall,
for example.
100541 Concrete formwork 30 comprises a plurality of blocks 32
fabricated of
an insulating material, a plurality of panels 34, and a plurality of ties 40
connecting
the blocks 32 and the panels 34. When connected by the ties 40, the blocks 32
and the
panels 34 define a volume 42 into which the concrete is to be poured. Each
block 32
is fabricated of expanded polystyrene (EPS) foam by molding. The panels 34 may
be
fabricated of EPS foam, or of a rigid sheet material such as plywood, oriented
strand
board (OS B), and the like.
100551 Figure 2 shows one of the ties 40. Each tie 40 comprises a
tie anchor
44 and a tie member 46, which are separately fabricated. The tie anchor 44 is
configured to be embedded in a respective block 32 during fabrication of the
block
32. The tie member 46 is configured to be connected to the embedded tie anchor
44
during assembly of the concrete formwork 30. The tie anchor 44 and the tie
member
46 are each fabricated of a single piece of material, and in particular the
tie anchor 44
and the tie member 46 are each fabricated of polyurethane by injection
molding.
10056] The tie anchor 44 may be better seen in Figures 3 to 7. In
this
embodiment, the tie anchor 44 comprises a longitudinal tab guide 52, a
longitudinal
anchor plate 54, and a web comprising a plurality of struts 56 connecting the
tab guide
52 and the anchor plate 54. The tab guide 52 comprises a longitudinal base
plate 58
from which a plurality of angled tabs 62 and 64 extend. The base plate 58 and
the
angled tabs 62 and 64 define a channel 70 that is sized to receive a portion
of the tie
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member 46, for mating engagement of the tie anchor 44 and the tie member 46.
In
particular, the angled tabs comprise a first plurality of angled tabs 62 that
extend from
a first longitudinal edge of the base plate 58, and a second plurality of
angled tabs 64
that extend from a second, opposite longitudinal edge of the base plate 58. In
the
example shown, the angled tabs 62 and 64 are arranged in an alternating
pattern along
the length of the base plate 58. Each longitudinal tab 62 and 64 comprises a
first tab
portion 72 joined to the base plate 58, and a second tab portion 74 extending
from the
first tab portion 72 in a direction parallel to the base plate 58 and toward
the opposing
angled tabs 62 or 64. The ends of the second tab portions 74 of angled tabs 62
and 64
are spaced from each other by a distance, d, so as to enable the channel 70 to
be
accessible from a concrete-facing surface of the block. The channel 70 has a
first end
76 and a second end 78, each of which defines an opening of the channel 70 for
allowing the tie member 46 to be slidably inserted.
10057] Each strut 56 of the tie anchor web is in the form of a
flat strip that is
connected to the base plate 58 of the tab guide 52 and to the anchor plate 54.
As will
be understood, the flat shape of the strut 56 provides resistance to bending,
and has a
large interfacial area to provide better bonding between the tie anchor 44 and
the
material of the block 32 while utilizing less material, as compared to other
shapes
such as circular or square. The anchor plate 54 has a generally longitudinal,
planar
shape.
100581 The tie member 46 may be better seen in Figures 8 to 16. In
this
embodiment, tie member 46 comprises a longitudinal rail 82, a longitudinal
panel
fastening plate 84, and a central web 86 connecting the rail 82 and the panel
fastening
plate 84. The rail 82 comprises a longitudinal tab 88 and a longitudinal base
92,
which are connected by a longitudinal web 94 oreinted orthogonally thereto.
The
longitudinal tab 88 is configured to be slidably inserted into the channel 70
of the tie
anchor 44, for mating engagement of the tie anchor 44 and the tie member 46.
The
panel fastening plate 84 has an elongate panel fastening surface 96, to which
a panel
34 is to be fastened during assembly of the concrete formwork 30. The panel
fastening plate 84 comprises two (2) pairs of laterally extending flanges 98,
with each
flange 98 defining a portion of the fastening surface 96. As will be
understood, the
flanges 98 are configured to facilitate fastening of the panel 34 by providing
a
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laterally enlarged area for fastening, and by impeding rotation of the tie
member 46
relative to the panel 34. The web 86 is of generally planar shape, and has a
first edge
102, a second edge 104, and a central aperture 106 therebetween. The web 86
comprises a plurality of fingers 112 that extend outwardly from each of the
first edge
102 and the second edge 104. The fingers 112 define recesses 114 therebetween
that
are configured to accommodate reinforcement bar (not shown), also referred to
as
"rebar", that may be laid during assembly of the concrete form 30. Each finger
112
terminates in two (2) inwardly-extending hooks 116, which are configured to
assist in
retaining the reinforcement bar in the recesses 114 during assembly of the
concrete
form 30, and during pouring of concrete into the assembled concrete form 30.
