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Patent 3017682 Summary

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(12) Patent Application: (11) CA 3017682
(54) English Title: PRECAST REINFORCED CONCRETE FORM
(54) French Title: FORME DE BETON ARME PREMOULE
Status: Dead
Bibliographic Data
(51) International Patent Classification (IPC):
  • B28B 7/22 (2006.01)
  • B28B 23/22 (2006.01)
  • E04B 2/86 (2006.01)
  • E04G 13/06 (2006.01)
(72) Inventors :
  • MARIN, ENNIO (Canada)
  • VERRILLI, ROBERT (Canada)
  • VERRILLI, DANNY (Canada)
  • TRAVANI, ANDREA (United States of America)
(73) Owners :
  • MARIN, ENNIO (Canada)
  • VERRILLI, ROBERT (Canada)
  • VERRILLI, DANNY (Canada)
  • TRAVANI, ANDREA (United States of America)
(71) Applicants :
  • MARIN, ENNIO (Canada)
  • VERRILLI, ROBERT (Canada)
  • VERRILLI, DANNY (Canada)
  • TRAVANI, ANDREA (United States of America)
(74) Agent: CARSON LAW OFFICE PROFESSIONAL CORPORATION
(74) Associate agent:
(45) Issued:
(22) Filed Date: 2018-09-18
(41) Open to Public Inspection: 2020-03-18
Availability of licence: N/A
(25) Language of filing: English

Patent Cooperation Treaty (PCT): No

(30) Application Priority Data: None

Abstracts

English Abstract


The present invention relates to forms for forming poured-in-situ vertical
concrete
walls of residential or commercial buildings, in particular a form having at
least one
precast reinforced concrete panel.


Claims

Note: Claims are shown in the official language in which they were submitted.


THE EMBODIMENTS OF THE INVENTION IN WHICH AN EXCLUSIVE PROPERTY
OR PRIVILEGE IS CLAIMED ARE DEFINED AS FOLLOWS:
1. A form for forming poured-in-situ vertical concrete walls of residential
or
commercial buildings wherein the vertical walls are exterior walls below
grade,
the form comprising at least one precast reinforced concrete panel, the
precast
reinforced concrete panel has an inside surface facing the space in which the
poured-in-situ concrete is to be placed and an outside surface facing the
building
interior, first and second vertical sides and a top end and a bottom end, the
form
further comprises a plurality of interconnected horizontal reinforcing
trusses,
each of said trusses having a first longitudinal header section, said header
section
cast into the panel, and each of said trusses having horizontal reinforcing
members extending from said header section outwardly through the inside
surface of said panel to connect to a second longitudinal header.
2. A form according to claim 1 wherein the plurality of interconnected
horizontal
reinforcing trusses are further reinforced by vertical longitudinal
reinforcement
rods linking each of said trusses.
3. A form according to claim 1 or 2 wherein the a first longitudinal header
section
comprises a parallel first and second longitudinal headers .
4. A form for forming poured-in-situ vertical concrete walls of residential
or
commercial buildings the form comprising a pair of precast reinforced concrete

panels, each of the precast reinforced concrete panels having an inside
surface
facing the space in which the poured-in-situ concrete is to be placed and an
outside surface, first and second vertical sides and a top end and a bottom
end,
the form further having a plurality of horizontal reinforcing trusses, each of
said
trusses having a first pair of longitudinal headers, said headers cast into
one of
said panels, and each of said trusses having horizontal reinforcing members
18

extending from said one of the pair of headers and horizontal reinforcing
members extending from the other of said pair of headers outwardly through
the inside surface of said one panel to a second horizontal header cast into
the
other panel wherein each of the longitudinal headers is further reinforced by
vertical longitudinal reinforcement rods linking each of said trusses.
5. A method of making a form for forming poured-in-situ vertical concrete
walls of
residential or commercial buildings the form comprising at least one precast
reinforced concrete panel, the method comprising:
a. forming a mould for one of the precast panels,
b. positioning a plurality of vertical reinforcing trusses off the base of the
form
for the first precast panel, each of said trusses having a pair of
longitudinal
headers, said headers to be cast into the panel, and each of said trusses
having
horizontal reinforcing members extending from said headers outwardly
through the inside surface of said panel
c. pouring concrete into the mold with a sufficient cover to retain the pair
of
longitudinal headers, curing it, rotating it after reaching the required
strength
6. A method according to claim 5 wherein after a first panel is poured and
after
turning it, a mould is created for a second precast panel with the ends of the

