Note : Les descriptions sont présentées dans la langue officielle dans laquelle elles ont été soumises.
CA 02696509 2010-03-10
INSULATED CONCRETE FORM
Field of the Invention
[0001] This invention relates to insulated concrete formed wall construction
and in
particular to a method of efficiently installing insulating concrete forms.
Background of the Invention
[0002] Insulating concrete forms are commonly used in the construction of
concrete
walls. Insulating concrete forms have wall panels that define a cavity to hold
rebar as well as
poured concrete. After the concrete hardens, the wall panels can remain in
order to add furring,
vapour barrier, air barrier, strength, thermal insulation, fire-retardant, or
other desirable
properties.
[0003] Insulating concrete forms are commonly used in the construction of
walls as
follows: first two wall panels are placed in opposing locations (or
orientations) that will be the
inside and outside surface of the concrete wall. A (normally metallic or
plastic) webbing is then
placed in vertically between the panels by sliding the webbing downwards and
thereby
connecting the panels or in some cases moulded into the panels to form a block
with a specific
spacing between its two opposing panels. Rebar may then be placed horizontally
or vertically
within the cavity by sliding the rebar into receiving slots in the webbing.
Finally, concrete is
poured into the cavity and remains there to harden.
[0004] However, a common problem with current insulated concrete forms is that
the
components can be numerous and difficult to keep track of during installation,
take up a large
storage area on the job site and rebar (including the webbing) is not easily
visible at any time
during construction of the wall. Further, the methods of installation for
current insulated concrete
forming systems recognizably differ greatly from the traditional method of
concrete forming in
both installation sequence and dimensional size of installed components. Also
if during
construction it is discovered that a rebar section or webbing is missing,
often much of the entire
rebar, panel and webbing structure must be removed in order to put in place a
single missing
rebar section or webbing.
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[0005] This can be problematic, inefficient and time consuming (a 200 hundred
feet by 8
feet high basement wall, for example, may have 800 panels, 4800 web ties and
200 rebar
insertions).
[0006] Further, when constructing concrete walls using insulated concrete
forms, the
forms are often braced prior to pouring the concrete to hold the walls in
their correct alignment
and reduce the chance and/or occurrence of blowouts. Such braces are installed
by temporarily
screwing or nailing braces into the wall prior to pouring the concrete and
then when the concrete
has hardened the braces are removed. Due to the number of braces required to
adequately hold
the wall in the correct alignment and protect against blowouts, it would be
advantageous to
reduce the time needed to attach and then remove each brace.
[0007] A solution to at least one of the above problems is therefore desired.
Summary of the Invention
[0008] According to one aspect of the invention, disclosed is an insulated
concrete form,
comprising: an exterior panel having a substantially planar inner surface; a
plurality of first
furring strips embedded in the exterior panel, the first furring strips and
inner surface of the
exterior panel defining an exterior panel channel; an interior panel having a
substantially planar
inner surface; a plurality of second furring strips embedded in the interior
panel, the second
furring strips and inner surface of the interior panel defining an interior
panel channel; and an
open face webbing having a first edge opposite a second edge, the first edge
of the open face
webbing for slidably engaging one of the first furring strips within the
exterior panel channel, the
second edge of the open face webbing for slidably engaging with one of the
second furring strips
within the interior panel channel, the open face webbing having a plurality of
arms extending at
least partly between the first edge and second edge, the arms being open faced
along the second
edge for receiving rebar from the second edge so that the rebar can be
received prior to the open
face webbing slidably engages with the interior panel channel.
[0009] According to another aspect of the invention, the exterior panel of the
insulated
concrete form has an exterior surface; the interior panel of the insulated
concrete form has an
exterior surface; at least one of the plurality of furring strips embedded in
the exterior panel has
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at least one loop for receiving a hook on the exterior surface of the exterior
panel; and at least
one of the plurality of furring strips embedded in the interior panel has at
least one loop for
receiving a hook on the exterior surface of the interior panel.
[0010] According to another aspect of the invention, at least one of the
exterior panel and
interior panel is a planar lattice, the insulated concrete form for filling
with soil to support the
growth of plants on the outer surface of the panel.
[0011] According to another aspect of the invention, a quick-release brace
assembly for
bracing a panel of the insulated concrete form is disclosed, comprising: an
adjustable length
strongback having a hook and/or a push turn locking mechanism (not shown) for
engaging the
loop of a furring strip embedded in at least one of the exterior panel and
interior panel; a brace
having a first end opposite a second end, the first end of the brace rotatably
attachable to the
strongback, the second end of the brace for engaging with the ground.
[0012] According to another aspect of the present invention, disclosed is a
method of
bracing the insulated concrete form, comprising: providing the quick-release
brace assembly;
hooking the strongback hook into the loop of the furring strip embedded in at
least one of the
exterior panel and interior panel; and rotating the brace so that the second
end of the brace
engages the ground.