The
web 86 has a notch 118 defined in each of the first edge 102 and the second
edge 104
adjacent the panel fastening plate 84. The notch 118 is configured to engage a
connecting rod 120, described below, for maintaining parallel alignment of
adjacent
tie members 46 during assembly of concrete formwork 30.
100591 The tie member 46 also comprises a plurality of connectors
for
enabling vertically abutting tie members 46 to be connected. In the example
shown,
each tie member 46 comprises a first connector 124 at each end of the panel
fastening
plate 84. As will be understood, each first connector 124 is configured to
engage the
first connector 124 of a vertically abutting tie member 46. In the example
shown,
each first connector 124 comprises a longitudinally extending tongue 126, and
an
angled tab 128 and sidewall 132 defining a recess 136 sized to receive the
tongue 126
of another connector 124. As will be understood, when vertically adjacent tie
members 46 abut, the tongue 126 of one connector 124 is received in the recess
136
of another connector 124, and relative lateral movement of tie members 46 is
prevented. Each tie member 46 also comprises a second connector 138 at each
end of
the longitudinal base 92 of the rail 82. The second connector 138 is
configured to
engage a second connector 138 of a vertically abutting tie member 46. In the
example
shown, each second connector 138 is in the form of a hook-shaped clip. As will
be
understood, when vertically adjacent tie members 46 abut, the second connector
138
of one tie member 46 engages the second connector 138 of another tie member
46,
and relative vertical movement of the tie members 46 is prevented. Vertically
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abutting tie members 46, connected in this manner by connectors 124 and 138,
yield
columns 140 of connected tie members 46.
100601 Figures 17 to 19 show the connecting rod 120. In this
embodiment, the
connecting rod 120 is in the form of a longitudinal angled rod, and has a
plurality of
spaced notches 142 formed therein, with each notch 142 being configured to
engage a
respective notch 118 of a tie member 46. In the example shown, the connecting
rod
120 has three (3) notches 142 formed therein. The connecting rod 120 has
connecting
portions at its ends for enabling adjacent connecting rods 120 to be
connected. In the
example shown, the connecting portions comprise a barbed clip 144 at a first
end of
the connecting rod 120, and a corresponding recess 146 at a second end of the
connecting rod 120 shaped to receive a barbed clip 144 of another connecting
rod
120. As will be understood, when the connecting rod 120 is seated on three (3)
tie
members 46 within concrete formwork 30 such that each notch 142 of the
connecting
rod 120 engages a notch 118 of a respective tie member 46, the connecting rod
120
links the free ends of the three (3) tie members 46 and maintains parallel
alignment of
the tie members 46, including the tie members 46 below and connected within
columns 140, which facilitates fastening of the panels 34. Further, when
adjacent
connecting rods 120 are connected, the free ends of the tie members 46 of the
plurality of columns 140 on which the connecting rods 120 are seated are
linked.
100611 Figures 20 and 21 show a spacer for use with the concrete
formwork
30, which is generally indicated by reference numeral 150. Spacer 150
comprises a
tapered body 152 and a hollow, splined shaft 154 extending therefrom. A bore
156
for accommodating a fastener extends through the body 152 and the shaft 154.
The
body 152 has a flat surface 158 on an end thereof for abutting the fastening
surface 96
of the tie member 46. As will be understood, the splined shaft 154 is
configured to be
embedded in the panel 34, such that when the spacer is embedded in this manner
the
thickness of the body 152 defines a fixed space between the concrete-facing
surface
of the panel 34 and the tie member 46.
100621 During fabrication of the block 32, a mold (not shown) of a
molding
machine (not shown) is filled at least partially with EPS particles, commonly
referred
to in the art as EPS "beads". Prior to introducing the EPS particles, the tie
anchors 44
are positioned in the mold such that the tie anchors 44 become embedded at a
desired
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position within the fabricated block 32. In particular, the tie anchors 44 are
positioned
such that outer surfaces of the second tab portions 74 of the angled tabs 62
and 64 are
flush with a concrete-facing surface 160 of the fabricated block 32, such that
channel
70 is accessible from the concrete-facing surface 160 of the fabricated block
32, and
such that at least one of the first end 76 and the second end 78 of the
channel 70 is
accessible from an adjacent surface of the fabricated block 32, as shown for
example
in Figures 1 and 22A. Additionally, each tie anchor 44 is positioned in the
mold such
that the free surfaces of the anchor plate 54 and the struts 56 are surrounded
by the
material of the fabricated block 32, and are thereby encapsulated within the
fabricated
block 32.