horizontal reinforcing members extending from said headers in said first panel

connecting to a second longitudinal header to be cast into the second panel.
7. A system of erecting formwork for forming poured-in-situ vertical
concrete walls
of residential or commercial buildings comprising:
19

a. A plurality of forms for forming poured-in-situ vertical concrete walls of
residential or commercial buildings wherein the vertical walls are
exterior walls below grade according to claim 2 is erected on spacers that
allow for a concrete base as wide as the form.
b. To ensure the loads are adequately flowing through adjacent forms,
dowels can be protruding from the structure below and going in between
the prefabricated panels of the forms.
c. Similarly, when the forms are being erected over a concrete slab, the
prefabricated panels will be placed over slab dowels that were left
protruding from the slab itself.
d. Also some rebar protruding from the wall below can be incorporated
into the new forms being erected.
e. During the erection, the forms will be lifted in place by the tower crane
and then supported laterally and kept vertical by temporary props to be
connected to the wall.
f. Finally, when enough forms have been erected and the onsite rebar has
been placed, concrete will be poured in between the precast panels until
reaching the full height of the panels or could be poured in lifts,
depending on the site needs and on the design.
8. A
method of constructing for forming poured-in-situ vertical concrete walls for
a
stairwell using form comprising at a pair of precast reinforced concrete
panels
said panels having an inside surface facing the space in which the poured-in-
situ
concrete is to be placed and an outside surface, first and second vertical
sides and
a top end and a bottom end, and said form further comprising a plurality of
vertical reinforcing trusses, each of said trusses having a pair of
longitudinal

headers, said headers cast into one of said panels, and each of said trusses
having
horizontal reinforcing members extending from said headers outwardly through
the inside surface of said panel to a second header cast into the other one of
said
panels, said method comprising:
a. Along one end of the stairwell, a precast concrete form according to claim
2 is erected,
b. After erection of the first the precast concrete form, the formwork for the

long wall of the stairwell is erected using the precast concrete form
according to claim 2;
c. The formwork for the second end of the stairwell is erected next using a
precast concrete form according to claim 2;
d. Lastly the formwork for the doorway side wall of the stairwell is erected
using the precast concrete form according to claim 2.
9. A method according to claim 6 further comprising once the precast
concrete forms
have been setup for the stairwell concrete walls, a precast landing is
attached to
the inside surface of the panels adjacent their top ends.
10. A method according to claim 7 wherein a set of precast stairs can be
set on the
landing and floor of the stairwell.
21

Description

Note: Descriptions are shown in the official language in which they were submitted.


TITLE: PRECAST REINFORCED CONCRETE FORM
FIELD OF THE INVENTION
[0001] This invention generally relates to forms for forming poured-in-situ
vertical
concrete walls of residential or commercial buildings, in particular a form
having at least
one precast reinforced concrete panel.
DESCRIPTION OF THE PRIOR ART
[0002] Concrete wall construction has been historically mostly relegated to
the cast in
place method through the installation of formwork. This basically involves
setting up the
forms in advance, placing the required rebar and any external reinforcement to
secure
the forms in place when the concrete is poured, then pouring the concrete
inside the
forms. The concrete is allowed to cure sufficiently to enable the forms to be
removed
(stripped). It may be necessary after the forms are removed to brace the walls
while the
concrete continues to cure. The cycle therefore requires these operations to
be performed
on site. The schedule consequently becomes a critical factor because all these
elements
get on the critical path. Additionally, the formwork is not the best method in
terms of
quality, requiring several touch ups and patching to the walls after
stripping.
SUMMARY OF THE INVENTION
[0003] In one embodiment, the present invention provides a form for forming
poured-
in-situ vertical concrete walls of residential or commercial buildings wherein
the
vertical walls are exterior walls below grade. The form comprises at least one
precast
reinforced concrete panel said panel having an inside surface facing the space
in which
the poured-in-situ concrete is to be placed and an outside surface facing the
building
interior. The panel has first and second vertical sides and a top end and a
bottom end.
The form further comprises a plurality of vertical reinforcing trusses, each
of said
CA 3017682 2018-09-18