[0013] According to another aspect of the present invention, disclosed is a
method of
removing the quick-release bracing from the insulated concrete form,
comprising: rotating the
brace so that the second end of the brace disengages from the ground; and
unhooking the
strongback hook from the loop of the furring strip embedded in the at least
one of the exterior
panel and interior panel.
[0014] According to another aspect of the present invention, disclosed is a
method of
constructing the insulated concrete form is disclosed comprising: erecting the
exterior panel;
slidably engaging the first edge of the open face webbing with a first furring
strip within the
exterior panel channel; selectively placing a rebar onto the at least one arm
of the open face
webbing from the through the second edge; slidably engaging one of the second
furring strips
embedded in the interior panel with the second edge of the webbing, wherein
the step of
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selectively placing a rebar onto the at least one arm of the open face webbing
occurs before the
step of slidably engaging one of the second furring strips with the second
edge of the webbing.
[0015] According to another aspect of the present invention, disclosed a
method of
constructing the insulated concrete form comprising: erecting the exterior
panel; slidably
engaging the first edge of the open face webbing with a first furring strip
within the exterior
panel channel; selectively placing a rebar onto the at least one arm of the
open face webbing
from the through the second edge; slidably engaging one of the second furring
strips embedded
in the interior panel with the second edge of the webbing, wherein the step of
selectively placing
a rebar onto the at least one arm of the open face webbing occurs before the
step of slidably
engaging one of the second furring strips with the second edge of the webbing.
[0016] According to another aspect of the present invention disclosed is a
method of
constructing a concrete wall comprising: constructing an insulated concrete
form; bracing the
exterior panel; bracing the interior panel; and pouring concrete into the
cavity defined between
the interior panel and exterior panel.
[0017] According to another aspect of the present invention disclose is a
method of
constructing a concrete wall comprising: constructing an insulated concrete
form; bracing the
exterior panel; bracing the interior panel; and pouring concrete into the
cavity defined between
the interior panel and exterior panel; hardening the concrete; removing the
bracing from the
exterior panel; and removing the bracing from the interior panel according.
[0018] According to another aspect of the present invention disclosed is a
method of
constructing a concrete wall comprising: constructing a first insulated
concrete form and a
second insulated concrete form, the second concrete form next to the first
concrete form so the
cavity defined by the interior panel and exterior panel of the first concrete
form is fluidly
connected to the cavity defined by the interior panel and exterior panel of
the second concrete so
that a single interior cavity is formed; and bracing the exterior panel of the
first concrete form;
bracing the exterior panel of the second concrete form; bracing the interior
panel of the first
concrete form; bracing the interior panel of the second concrete form; pouring
liquid concrete
into the interior cavity; hardening the concrete; removing the bracing from
the interior panel of
the second concrete form; removing the bracing from the exterior panel of the
second concrete
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form; removing the bracing from the interior panel of the first concrete form;
and removing the
bracing from the exterior panel of the first concrete form.
Brief Description of the Drawings
[0019] In order that the subject matter be readily understood, embodiments are
illustrated
by way of examples in the accompanying drawings, in which:
[0020] Figure 1 shows a perspective view of an exemplary embodiment of a panel
for use
in insulated concrete forms according to the present invention;
[0021] Figure 2 shows a side elevation view of an exemplary embodiment of the
inside
surface of a panel that is directed towards the receiving cavity coming in
contact with the poured
concrete for use in insulated concrete forms according to the present
invention;
[0022] Figure 2.1 shows a side elevation view of an exemplary embodiment of
the
outside surface of a panel that is directed away from receiving cavity not
coming in contact with
the poured concrete for use in insulated concrete forms according to the
present invention;
[0023] Figure 3 shows a side elevation view of an exemplary embodiment of the
inside
surface a panel having embedded lattice reinforcement according to the present
invention;
[0024] Figure 3.1 shows a side elevation view of an exemplary embodiment of
the
outside surface of a panel having embedded lattice reinforcement integrated
with furring
channels according to the present invention;
[0025] Figure 3.2 shows a perspective view of a portion of a furring channel
with
integrated lattice reinforcement;
[0026] Figure 4 shows a perspective view of an exemplary embodiment of an
internal
mechanical tie for a furring channel connector according to the present
invention;
[0027] Figure 5 shows a perspective view of an exemplary embodiment of a
corner edge
of a panel according to the present invention;
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[0028] Figure 5.1 shows a perspective view of an exemplary embodiment of the
corners
edges of two panels abutting in accordance with the present invention;
[0029] Figure 6 shows a perspective view of an exemplary embodiment of one end
of a
panel in accordance with the present invention;
[0030] Figure 7 shows a perspective view of an exemplary embodiment of a
furring
channel in isolation in accordance with the present invention;
[0031] Figure 7.1 shows a perspective view of an exemplary embodiment of one
end of a
furring channel in accordance with the present invention;