100631 With the tie anchors 44 and the EPS particles in the mold,
the molding
machine is configured to apply heat to the mold, such as for example by
passing hot
air or steam through the mold, so as to heat the EPS particles to above their
melting
point. The applied heat causes the EPS particles therein to form a continuous
foam
body (not shown) in which the tie anchors 44 are embedded.
100641 Each block 32 has interlocking features that enable it to be
fitted with
other blocks 32 during assembly of the concrete formwork 30. In the example
shown
in Figure 1 and Figures 22A to 22C, each block 32 has a tongue 164 formed on a
first
side, and a groove 166 formed in a second, opposing side. As will be
understood, the
tongue 164 and the groove 166 enable horizontally abutting blocks 32 to engage
each
other in an end-to-end manner, for extending the length of the concrete form
30.
Additionally, in the example shown, each block 32 has two (2) pedestals 168
formed
on a top side, and two (2) corresponding recesses (not shown) formed on a
bottom
side. As will be understood, the pedestals 168 and the recesses enable blocks
32 to be
stacked in a staggered, "brickwork" like manner as shown in Figure 1, for
extending
the height of the concrete form 30. When the blocks 32 are stacked in this
manner,
the channels 70 of the stacked blocks 32 are aligned, as shown for example in
Figures
1 and 22A.
100651 In use, the concrete formwork 30 is assembled by arranging a
plurality
of blocks 32 end-to-end such that tongues 164 engage grooves 166 of
horizontally
abutting blocks, and by stacking the blocks 32 in a staggered manner such that
pedestals 168 engage recesses of vertically abutting blocks 32. Tie members 46
are
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then slideably inserted into the channels of the tie anchors 44, to connect
the tie
members 46 and the tie anchors 44. Vertically abutting tie members 46 are
connected
using first connectors 124 by inserting the tongues 126 into the recesses 136,
and by
engaging the second connectors 138 to yield columns 140 of connected tie
members
46. A connecting rod 120 is then seated on three (3) horizontally adjacent tie
members 46, such that the notches 142 of the connecting rod 120 engage the
notches
118 of the tie members 46. With the connecting rod 120 positioned in this
manner,
the horizontally adjacent tie members 46, and the tie members 46 below and
connected within columns 140, are linked, as shown in Figure 1.
[0066] Spacers 150 are then embedded into the panels 34, and the
panels 34
are fastened to the fastening plates 74 of the tie members 46 using fasteners
F, which
in the example shown are screws. With the panels 34 fastened to the tie
members 46,
the blocks 32 and the panels 34 define the volume 42 into which concrete is to
be
poured to form the wall. Reinforcement bar may be laid in the recesses 114 of
the
webs 86 of the tie members 46 prior to pouring of the concrete. Concrete is
then
poured into the volume 42, and is allowed to set. Once the concrete has set,
concrete
wall 170 is formed. The panels 34 may then be removed, exposing an interior
surface
of the concrete wall 170 on which the spacers 150 are visible, as shown in
Figure 23.
As will be understood, the fixed space defined by the bodies 152 of the
spacers 150
between the panel 34 and the tie member 46 is filled with concrete. This
ensures that
no portion of tie member 46 is exposed on the interior surface of the concrete
wall
170, and thereby enables the concrete wall 170 to comply with fire safety
regulations.
100671 If the panels 34 are expanded polystyrene (EPS) foam panels,
the
removed panels 34 can be reused as an insulating layer during subsequent
construction of a concrete floor slab. For example, Figures 24A to 24D show
formation of a concrete floor slab after formation of the concrete wall. In
the example
shown, the concrete wall 170 is a concrete foundation wall fotnied on a
concrete
footing 182 using the concrete formwork 30. Once the concrete has set, the
concrete
wall 170 is formed, as shown in Figure 24A. The panels 34 are then removed.
Backfill 184 is added to an exterior side of the concrete wall 170, and fill
in the form
of a gravel bed 186 is added to an interior side of the concrete wall 170
above the
concrete footing 182, as shown in Figure 24B. A vapour barrier 188 is then
laid on
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the gravel bed 186 and against a lower portion of the concrete wall 170, and
the
panels 34 are laid on the vapour barrier 188, as shown in Figure 24C. Concrete
is
then poured onto the panels 34, and once the concrete has set the concrete
floor slab
190 is formed, as shown in Figure 24D.