trusses having a longitudinal header, said header cast into the panel, and
each of said
trusses having horizontal reinforcing members extending from said header
outwardly
through the inside surface of said panel.
[0004] The forms of the present invention are intended to include the
reinforcing rebar
for the wall section to be poured behind the form as required by the
applicable building
code. The only rebar required to be placed on site is that required between
adjacent forms.
Use of the present invention thereby significantly reduces forming set up time
on site.
[0005] The forms of the present invention are intended to remain in place
after the
concrete is poured. The outside surface of the precast panel is intended to
form the visible
surface facing the building interior. The use of the present invention further
significantly
saves time on site by eliminating the need and in the case of below grade
walls the
difficulty in stripping (removing the forms) after the poured concrete is
cured.
[0006] In another embodiment, the present invention provides a precast
reinforced
concrete form for forming poured-in-situ vertical concrete walls of
residential or
commercial buildings wherein the vertical walls are exterior or interior walls
above or
below grade. The precast reinforced concrete form comprises a pair of precast
reinforced
concrete panels. Each of the precast reinforced concrete panels has an inside
surface
facing the space in which the poured-in-situ concrete is to be placed and an
outside
surface, first and second vertical sides and a top end and a bottom end The
form further
comprises a plurality of horizontal reinforcing trusses. Each of said trusses
typically has
a first longitudinal header cast into one panel, horizontal reinforcing
members extending
from said first header outwardly through the inside surface of said panel to a
second
horizontal header cast into the second panel. Each of the longitudinal headers
can be
further reinforced by vertical longitudinal reinforcement rods linking each of
said
trusses. The longitudinal headers, horizontal reinforcing members and
longitudinal
reinforcement rods can be formed from rebar, threaded wire rod or other
acceptable
2
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material as required pursuant to building codes in the jurisdiction the forms
are being
used.
[0007] Another embodiment of the present invention provides a precast
reinforced
concrete form for forming poured-in-situ vertical concrete stairwell walls of
residential
or commercial buildings. The precast reinforced concrete form comprises a pair
of
precast reinforced concrete panels. Each of the precast reinforced concrete
panels has an
inside surface facing the space in which the poured-in-situ concrete is to be
placed and
an outside surface, first and second vertical sides and a top end and a bottom
end. The
form further comprises a plurality of horizontal reinforcing trusses, each of
said trusses
having a first longitudinal header, said header cast into one of the panels
and horizontal
reinforcing members extending from said header outwardly through the inside
surface
of said panel to a second horizontal header cast into the other panel. Each of
the
longitudinal headers may be further reinforced by vertical longitudinal
reinforcement
rods linking each of said trusses. The longitudinal headers, horizontal
reinforcing
members and longitudinal reinforcement rods can be formed from rebar, threaded
wire
rod or other acceptable material as required pursuant to building codes in the
jurisdiction
the forms are being used.
[0008] The use of the forms of the present invention provide the jobsite with
a method of
forming poured-in-situ vertical concrete walls faster than using conventional
methods as
stay in place formwork. It will also avoid quality issues by prefabricating
the forms in a
controlled environment where the tolerances allow for far less mistakes than
on a jobsite
with site formwork. Therefore, there is a significant improvement in terms of
quality with
very few repairs and touch ups necessary after concrete pour.
[0009] The forms of the present invention are light enough to be erected on
site by the
available regular tower crane and incorporate the reinforcing steel foreseen
by the design
and applicable codes.
3
CA 3017682 2018-09-18

[0010] In another embodiment the present invention provides A method of making
a
form for forming poured-in-situ vertical concrete walls of residential or
commercial
buildings the form comprising at least one precast reinforced concrete panel,
the method
comprising:
a. forming a mould for one of the precast panels,
b. positioning a plurality of vertical reinforcing trusses off the base of the
form for
the first precast panel, each of said trusses having a pair of longitudinal
headers, said headers to be cast into the panel, and each of said trusses
having
horizontal reinforcing members extending from said headers outwardly
through the inside surface of said panel.
c. pouring concrete into the mold with a sufficient cover to retain the pair
of
longitudinal headers, curing it, rotating it after reaching the required
strength
[0011] In another embodiment the present invention provides a system of
erecting
formwork for forming poured-in-situ vertical concrete walls of residential or
commercial
buildings comprising:
a plurality of forms for forming poured-in-situ vertical concrete walls of
residential
or commercial buildings wherein the vertical walls are exterior walls below
grade
according to the description noted above are erected on spacers that allow for
a
concrete base as wide as the form.
to ensure the loads are adequately flowing through adjacent forms, dowels may
be
protruding from the structure below and going in between the prefabricated
panels
of the forms,
4
CA 3017682 2018-09-18