[0032] Figure 8 shows a perspective view of a half-furring channel in
isolation in
accordance with the present invention;
[0033] Figure 8.1 shows a perspective view of an exemplary embodiment of two
half-
furring channels in accordance with the present invention;
[0034] Figure 9 shows a perspective view of an exemplary embodiment of a
webbing in
accordance with the present invention;
[0035] Figure 10 shows a side elevation view of an exemplary embodiment of a
webbing
in accordance with the present invention;
[0036] Figure 11 shows a perspective view of an exemplary embodiment of a
portion of a
webbing arm in accordance with the present invention;
[0037] Figure 12 shows a perspective view of an exemplary embodiment of a
webbing
arm having a facilitator in accordance with the present invention;
[0038] Figure 13 shows a side elevation view of an exemplary embodiment of a
double-
sided webbing in accordance with the present invention;
[0039] Figure 13.1 shows a side elevation view of an exemplary embodiment of a
double-sided webbing having perforations in accordance with the present
invention;
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[0040] Figure 14 shows a side elevation view of another embodiment of a
webbing in
accordance with the present invention;
[0041] Figure 14.1 shows a side elevation view of an exemplary embodiment of a
webbing with perforations in accordance with the present invention;
[0042] Figure 15 shows a side elevation view of another embodiment of a
webbing in
accordance with the present invention;
[0043] Figure 15.1 shows a side elevation view of an exemplary embodiment of a
webbing with perforations in accordance with the present invention;
[0044] Figure 16 shows a side elevation view of another embodiment of a
webbing in
accordance with the present invention;
[0045] Figure 16.1 shows a side elevation view of another embodiment of a
webbing in
accordance with the present invention;
[0046] Figure 17 is three views, each showing a webbing attached by elongate
inflexible
rotating hinge attached members in accordance with the present invention;
[0047] Figure 17.1 is a perspective view of the webbing attached by elongate
inflexible
rotating hinge attached members from Figure 17;
[0048] Figure 17.2 is a perspective view of a portion of the webbing attached
by elongate
inflexible rotating hinge attached members from Figure 17;
[0049] Figure 17.3 is a perspective view of a portion of the webbing attached
by elongate
inflexible rotating hinge attached members from Figure 17;
[0050] Figure 18 is a perspective view of two webbing portions each hingedly
attached to
a furring channel in accordance with the present invention;
[0051] Figure 18.1 is a perspective view of two panels each having embedded
furring
channels with webbing portions hingedly attached thereto in accordance with
the present
invention;
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[0052] Figure 19 is a perspective view of one end of a furring channel with a
webbing
partially slidingly attached thereto in accordance with the present invention;
[0053] Figure 19.1 is a perspective view of one end of adjacent two half
furring channel
with a webbing partially slidingly attached thereto in accordance with the
present invention;
[0054] Figure 20 is a perspective view of one or more furring channels with
webbing and
rebar attached thereto in accordance with the present invention;
[0055] Figure 21 is a perspective view of one or more panels with webbing and
rebar
attached thereto in accordance with the present invention;
[0056] Figure 22 is a perspective view of a partially constructed insulated
concrete form
wall in accordance with the present invention;
[0057] Figure 23 is a side elevation view of a fully constructed insulated
concrete form
with waterproofing membrane and waterproofing seem tape in accordance with the
present
invention;
[0058] Figure 24 is a perspective view of a partially constructed insulated
concrete form
with braces attached to it in accordance with the present invention;
[0059] Figure 25 is a perspective view of a furring channel with notches in
accordance
with the present invention;
[0060] Figure 26 is a side elevation view of a furring channel and a
strongback in
accordance with the present invention;
[0061] Figure 27 is a side elevation view of a furring channel with a hook
through its
notch in accordance with the present invention;
[0062] Figure 28 is a perspective view of a double sided furring channel in
accordance
with the present invention;
[0063] Figure 29 is a perspective view of a double sided half-furring channel
in
accordance with the present invention;
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[0064] Figure 30 is a perspective view of the end of a panel with a double
sided half-
furring channel embedded therein in accordance with the present invention;
[0065] Figure 31 is a perspective view of the ends of two panels abutting in
accordance
with the present invention;
[0066] Figure 32 is a perspective view of a double sided panel for use in
insulated
concrete forms in accordance with the present invention;
[0067] Figure 33 is a side perspective view of an insulated concrete form
having two
cavities in accordance with the present invention;
[0068] Figure 34 is a side perspective view of an insulated concrete form
having two
cavities in accordance with the present invention;
[0069] Figure 35 is a perspective view of a partially constructed insulated
concrete form
having two cavities in accordance with the present invention;
[0070] Figure 36 is a perspective view of a partially constructed insulated
concrete form
having two cavities in accordance with the present invention;
[0071] Figure 37 is a perspective view of a partially constructed insulated
concrete form
having two cavities in accordance with the present invention;
[0072] Figure 38 is a perspective view of an insulated concrete form having
two cavities
in accordance with the present invention; and
[0073] Figure 39 is a perspective view of an insulated concrete form having
two cavities
in accordance with the present invention.