100681 As will be appreciated, the flanges 98 of the tie members 46
are
configured to facilitate fastening of the panel 34 by providing a laterally
enlarged area
for fastening, and by impeding rotation of the tie member 46 relative to the
panel 34
during fastening. As will be understood, this advantageously allows the panels
34 to
be fastened more easily by workers at the construction site, and
advantageously
allows to the panels 34 to be fastened to the tie members 46 in a
perpendicular manner
more quickly, as compared to prior art tie members forming part of prior art
concrete
form ties.
100691 As will be appreciated, the first connectors 124 of the tie
members 46
enable the free ends (i.e. the ends of the tie members 46 distal from the tie
anchors 44)
of vertically abutting tie members 46 to be connected, which prevents relative
lateral
movement of the members 46. As will be understood, this connection unifies the
panel fastening surfaces 96 of the tie members 46 within the columns 140,
which
advantageously allows the panels 34 to be fastened more easily by workers at
the
construction site, and advantageously allows to the panels 34 to be fastened
to the tie
members 46 in a perpendicular manner more quickly, as compared to prior art
tie
members forming part of prior art concrete form ties.
100701 As will be appreciated, when the connecting rod 120 is
seated on three
(3) tie members 46 within the concrete formwork 30, the connecting rod 120
links the
free ends of the three (3) tie members 46, and the tie members 46 below and
connected within columns 140, and maintains parallel alignment of the tie
members
46 of the linked columns 140. As will be understood, this alignment
advantageously
ensures that the panel fastening surfaces 96 of i) the tie members 46 on which
the
connecting rod 120 is seated and ii) the tie members 46 below and connected
within
columns 140, are all parallel. As will be understood, this parallel alignment
of all
panel fastening surfaces 96 advantageously allows the panels 34 to be fastened
more
easily by workers at the construction site, and advantageously allows to the
panels 34
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to be fastened to the tie members 46 in a perpendicular manner more quickly,
as
compared to prior art tie members forming part of prior art concrete form
ties.
100711 The concrete fon-nwork 30 and components thereof are not
limited to
the configuration described above, and in other embodiments, other
configurations are
possible. For example, Figure 25 shows another embodiment of a tie member for
use
with the concrete formwork 30, and which is generally indicated by reference
numeral
246. Tie member 246 is generally identical to tie member 46 described above
and
with reference to Figures 8 to 16, and comprises the longitudinal rail 82, the
longitudinal panel fastening plate 84, and the central web 86 connecting the
rail 82
and the panel fastening plate 84. The panel fastening plate 84 has the
elongate panel
fastening surface 96, to which the panel 34 is to be fastened during assembly
of the
concrete formwork 30, and the panel fastening plate 84 comprises two (2) pairs
of the
laterally extending flanges 98 each defining a portion of the fastening
surface 96. The
web 86 has the first edge 102, the second edge 104, and the central aperture
therebetween. In this embodiment, the web 86 has a pin 318 formed in each of
the
first edge 102 and the second edge 104 adjacent the panel fastening plate 84.
The pin
318 is configured to engage a connecting rod 320, described below, for
maintaining
parallel alignment of adjacent tie members 246 during assembly of concrete
formwork 30.
100721 Similar to tie member 46, the tie member 246 also comprises
the
plurality of connectors for enabling vertically abutting tie members 246 to be
connected. Each tie member 246 comprises the first connector 124 at each end
of the
panel fastening plate 84, and the second connector 138 at each end of the
longitudinal
base 92 of the rail 82.
[00731 Figure 26 shows the connecting rod 320. Connecting rod 320
is
similar to connecting rod 120 described above and with reference to Figures 17
to 19,
but is in the form of a longitudinal strip comprising a plurality of bores 342
formed
therein and extending through the thickness of the strip. Each bore 342 is
configured
to receive a respective pin 318 of a tie member 246. In the example shown, the
connecting rod 320 has three (3) bores 342 formed therein. The connecting rod
320
has connecting portions at its ends for enabling adjacent connecting rods 320
to be
connected, and in the example shown the connecting portions comprise the
barbed
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clip 144 and the recess 146. As will be understood, when the connecting rod
320 is
seated on three (3) tie members 246 within concrete formwork 30 such that each
bore
342 of the connecting rod 320 receives a pin 318 of a respective tie member
246, the
connecting rod 320 links the free ends of the three (3) tie members 246 and
maintains
parallel alignment of the tie members 246, and including the tie members 246
below
and connected within columns 140, which facilitates fastening of the panels
34.