when the forms are being erected over a concrete slab, the prefabricated
panels will
be placed over slab dowels that were left protruding from the slab itself.
some rebar protruding from the wall below can be incorporated into the new
forms
being erected.
during the erection, the forms will be lifted in place by the tower crane and
then
supported laterally and kept vertical by temporary props to be connected to
the
wall.
when enough forms have been erected and the onsite rebar has been placed,
concrete will be poured in between the precast panels until reaching the full
height
of the panels or could be poured in lifts, depending on the site needs and on
the
design.
[0012] In another embodiment, the present invention provides a method for
forming
poured-in-situ vertical concrete walls for a stairwell using a plurality of
precast forms,
each form comprising at a pair of precast reinforced concrete panels said
panels having
an inside surface facing the space in which the poured-in-situ concrete is to
be placed and
an outside surface, first and second vertical sides and a top end and a bottom
end, and
said form further comprising a plurality of vertical reinforcing trusses, each
of said
trusses having a first longitudinal header section, said header section cast
into one of said
panels, and each of said trusses having horizontal reinforcing members
extending from
said header sections outwardly through the inside surface of said panel to a
second
header section cast into the other one of said panels, said method comprising:
along one end of the stairwell, a precast concrete form as described above is
erected,
after erection of the first the precast concrete form, the formwork for the
long wall
of the stairwell is erected using another precast concrete form;
5
CA 3017682 2018-09-18

the formwork for the second end of the stairwell is erected next using another
of the
precast concrete forms;
lastly the formwork for the doorway side wall of the stairwell is erected
using the
another of the precast concrete forms.
[0013] The method for forming poured-in-situ vertical concrete walls for a
stairwell may
further comprises once the precast concrete forms have been setup for the
stairwell
concrete walls, a precast landing is attached to the inside surface of the
panels adjacent
their top ends.
[0014] The method for forming poured-in-situ vertical concrete walls for a
stairwell may
further include having a set of precast stairs set on the landing and floor of
the stairwell.
[0015] Further features of the invention will be described or will become
apparent in the
course of the following detailed description.
BRIEF DESCRIPTION OF THE DRAWINGS
In order that the invention may be more clearly understood, the preferred
embodiment
thereof will now be described in detail by way of example, with reference to
the
accompanying drawings, in which:
[0016] Figure 1 is a schematic view of one embodiment of a precast reinforced
concrete
form for forming poured-in-situ vertical concrete walls of residential or
commercial
buildings wherein the vertical walls are exterior walls below grade according
to the
present invention.
[0017] Figure 2 is top plan view of the precast reinforced concrete form of
Figure 1.
[0018] Figure 3 is a side view in cross-section of the precast reinforced
concrete form of
Figure 1.
6
CA 3017682 2018-09-18

[0019] Figure 4 is a schematic side plan view of a precast reinforced concrete
form of
Figure 1 erected on a footing.
[0020] Figure 5 is another embodiment of a precast reinforced concrete form
for forming
poured-in-situ vertical concrete walls of residential or commercial buildings
wherein the
vertical walls are exterior or interior walls above or below grade according
to the present
invention
[0021] Figure 6 is a top plan view of the precast reinforced concrete form of
Figure 5.
[0022] Figure 7 is a side view in cross-section of the precast reinforced
concrete form of
Figure 5.
[0023] Figures 8A-8D show another embodiment of a precast reinforced concrete
form for
forming poured-in-situ vertical concrete stairwell walls of residential or
commercial
buildings, according to the present invention.
[0024] Figure 9 is a schematic representation of how the forms of Figures 8A-
8D are
erected to enable the stairwell walls to be poured.
[0025] Figures 10A -10D are a series of cross-sectional views of the
connection between
adjacent forms as shown in 8A-8D.
[0026] Figure 11 is a top plan view of a precast landing attached to the top
of the precast
reinforced concrete forms of Figures 8A-8D erected as a stairwell.
[0027] Figure 12 is a side plan view of one embodiment of a set of precast
stairs attached
to the landing shown in Figure 11.
[0028] Figure 13 is a top view in partial cross section showing one embodiment
of means
for lifting a precast reinforced concrete form according to the present
invention.
[0029] Figure 14 is a partial perspective view showing another embodiment of a
precast
concrete form for forming columns according to the present invention.
7
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[0030] Figure 15 is a perspective view showing another embodiment of a precast
concrete
form for forming parapets according to the present invention.
[0031] Figure 16 is a perspective view showing installation of precast stairs
in conjunction
with precast concrete forms according to the present invention.
[0032] Similar references are used in different figures to denote similar
components
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0033] Referring to Figures 1-3, an embodiment of a precast reinforced
concrete form for
forming poured-in-situ vertical concrete walls of residential or commercial
buildings
wherein the vertical walls are exterior walls below grade, according to the
present
invention, is generally indicated at 1. Referring to Figure 1, the form 1
comprises at least
one precast reinforced concrete panel 2. The precast reinforced concrete panel
2 in the
embodiment shown has an inside surface 3 facing the space in which the poured-
in-situ
concrete is to be placed and an outside surface 4 facing the building
interior, first and
second vertical sides 5,6 and a top end 7 and a bottom end 8. The outside
surface 4 can be
a smooth finished concrete surface.The precast reinforced concrete panel 2
preferably has
a nominal thickness of 60-150 mm and may be formed from air or non-air
entrained
concrete have the required psi prescribed by applicable codes. Typical values
are 3000-
7000 psi.
[0034] The form 1 further comprises a plurality of interconnected horizontal
reinforcing
trusses 9. Each of said trusses 9 have a first longitudinal header section,
generally
indicated at 10, cast into the panel 2. In the embodiment shown the first
longitudinal
header section 10 comprises a pair of parallel longitudinal headers 10A and
10B. Each of
said trusses 9 have horizontal reinforcing members extending from said header
section
outwardly through the inside surface 3 of said panel 3. In the embodiment
shown
8
CA 3017682 2018-09-18