Detailed Description of the Invention
[0074] Described herein is an insulated concrete form used for the
construction of walls.
For example, after an insulated concrete form is constructed its interior may
be filled with wet
cement. The cement hardens after a time, forming a wall.
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[0075] Figures 1, 2 and 2.1 show an embodiment of a planar panel 100 for use
in an
insulating concrete form. The planar panel 100 may be at least either an
exterior panel 100 or an
interior panel 100 for constructing an insulating concrete form. The panel 100
has an inner
surface 102 having a plurality of vertically aligned channels 104, with each
channel 104 being
spaced apart an equal distance 120. It is recognized that the channels 104 may
be spaced apart an
unequal distance. Embedded within each channel 104 is a furring channel 106
(described in
greater detail below in reference to Figure 7, for example). Figure 2.1 shows
a transparent view
of the outer surface 103 of the outside panel 100. The inner surface 102 and
outer surface 103 are
preferably fabricated from an insulating material such as expanded polystyrene
(or EPS).
[0076] Inside of each channel 104 are mechanical ties 108 for securing the
furring
channel 106 (and hence the panel 100) to the cement portion of the wall when
the cement
hardens. Each mechanical tie 108 may be spaced apart by an equal distance 122
along the
channels 104. The mechanical ties 108 are also located at the ends 112 of the
panel 100.
[0077] In one embodiment, the mechanical ties 108 are set inside of the
channels 104 of
the panel 100 and preferably do not protrude above the panel's 100 inner
surface 102. A panel
100 can be stacked flatly one on top of another panel 100 (not shown) for
storage or
transportation without any protrusions from the inner surfaces 102 of any one
panel 100
scratching or otherwise damaging any other panel 100.
[0078] The panel 100 preferably has a width 118 of 4 feet and a length 116 of
8 feet. The
panel 100 may be made of any suitable material, for example expanded
polystyrene (or EPS).
[0079] The outer surface 103 of the outside (or exterior) panel 100 may be
covered in a
waterproof layer and/or thermally reflective covering made out of plastic,
metallic foil or any
other suitable material that would be apparent to a person skilled in the art
upon reading this
disclosure.
[0080] Similarly, a waterproofing strip 111 (see Figure 23) may be placed
along a furring
channel 106 (e.g. a first or second furring channel 106) on the exterior 103
portion of the panel
100 that will be underground during construction. During construction the
panels 100 can be
manufactured with a waterproofing layer and then the waterproofing strip (e.g.
tape or brush-on
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or spray on waterproof material) can be placed on top of the seams between the
panels 100. The
waterproofing strip is for restricting water from seeping into the wall formed
from the insulated
concrete forms especially in the portion of the wall underneath ground level.
[0081] The inner surface 110 of the outer wall without the EPS foam surfaces
(103 and
102) is shown in Figure 3. The furring channels 106 are aligned vertically and
spaced apart an
equal distance 304. The distance 304 between the furring channels 106 may, for
example, be 8
inches. A lattice 302 may optionally be embedded within the panel 100 moulded
onto or
connected to the furring channels 106 (as shown) to provide increased
protection against tensile
forces operating on the wall or panel during construction and once
constructed. The lattice 302
may be made of any suitable structural material including for example
fibreglass, EPS, fabric,
plastic or stamped metal. Figure 3.1 shows the outside surface of the outer
wall of Figure 3. The
lattice 302 is shown attached to the furring channel 106.
[0082] Figure 3.2 shows a close-up of a furring channel 106 attached to the
lattice 302.
The lattice 302 may be embedded or welded to the furring channel 106. Such a
configuration
may be use in living green wall construction, for example, where insulation is
not required.
[0083] In an exemplary embodiment (shown in Figures 3, 3.1 and 3.2) the
lattice 302 is
molded or welded or similarly attached to the furring channels 106 during
manufacturing and/or
construction resulting in a single integral structure comprising both the
furring channels 106 and
the lattice 302. The panel 100 surface (103, 102) material (e.g. the EPS foam)
can then be
injected into place around the furring channels 106 and lattice 302 structure.