Further, when adjacent connecting rods 320 seated on tie members 246 are
connected,
the free ends of the tie members 246 of the plurality of columns 140 on which
the
connecting rods 320 are seated are linked.
[0074] Still other configurations are possible. For example,
Figures 27A and
27B show a portion of a partially assembled concrete formwork in various
stages of
assembly, which is generally indicated by reference numeral 430. Concrete
formwork
430 is generally similar to concrete formwork 30 described above, and is
configured
to serve as a mold into which concrete (not shown) is poured to form a
concrete wall
during construction of a building. The building may be a residential building,
such as
a house, and the concrete wall may be a concrete foundation wall, for example.
[0075] Concrete fon-nwork 430 comprises a plurality of blocks 432
fabricated
of an insulating material, the plurality of panels 34, and a plurality of ties
connecting
the blocks 432 and the panels 34. When connected by the ties, the blocks 432
and the
panels 34 define the volume into which the concrete is to be poured. In this
embodiment, each block 432 is fabricated of expanded polystyrene (EPS) foam by
molding.
[0076] Each tie comprises a tie anchor 444 and a tie member 446,
which are
separately fabricated. The tie anchor 444 is configured to be embedded in a
respective block 432 during fabrication of the block 432. The tie member 446
is
configured to be connected to the embedded tie anchor 444 during assembly of
the
concrete formwork 430. The tie anchor 444 and the tie member 446 are each
fabricated of a single piece of material, and in particular the tie anchor 444
and the tie
member 446 are each fabricated of polyurethane by injection molding.
[0077] The tie anchor 444 may be better seen in Figure 28. The tie
anchor
444 is similar to tie anchor 44 described above and with reference to Figures
3 to 7,
but in this embodiment the tie anchor comprises a longitudinal connector strip
452,
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the longitudinal anchor plate 54, and the web comprising the plurality of
struts 56
connecting the connector strip 452 and the anchor plate 54. The connector
strip 452
comprises a longitudinal rib 458 having a series of spaced knobs 462 formed
thereon.
The spaced knobs 462 and a portion of the longitudinal rib 458 are configured
to be
slidably received in a longitudinal slot of the tie member 446, for mating
engagement
of the tie anchor 444 and the tie member 446.
100781 The tie member 446 may be better seen in Figure 29. The tie
member
446 is similar to tie anchor 44 described above and with reference to Figures
8 to 16,
but in this embodiment the tie member comprises a longitudinal guide 482, the
longitudinal panel fastening plate 84, and the central web 86 connecting the
guide 482
and the panel fastening plate 84. The longitudinal guide 482 has a generally
"C-
shaped" section along its length, and defines a longitudinal channel 484 that
is sized
to accommodate the knobs 462 and a portion of the longitudinal rib 458 of the
tie
anchor 444. The "C-shaped" guide 482 has longitudinal opening that extends its
length, and which is configured to accommodate the longitudinal rib 458 when
the tie
anchor 444 and the tie member 446 are matingly engaged.
[00791 The tie member 446 also comprises a plurality of connectors
for
enabling vertically abutting tie members 446 to be connected. In the example
shown,
each tie member 446 comprises the first connector 124 at each end of the panel
fastening plate 84. As discussed above for tie member 46, when vertically
adjacent
tie members 446 abut, the tongue 126 of one connector 124 is received in the
recess
136 of another connector 124, and relative lateral movement of tie members 446
is
prevented. Each tie member 446 also comprises the second connector 138 at each
end
of the longitudinal guide 482. The second connector 138 is configured to
engage a
second connector 138 of a vertically abutting tie member 46. In the example
shown,
each second connector 138 is in the form of the hook-shaped clip. As will be
understood, when vertically adjacent tie members 46 abut, the second connector
138
of one tie member 46 engages the second connector 138 of another tie member
46,
and relative vertical movement of the tie members 46 is prevented. Vertically
abutting tie members 446, connected in this manner by connectors 124 and 138,
yield
columns 540 of connected tie members 446.
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[00801 Although in the embodiments described above, the panels are
fabricated of EPS foam, or of a rigid sheet material such as plywood, oriented
strand
board (OS B), and the like, in other embodiments, the panels may alternatively
be
fabricated of other suitable foam materials, such as for example extruded
polystyrene
(XPS) foam, or of other suitable rigid sheet materials, such as for example
drywall.