horizontal reinforcing members 11 extend outwardly from the first longitudinal
header
10A in pairs that are spaced apart at the point of connection with the first
longitudinal
header 10A and inclined downwardly to connect to a second longitudinal header
section
12, offset vertically down from the first longitudinal header 10A, at a common
point of
connection 15. In the embodiment shown horizontal reinforcing members 14
extend
outwardly from the longitudinal header 10B in pairs that are spaced apart at
the point of
connection with the longitudinal header 10B and inclined upwardly to connect
to the
second longitudinal header section 12, offset vertically up from the
longitudinal header
10B, at a common point of connection 16. Each of the longitudinal headers 10A,
10B, 12,
may be further reinforced by vertical longitudinal reinforcement rods 15A
linking each
of said trusses 9. The longitudinal headers 10A,10B,12, horizontal reinforcing
members
11, 14 and longitudinal reinforcement rods 15A can be formed from rebar,
threaded wire
rod or other acceptable material as required pursuant to building codes in the
jurisdiction
the forms are being used. Additional rebar can be placed in the form on site
if needed to
match design requirements. The precast panel may differ in dimensions
depending on
each individual application of the precast reinforced concrete forms.
[0035] The concrete form 1 of Figures 1-3 is fabricated by creating a mold the
size and
shape of precast panel 2 and positioning the plurality of interconnected
trusses 9 that
have been pre-fabricated above the base of the mold with the longitudinal
header section
10 set off the base of the mold. Concrete is then poured into the mold to form
precast
panel 2 with a sufficient cover of concrete over the longitudinal header
section 10. An
adequate cover needs to be calculated to avoid the longitudinal header section
10 being
extracted from the precast panels during use. Codes may require typically a 30
mm cover
for exterior walls. The precast panel 2 is allowed to cure, until the precast
panel 2 has
reached the required strength which may take a day or longer. The plurality of

interconnected trusses 9 create a lattice that provide stability during the
precast
9
CA 3017682 2018-09-18

reinforced concrete form handling and to resist the hydraulic pressure of the
wet concrete
when the concrete is poured in situ.
[0036] Once the concrete precast panel 2 has sufficiently hardened, the
precast reinforced
concrete forms 1 can be transported to the site. The precast reinforced
concrete forms 1
are placed around the outside of the intended building near a retaining wall
or a rock
wall so that the concrete is poured in between the precast panel 2 of the
precast reinforced
concrete form 1 and the retaining wall or rock wall. A plurality of precast
reinforced
concrete forms 1 are placed standing on their bottom ends 8 resting on spacers
15B that
allow for a concrete base 16A as wide as the precast reinforced concrete form
1. The
spacers are made of any material that is durable, does not corrode and deemed
appropriate for each application including but not limited to plastic. To
ensure the loads
are adequately flowing through the precast reinforced concrete form 1, dowels
17 can be
protruding from the structure below and going in between the plurality of
trusses 9 of
the precast reinforced concrete form 1.
[0037] During the erection, the precast reinforced concrete forms 1 will be
lifted in place
by the tower crane and then supported laterally and kept vertical by temporary
A-frame
props 18, see Figure 4, to be connected at one end to the wall at generally
2/3 the panel's
height and at the other end to the slab or grade the form is resting on. Where
the precast
reinforced concrete forms are erected over a slab it may be necessary to
install sheer
brackets or support at the bottom end 8 of each form.
[0038] Each concrete form 1 should preferably be provided with means to assist
the crane
on site lifting the forms into place. One possible means to assist lifting the
forms 1 of the
present invention into place is illustrated in Figure 13. The lifting means
illustrated in
Figure 13 includes a coil tie member 18A cast into the top end 7 of precast
panel 2 so that
an eyebolt 19 can be threaded into the coil tie 18 to allow the crane a
lifting point on the
form 1.
CA 3017682 2018-09-18