If damage (e.g. a
rupture or breakage) occurs to a portion of the lattice 302, the damage will
be contained within
the area between the two adjacent furring channels 106 were the lattice 302
was located. Also the
reinforcing lattice structure does not require a certain amount of material
(e.g. foam) coverage
away from the outer surface in order to have maximum effectiveness in
resisting the tensile
forces exerted by the concrete. The panel 100 without insulating foam surface
may be used in
conjunction with embedded lattice 302 connected to furring channels 106 to
form earth filled
walls to support the growth of plants on the outer surface 103 of the panel
100.
[0084] An exemplary embodiment of the mechanical tie 108 is shown in greater
detail in
Figures 4 to 6. The panel 100 has an inlet 402 extending into its inner
surface for providing the
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mechanical tie 108. The furring channel 106 has an aperture 602 through it to
provide a passage
through the furring channel within the inlet 402 for the concrete to now
through.
[0085] The mechanical tie 108 does not protrude beyond the inner surface 102
of the
panel and therefore assists in maintaining a flat panel 100 so that the panels
100 can be stacked
on top of each other with minimal risk of damage to any of the mechanical ties
108 or to the
panels 100 themselves. Further, with the mechanical ties 108 being internal to
the panel 100 the
panels 100 can be stacked using less volume than if the mechanical ties 108
were located
external to the panel 100 as is common in practice.
[0086] Figure 4 shows a close-up of an internal mechanical tie 108 for
securing the
panels 100 and furring channels 106 to a cement wall. The inner surface 102 of
the panel 100
contains opposing inlets 402 on either side of the furring channel 106. The
inlets are fluidly
connected by an aperture 602 in the furring channel 106. Running along either
side of the furring
channel 106 are channels 104.
[0087] At each corner 124 of a panel 100, referring to Figure 5, the furring
channel 106
ends in an aperture 602; similarly, an inlet 402 is located at the top surface
102 of the corner 124.
A channel 104 runs along the edge 126 of the panel 100. Similarly a half
furring channel 106
runs along the edge of the panel 100. When the corners 124 of two panels 100
are side-by-side,
as shown in Figure 5.1, they form half of a mechanical tie 108. Similarly, a
half mechanical tie
108 is located at the end of the panel as shown in Figure 6. The furring
channel 106 used on the
edge 126 of the panel 100 is a half furring channel 106 (as described below
and shown in
reference to Figure 8). Therefore, when the ends 112 of two panels 100 are
aligned so that the
apertures 602 in the furring channels 106 and the inlets 402 in the channels
104 line up, a half
mechanical tie 108 will be formed as shown in figures 5.1 and figures 6.
Similarly, when four
corners 124 of four panels 100 are aligned to meet in a central point they
form a complete
mechanical tie 108 as shown in figure 4.
[0088] Figures 7 and 7.1 show an exemplary embodiment of a furring channel 106
in
isolation (i.e. before being embedded in the panel 100 and without lattice 302
attached to it). The
furring channel 106 has a flat front plate 710 with a back surface 704. An
internal portion 706
extends perpendicularly from the back surface 704 of the front plate 710 to
the inner plate 708.
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At one end 712 of the furring channel 106 is the aperture 602 used for the
mechanical tie 108 as
described above.
[0089] Figure 8 shows an end of a half-furring channel 106 in isolation and
Figure 8.1
shows two half furring channels 106 abutting each other and aligned. Each half-
furring channel
106 also has a front plate 710 with a back surface 704 and an inner plate 708.
An internal portion
706 extends from the back surface 704 of the front plate 710 to the inner
plate 708. When two
half-furring channels 106 abut one another the two front plates 710 form the
shape of the front
plate 710 of a single full furring channel 106 as shown in figure 8.1.
Similarly, when two inner
plates 708 of a half-furring channel 106 abut they form the shape of an inner
plate 708 of a single
full furring channel 106 as shown in figure 8.1.
[0090] As discussed above in reference to Figures 5 and 5.1 a half furring
channel 106 is
embedded at the edge 126 of the panel 100 so that when two panel 100 edges 126
are adjacent
each other the two half-furring channels 106 abut to form the shape of a
single furring channel
106 as shown in figure 6.
[0091] The furring channels 106 may be integrally embedded or molded with
lattice 302.
To embed furring channels 106 with lattice 302 into a panel 100, the furring
channel 106 is held
in place (for example by using a mould) using methods that would be known to
those of skill in
the art upon reading this disclosure, and a foam, which forms the panel (e.g.
EPS foam) is
injected into place. Similarly to embed furring channels 106 without lattice
302 each furring
channel 106 is placed individually into the mould to then be injected with the
foam, for example.
[0092] Thus, using the furring channels 106 with the lattice 302 provides for
more
efficient factory manufacturing of the panel 100 as each individual furring
channel 106 does not
need to be individually placed into the mould prior to injection of the
surrounding foam.