Still other materials or combinations of materials may alternatively be used.
[00811 Although in the embodiments described above, each of the tie
anchor
and the tie member is fabricated of a single piece of material, in other
embodiments,
one or both of the tie anchor and the tie member may alternatively be
fabricated of
more than one (1) piece of material.
[0082] Although in the embodiments described above, each of the tie
anchor
and the tie member is fabricated of polyurethane by injection molding, in
other
embodiments, one or both of the tie anchor and the tie member may
alternatively be
fabricated of another material, and/or by another suitable fabrication method.
[0083] Although in the embodiments described above, the tie anchor
comprises a web comprising a plurality of struts, in other embodiments, the
tie anchor
may alternatively comprise a web having a different configuration, such as a
web
having a generally planar shape and comprising a central aperture. Still other
configurations are possible.
[0084] Although in an embodiment described above, the tie anchor
comprises
the guide comprising the base plate and the angled tabs which define a channel
that is
sized to receive the portion of the tie member, in other embodiments, the tie
anchor
may alternatively comprise other features that define a channel that is sized
to receive
the portion of the tie member.
[0085] Although in an embodiment described above, the tie anchor
comprises
a longitudinal rib having a series of spaced knobs formed thereon, in other
embodiments, the tie anchor may alternatively be comprise another
configuration
configured to be slideably received in the longitudinal slot of the tie
member. For
example, in one such embodiment, the tie anchor may alternatively comprise a
longitudinal rib having a longitudinal tab or rail formed thereon. Other
configurations
are possible.
CA 3014571 2018-08-17
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100861 Although in an embodiment described above, the tie member
comprises a longitudinal guide having a generally "C-shaped" section along its
length
and defining a longitudinal channel that is sized to accommodate a portion of
the tie
anchor, in other embodiments, the tie member may alternatively be comprise
another
configuration configured to accommodate a portion of the tie anchor. For
example, in
one such embodiment, the tie member may alternatively comprise a series of
angled
tabs extending from a longitudinal baseplate, which define a channel that is
sized to
accommodate a portion of the tie anchor. Other configurations are possible.
[0087] Although in the embodiments described above, the tie member
has a
panel fastening plate comprising two (2) pairs of laterally extending flanges,
in other
embodiments, the tie member may alternatively have a panel fastening plate
comprising one (1) pair, or greater than two (2) pairs, of laterally extending
flanges,
with each flange defining a portion of the fastening surface.
[0088] Although in an embodiment described above, the connecting
rod is in
the foi __ in of a longitudinal angled rod, in other embodiments, the
connecting rod may
alternatively be in another form, such as in the form of a notched strip, for
example.
[0089] Although in the embodiments described above, the concrete
formwork
comprises a connecting rod having linking features, in other embodiments, the
concrete formwork may alternatively comprise a generic rod such as a length of
reinforcement bar ("rebar"), or other rod or length or strip of material, and
each tie
member may alternatively have a clip for securing the rod to the tie member.
In still
other embodiments, the connecting rod may alternatively comprise clips, with
each
clip being securable to a respective tie member.
[0090] Although in the embodiments described above, each block has
interlocking features comprising a tongue formed on a first side, and a groove
formed
in a second, opposing side for enabling horizontally abutting blocks to engage
each
other in an end-to-to end manner, in other embodiments, each block may
alternatively
have other provisions for enabling adjacent blocks to engage each other in an
end-to-
end manner. Similarly, although in the embodiments described above, each block
has interlocking features comprising two (2) pedestals formed on a top side,
and two
(2) corresponding recesses formed on a bottom side for enabling blocks to be
stacked,
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in other embodiments, each block may alternatively have other provisions for
enabling blocks to be stacked.
100911 Although in the embodiments described above, the concrete
formwork
comprises spacers embedded in the panel such that each spacer creates a fixed
space
between the concrete-facing surface of the panel and the tie member, in other
embodiments, the concrete formwork may alternatively comprise spacers not
embedded in the panel but rather inserted between the panel and the tie
member,
which may optionally held in place by the fasteners. In still other
embodiments, the
concrete formwork may alternatively comprise no spacers between the concrete-
facing surface of the panel and the tie member.
100921 Although embodiments have been described above with
reference to
the accompanying drawings, those of skill in the art will appreciate that
variations and
modifications may be made without departing from the scope thereof as defined
by
the appended claims.
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