[0039] Referring to Figures 5-7, another embodiment of a precast reinforced
concrete form
20 for forming poured-in-situ vertical concrete walls of residential or
commercial
buildings wherein the vertical walls are exterior or interior walls above or
below grade
according to the present invention is illustrated. In this embodiment the
precast
reinforced concrete form 20 comprises a pair of precast reinforced concrete
panels 21, 22.
Each of the precast reinforced concrete panels 21,22 in the embodiment shown
has an
inside surface 23 facing the space in which the poured-in-situ concrete is to
be placed and
an outside surface 24, first and second vertical sides 25,26 and a top end 27
and a bottom
end 28. The form 20 further comprises a plurality of horizontal reinforcing
trusses 29,
.. each of said trusses 29 having a first longitudinal header section
generally indicated at
30A cast into the panel 21. In the embodiment shown the first longitudinal
header section
30A includes a pair of parallel longitudinal headers 30, 31. Each of said
trusses 29 having
horizontal reinforcing members extending from the first header section 30A
extending
outwardly through the inside surface 23 of said panel 21 to a second
horizontal header
34 cast into the panel 22. In the embodiment shown horizontal reinforcing
members 32
extend from said header 30 and horizontal reinforcing members 33, extend from
header
31, outwardly through the inside surface 23 of said panel 21 to a second
horizontal header
34 cast into the panel 22. Each of the longitudinal headers 30, 31, 34 may be
further
reinforced by vertical longitudinal reinforcement rods 35 linking each of said
trusses 29.
The longitudinal headers 30, 31, 34, horizontal reinforcing members 32, 33 and

longitudinal reinforcement rods 35 can be formed from rebar, threaded wire rod
or other
acceptable material as required pursuant to building codes in the jurisdiction
the forms
are being used.
[0040] One form of the connections between adjacent precast reinforced
concrete forms 1
.. or 20 to ensure the proper behavior of the structure are shown in Figures
10A ¨ 10D. The
11
CA 3017682 2018-09-18

Figures show the precast reinforced concrete forms 20 but similar connections
are
appropriate with suitable modifications for precast reinforced concrete forms
1.
[0041] Referring to Figure 10A, if there is a corner connection, it is likely
that some rebar
needs to be installed in the space between the panels 21, 22 of adjoining
forms 20. This
installation may require some modifications of the panels 21,22 to facilitate
the correct
positioning of this additional rebar. For example, small portions of the
precast panels 21
can be eliminated so the forms 20 fit closely with minimal on site formwork
used. The
additional rebar shown in Figure 10A is a plurality of pairs of elongated U
shaped rebar
sections 41, 42. This flexibility allows the installer to see some of his/her
specific needs
incorporated in the design of the panels. This means that in places where the
rebar
installed on site is particularly congested, the precast reinforced concrete
form 20 can be
fabricated with specific openings in its precast panels 21,22. Also, a corner
bracket (not
shown) may be installed on site to reinforce the corner area during concreting
operations.
This corner bracket may or may not be required depending on the pour sequence
and the
relevant hydraulic pressures.
[0042] Figure 10B shows a wall end of a precast reinforced concrete forms 20
where the
open side of an end panel 21,22 of precast reinforced concrete forms 20 is
enclosed with
end formwork 43. This may be installed on site or at the plant during
fabrication of the
forms.
[0043] Figure 10C shows a bottom wall connection of precast reinforced
concrete forms
20 to a slab, footing or top of another form 20 where the additional rebar is
vertical
upstanding dowels 44.
[0044] Figure 10D shows the wall connection between adjacent forms 20. In this
case the
additional rebar is a plurality of horizontal sections extending between the
space between
panels 21, 22 of each form 20.
12
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[0045] Finally, when enough precast reinforced concrete forms have been
erected and the
onsite rebar 3A has been placed, concrete will be poured in between the
prefabricated
elements. The concrete could be poured until reaching the full height of the
panels 2, 21,
22 or could be poured in lifts, depending on the site needs and on the design
of the metal
.. connectors of the precast reinforced concrete form 1 or 20.
[0046] Similarly, and referring to Figure 7, when the precast reinforced
concrete form 1 is
being erected over a concrete slab 19B, the prefabricated panels 2 will be
placed over the
slab dowels 19A that were left protruding from the slab itself. Also, some
rebar 3A
protruding from the precast reinforced concrete form 1 below can be
incorporated into
the new precast reinforced concrete form 1 being erected.
[0047] Another embodiment of a precast reinforced concrete form 50 for forming
poured-
in-situ vertical concrete stairwell walls of residential or commercial
buildings according
to the present invention is illustrated in Figures 8A-8D. The precast
reinforced concrete
form 50 in each of Figures 8A-8D comprises a pair of precast reinforced
concrete panels
51, 52. Each of the precast reinforced concrete panels 51,52 in the embodiment
shown has
an inside surface 53 facing the space in which the poured-in-situ concrete is
to be placed
and an outside surface 54, first and second vertical sides 55,56 and a top end
57 and a
bottom end 58. The form 50 further comprises a plurality of horizontal
reinforcing trusses
59, each of said trusses 59 having a first longitudinal header section 60A
cast into the
panel 51. In the embodiment shown the first longitudinal header section 60A
comprises
a pair of longitudinal headers 60, 61, and each of said trusses 59 having
horizontal
reinforcing members 62, extending from said header 60 and horizontal
reinforcing
members 63, extending from said header 61 outwardly through the inside surface
53 of
said panel 51 to a second horizontal header 64 cast into the panel 52. Each of
the
longitudinal headers 60, 61, 64 may be reinforced by vertical longitudinal
reinforcement
rods 65 linking each of said trusses 59. The longitudinal headers 60, 61, 64,
horizontal
13
CA 3017682 2018-09-18