[0093] Figures 9 to 12 show one embodiment of webbing 900. The webbing 900 may
be
fabricated out of stamped metal, EPS or any other suitable material. The
webbing 900 is
preferably substantially flat having an attachment edge 902 along one side for
attaching into a
furring channel 106 in a channel 104 of a panel 100. Extending from the
attachment edge 902 is
a number of webbing arms 904. Each webbing arm 904 has three indentations 910
on each side,
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each indentation 910 being sized to receive a rebar (see Figures 20, 21, and
22, for example). It is
recognized that a webbing arm 904 can have more than or fewer than three
indentations 910.
Additionally, there are interior indentations 912 that are not on the webbing
arms 904 but are
instead on any portion of the webbing 900 that is near the attachment edge 902
from where the
webbing arms 904 projects. Each end of the webbing 900 is a substantially flat
end 914.
[0094] On the end of each webbing arm 904 opposite the attachment edge 902 is
a
receiving end 906 (e.g. a first or second edge). The receiving end 906 may be
configured for
slidably receiving the inner plate 708 of a furring channel 106.
Alternatively, the receiving end
906 and/or the attachment edge 902 can be sized to receive a female end of a
furring channel (not
shown). The receiving end 906 and/or attachment edge 902 and the female end of
a furring
channel can be any attachment method known or apparent to a person of skilled
in the art upon
reading this disclosure.
[0095] The receiving end 906 on the webbing arm 904 at the substantially flat
end 914
has a facilitator 920. The facilitator 920 is an outwardly angled or flared
side or end of the
receiving end 906 or the attachment edge 902. The facilitator 920 may be
located at either of the
substantially flat ends 914 and/or any number of the webbing arms 904.
[0096] The webbing 900 may be securely attached to the furring channel 106
(e.g. the
first or second furring channel 106) by sliding the attachment edge 902 over
the inner plate 708
located within the channel 104. The inner plate 708 of the furring channels
106 are sized to slide
into the receiving end 906 of the webbing arm 904 or interchangeably the
attachment edge 902
thereby securing the panel 100 to the webbing 900. Figure 19 and 19.1 shows
the attachment
edge 902 of the webbing 900 sliding over the inner plate 708 of the furring
channel 106. Figure
19.1 shows the attachment edge 902 of a webbing 900 sliding over the inner
plate 708 of two
half furring channels 106. In this way, two panels are placed side-by-side
with half-furring
channels 106 abutting so that when a webbing 900 slides overtop of the two
half-furring
channels 106 (and hence the panels 100) the half furring channels are locked
together. Thus, the
two panels 100 are locked side-by-side as a result of the webbing 900
placement.
[0097] In a further alternative embodiment, faster construction time maybe
achieved
where the attachment edge 902 may be attached to the furring channel 106 in
the channel 104 of
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the panel 100 by a hinge (discussed below in relation to Figures 18 and 18.1).
When the panels
are not used, the web 900 can be rotated using the hinge so that the web 900
lays flat against the
inner surface of the panel 100. This allows for the panels 100 to be stacked
together and/or
transported safely and easily. Additionally, it minimizes damage that would
otherwise occur to
the web 900 or panels 100 if the web 900 was not able to lay flat against the
panel 100. The
hinges may, for example, be molded into the panel with a metal or plastic pin
along its pivoting
axis 100.
[0098] The webbing 900 may define an open face webbing in that the
indentations 910,
912 may be accessible from the edge opposite the attachment edge 902. For
example, when the
attachment edge 902 is attached to the furring channel 106 the webbing 900 can
receive rebar
through the edge opposite the attachment edge 902 prior to the receiving end
906 slidably
engaging with a furring channel 106 on a panel 900 (e.g. and interior panel
channel).
[0099] In another embodiment, as shown in Figure 13, the webbing 1000 may be
open on
both sides. The webbing 1000 has opposing substantially flat ends 1008 (e.g. a
first edge
opposite a second edge). Webbing arms 1004 with receiving ends 1006 are
located on either side
of the webbing 1000. The webbing arms 1004 have indentations 1010 sized to fit
rebar. Because
the webbing 1000 is substantially symmetrical, either end 1008 of the webbing
1000 can be used
as the top or bottom during operation. The receiving ends 1006 are sized to
slidably fit the inner
plates 708 of the furring strip 106. The webbing arms 1000 have a triangular
inclinations from
the receiving end 1006 to the central portion 1012 of the webbing 1000. These
substantially
triangular inclinations can assist with structural strength of the webbing 900
to hold rebar 950 or
any suitable reinforcement in place prior to pouring concrete into the wall
cavity.
[00100] In an alternative embodiment, shown in figure 13.1, the webbing 1000
comprises
perforations 1300 running along the central axis of each webbing arm 1004.