reinforcing members 62, 63 and longitudinal reinforcement rods 65 can be
formed from
rebar, threaded wire rod or other acceptable material as required pursuant to
building
codes in the jurisdiction the forms are being used.
[0048] Each of the concrete forms 50 shown in Figures 8A ¨ 8D have had the
alignment
of the panels 51,52 modified to accommodate the formation of the stairwell
walls when
the forms are joined.
[0049] Figure 9 shows schematically in sequence how the precast reinforced
concrete
forms shown in Figures 8A to 8D are erected to create the formwork for the
stairwell
walls. Along one end of the stairwell, the precast concrete form 50 shown in
Figure 8D is
erected. This form has panel 51 narrower than panel 52 so one side 56 of panel
51 is
setback from the corresponding side 56 of panel 52.
[0050] After erection of the first the precast concrete form 50, the formwork
for the
longwall of the stairwell is erected using the precast concrete form 50 shown
in Figure
8B. This form has panel 51 narrower than panel 52 so both sides 55,56 of panel
51 are
setback from the corresponding side 55,56 of panel 52.
[0051] The formwork for the second end of the stairwell is erected next using
a precast
concrete form 50 shown in Figure 8C. This form has panel 51 narrower than
panel 52 so
again both sides 55,56 of panel 51 are setback from the corresponding side
55,56 of panel
52.
[0052] Lastly the formwork for the doorway side wall of the stairwell is
erected using the
precast concrete form 50 shown in Figure 8A. This form has panel 51 narrower
than panel
52 so the side 55 of panel 51 is setback from the corresponding side 55 of
panel 52. The
other side 56 of form 50 is enclosed on site.
[0053] Once the precast concrete forms 50 have been setup for the stairwell
concrete walls,
a precast landing 70 as shown in Figure 11 can be attached to the inside
surface 53 of the
14
CA 3017682 2018-09-18

panels 51 adjacent their top ends 57 or in some cases half way down the form.
A set of
precast stairs 80 can be set on the landing 70 and floor of the stairwell as
shown in Figure
12 or Figure 16.
[0054] Figure 14 shows a precast form according to the present invention for
forming a
column. The form has four vertical side walls of pre-cast concrete each side
50-70 mm
thick with reinforced rebar typically 15mm to 25 mm diameter, and sticking up
from the
top end of each side wall. The form is typically 12 inches to 36" square with
the interior
space between the four vertical side walls filled with in-situ poured
concrete. The forms
may be any height.
[0055] Figure 15 shows another embodiment of a precast form according to the
present
invention for forming a parapet. The form has a pair of parallel precast side
panels with
rebar reinforcement as shown in the drawing.
[0056] The precast concrete forms of the present invention preferably have
means
incorporated into the top end of the forms to enable the forms to be lifted by
the crane
and put into place. Figure 13 shows one possible embodiment of such lifting
means.
[0057] A beneficial feature is the ability of the precast reinforced concrete
form 1 or 20 to
create continuity with the structure below. The precast reinforced concrete
form 1 or 20
is to create continuity with the structure below. The precast reinforced
concrete form 1 or
may be erected on spacers 91 that allow for a concrete base 92 as wide as the
precast
20 reinforced concrete form 1 or 20. The spacers are made of any material
that is durable,
does not corrode and deemed appropriate for each application including but not
limited
to plastic. To ensure the loads are adequately flowing through the precast
reinforced
concrete form 1, 20, dowels 93 can be protruding from the structure below and
going in
between the prefabricated panels 2, 21, 22 of the precast reinforced concrete
form 1, 20.
Similarly, and referring to Figure 4, when the precast reinforced concrete
form 1 is being
erected over a concrete slab, the prefabricated panels 2 will be placed over
the slab dowels
CA 3017682 2018-09-18