These perforations
1300 allow the webbing 1000 to be broken to form a substantially flat end so
that the length of
the webbing 1000 can be sized to suit a user.
[00101] Figure 14 shows a webbing 1000 with an attachment edge 1011 on one
side and
webbing arms 1004 extending away from the central portion of the webbing 1000.
In the
embodiment shown in Figure 14 there are no triangular inclinations extending
between the
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receiving ends 1006 and the central portion 1012. Figure 14.1 shows the
webbing 1000 of Figure
14 with the alternative embodiment of perforations 1300 extending along the
central axis of each
webbing arm 1004.
[0100] Figure 15 shows a webbing with an attachment edge 1011 on one side and
webbing arms 1004 extending away from the central portion of the webbing 1000.
The
embodiment shown in Figure 15 does not have a triangular inclination extending
between the
receiving ends 1006 and the central portion 1012. However, an additional
support member 1500
extends the length of the webbing 1000 and attaches to each webbing arm 1004.
The support
member 1500 my also have indentations 1010 (not shown) on either side along
its length sized to
fit rebar. Figure 15.1 shows a similar embodiment to that shown in Figure 15
except that there
are the additional perforations 1300 extending along the central axis of each
webbing arm 1004.
[0101] Figure 16 shows an embodiment having a double open face webbing 1000
without triangular inclinations extending from the receiving ends 1006 of the
webbing arms to
the central portion 1012. The support member 1012 may also have indentations
1010 (not
shown) on either side along its length sized to fit rebar. In another
embodiment as shown in
figure 16.1 there are two parallel support members 1600 extending the length
of the webbing
1000 attaching to each webbing arm 1004. The support members 1600 my also have
indentations
1010 (not shown) on either side along its length sized to fit rebar.
[0102] Referring to Figures 17, 17.1, 17.2 and 17.3, elongated inflexible
members 1700
may rotatably or hingedly attach to and run perpendicular to each webbing 900,
1000. The
webbing 900, 1000 may be folded down in tandem because each webbing is
attached by the
inflexible members 1700. For example, as shown in Figure 17 there may be four
elongated
inflexible members 1700 with two members 1700 attached along the attachment
edge 902 of the
webbing 900, 1000. The elongate inflexible members may be rotatably attached
by a clip device
1702 as shown in the Figures, for example.
[0103] The webbing 900 itself may be hingedly attached to the furring channels
106 (see
Figures 18 and 18.1). This may be accomplished by using an attachment edge 902
that rotatably
attaches or rotatably receives the inner plate 708 of the furring channel 106.
The webbing 900
may be rotatable between a flat position wherein the webbing 900 is
substantially flush with the
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panel 100 (see Figure 18.1) and an extended position wherein the webbing is
perpendicular to the
panel 100. As shown in Figure 18.1 the webbing 900 may also be attached by
elongate inflexible
members 1700 in order to allow the webbing 900 to be simultaneously and easily
rotated into or
out of the flat position.
[0104] The space in between the two opposing panels 100, which contains the
webbing
1000 (and rebar), defines a cavity for receiving the concrete. After
hardening, the concrete
together with the opposing panels 100 and webbing 1000 (and rebar or suitable
reinforcement),
will form a wall. The webbing 1000 is placed such that each side 1004 will be
facing opposing
panels 100. A webbing 1000 open on both sides is reversible where either side
can be attached to
either opposing panel 100 so that either side of the webbing 1000 can present
an open face view
for efficiently placing the rebar. The webbing 1000 has a plurality of arms
1004 facing in the
direction of the sides 1006. Each arm has indentations 1010 sized to fit
rebar. The webbing 1000
further comprises two vertical bars 1012 and/or 1500 and/or 1600 vertically
aligned and
perpendicular to each webbing arm 1004. The webbing arms 1004 are spaced equal
distances
apart along the vertical bars 1012, 1500, 1600. Numerous webbings 1000 may be
used in the
insulated concrete form with the webbings 1000 sized and spaced apart so that
rebar may be
placed substantially horizontally within the indentations 1010 along the
webbing arms 1004.
[0105] In operation first an outside panel 100 having embedded furring
channels 106 is
erected. The webbing 900, 1000 slidably engages with the furring channels 106
(e.g. the
attachment edge 902 of the webbing 900 slides over the furring channel 106 so
as to attach
thereto). The webbing 900, 1000 slidably engages with the half furring
channels 106 locking the
abutting panels 100 together restricting either panel 100 from moving both
transversely or
horizontally relative to each other as a result of webbing 900, 1000
placements. Because the ends
914, 1008 of the webbing 900, 1000 are substantially planar they act as a
natural stabilizer for
the erected panel 100.