that were left protruding from the slab. Also, some rebar protruding from the
precast
reinforced concrete form 1, 20 below can be incorporated into the new precast
reinforced
concrete form 1, 20 being erected. During the erection, the precast reinforced
concrete
form 1 will be lifted in place by the tower crane and then supported laterally
and kept
vertical by temporary props to be connected to the wall in specific prop
locations
provided by the supplier of the precast reinforced concrete form 1.
[0058] While the principles of the invention have been shown and described in
connection with specific embodiments, it is to be understood that such
embodiments are
by way of example and are not limiting as is evident from the foregoing
description,
certain aspects of the present invention are not limited by the particular
details illustrated
in the drawings. Other modifications and applications, or equivalents, will
occur to those
skilled in the art. The terms "having", "comprising" and "including" and
similar terms
as used in the foregoing specification are used in the sense of "optional" or
"may include"
and not as "required". Many changes, modifications, variations and other uses
and
applications of the present construction will, however, become apparent to
those skilled
in the art after considering the specification and attached drawings. All such
changes,
modifications, variations and other uses and applications which do not depart
from the
spirit and scope of the invention are deemed to be covered by the invention
which is
limited only by the claims that follow. The scope of the disclosure is not
intended to be
limited to the embodiments shown herein, but is to be accorded the full scope
consistent
with the claims, wherein reference to an element in the singular is not
intended to mean
"one and only one" unless specifically so stated, but rather one or more. All
structural
and functional equivalents to the elements of the embodiment described
throughout the
disclosure that are known or later come to be known to those of ordinary skill
in the art
are expressly incorporated herein by reference and intended to be encompassed
by the
claims. For example, some variations to the precast reinforced concrete form
include but
16
CA 3017682 2018-09-18

are not limited to precast reinforced concrete forms integrated with precast
stair systems
(see Figures 8 and 9), windows, doors or other architectural or structural
elements;
referring to Figure 2, precast reinforced concrete forms integrated with the
foundation
below where part of the rebar of the foundation is already incorporated in the
bottom
part of the precast reinforced concrete form in order to improve the
connection between
the precast reinforced concrete form and the foundation; referring to Figure
6, a precast
reinforced concrete form using bolts to eliminate the need for welding.
17
CA 3017682 2018-09-18

Representative Drawing
A single figure which represents the drawing illustrating the invention.
Administrative Status

For a clearer understanding of the status of the application/patent presented on this page, the site Disclaimer , as well as the definitions for Patent , Administrative Status , Maintenance Fee  and Payment History  should be consulted.

Administrative Status

Title Date
Forecasted Issue Date Unavailable
(22) Filed 2018-09-18
(41) Open to Public Inspection 2020-03-18
Dead Application 2023-03-21

Abandonment History

Abandonment Date Reason Reinstatement Date
2022-03-21 FAILURE TO PAY APPLICATION MAINTENANCE FEE

Payment History

Fee Type Anniversary Year Due Date Amount Paid Paid Date
Application Fee $400.00 2018-09-18
Maintenance Fee - Application - New Act 2 2020-09-18 $100.00 2020-09-25
Late Fee for failure to pay Application Maintenance Fee 2020-09-25 $150.00 2020-09-25
Owners on Record

Note: Records showing the ownership history in alphabetical order.

Current Owners on Record
MARIN, ENNIO
VERRILLI, ROBERT
VERRILLI, DANNY
TRAVANI, ANDREA
Past Owners on Record
None
Past Owners that do not appear in the "Owners on Record" listing will appear in other documentation within the application.
Documents

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Document
Description 
Date
(yyyy-mm-dd) 
Number of pages   Size of Image (KB) 
Representative Drawing 2020-02-25 1 4
Cover Page 2020-02-25 2 28
Abstract 2018-09-18 1 6
Description 2018-09-18 17 725
Claims 2018-09-18 4 145
Drawings 2018-09-18 12 385