[0106] The open face webbing 900, 1000 is ready to receive the rebar 950 in
the
indentations 910, 912 of the webbing arms 904. Figures 20 and 21 show the
fully erected outside
wall along with vertically extending webbing 900 attached to the furring
channels 106. Parallel
to the webbing 900 and resting in the indentations 910 of the webbing arms 904
are lengths of
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rebar 950. The entire amount of rebar can be put into position before erecting
the opposing
panels 100 to complete the concrete form. At this point if rebar or webbing
900 is missing it is
very easy to tell and remedy by simply looking at the open faced structure of
panels 100,
webbing 900 and rebar 950. The rebar 950 is used at least to protect against
tensile forces. Rebar
may be any suitable rebar made out of any suitable material as is known to a
person skilled in the
art and which may be used along with the webbing 900, 1000 described herein.
[0107] For example as shown in Figure 22 each panel 100 can be placed one at a
time by
sliding the panel 100 over the receiving ends 906 of the webbing 900. A fully
constructed
concrete form 960 is shown in Figure 23.
[0108] During or after construction of the concrete forms 960, panels 100
manufactured
with a water impermeable surface may be sealed end-to-end in this position
using a sealant or
sealant tape 111 as shown in figure 23 as would be familiar to those with
skill in the art upon
reading this disclosure. When sealed end-to-end the panels 100 form a wall
that is water
impermeable along its entire surface that is exposed to the outside elements
in particular at
abutting horizontal and vertical panel 100 ends as shown in figure 23.
[0109] Double-sided webbing 1000 may be used, thereby providing a reversible
configuration. In other words either side of the double-sided webbing 1000 can
be attached first.
[0110] After the concrete forms 960 are constructed, the walls are aligned and
braced as
is known by those of ordinary skill in the art. After wall alignment and
bracing, liquid concrete is
poured into the cavity in the interior of the concrete form 960. When two
opposing panels are set
up in their vertical positions in a concrete form 960 and the concrete is
poured into the cavity
between the panels defined by the webbing 900, 1000 or the side walls (within
which the rebar
950 and/or webbing 900, 1000 are placed), concrete will flow into the inlet
402 and fill the
aperture 602 of the furring channel 106. Once the concrete is hardened the
furring channel 106
and the panel 100 will be secured to the concrete.
[0111] It is recognized that, when using webbing ties 900, 1000 as described
above, it
still may be necessary to brace the panels 100 from the exterior of the cavity
defined by opposing
panels 100 before pouring concrete into the cavity to prevent the panels 100
from blowing out
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due to the force exerted by the poured concrete and maintain a plumb upright
orientation of the
form panels 100.
[0112] According to another embodiment shown in Figures 24 to 27, the panels
100 can
be braced using quick-remove braces. A strongback 150 is attached to the
furring channel 106 on
the outer surface 103 of the panel 100. A brace 160 is attached at its first
end 164 to the
strongback 150 and is secured in the ground or floor at its second end 166 as
is known by those
of ordinary skill in the art.
[0113] The strongback 150 is attached to the furring channel 106 using a pull,
twist, and
lock mechanism (not shown) or a hook-and-loop attachment mechanism as follows.
The furring
channel 106 (shown in isolation in Figure 25) has notches 154 along its front
plate 710. Each
notch 154 is spaced equal distance apart along the longitudinal axis of the
furring channel 106.
For example, the notches may be 16 inches apart.
[0114] A strongback 150, shown in Figure 26, has hooks 152 extending from its
inner
surface 156. The hooks 152 are spaced an equal distance apart along the
longitudinal axis of the
strongback 150. Each hook 152 corresponds to a notch 154 in a furring channel
106. The hooks
152 have an arm portion 170 extending substantially perpendicularly from the
strongback 150
and an angled portion 172 extending downwardly (i.e. towards the ground when
in place) from
the arm portion 170. A fastening end 174 extends from the angled portion 172
to assist in
attaching the hook 152 to the notch 154.
[0115] To attach the hook 152 to the notch 154 the fastening end 174 is
inserted into the
notch 154 and the strongback 150 is pressed against the furring channel 106 so
that the angled
portion of the hook 152 slides into the notch 154. The notches 154 and hooks
152 must therefore
be spaced along the furring channel 106 and strongback 150 respectively in
order to allow the
hooks 152 to be inserted into the notches 154. It is recognized that the hooks
152 may be
directed towards the ground or away from the ground when attached.
[0116] A brace 160 is attached to the outer surface 158 of the strongback 150.
In
particular, the first end 164 of the brace 160 is rotatably attached via a pin
162 or other similar
attachment mechanism. When the strongback 150 is attached to the furring
channel 106 the brace
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160 is at an acute angle with the surface of the wall with respect to the
ground so that the second
end 166 of the brace 160 is attached to the ground to provide support to the
panels 100.
[0117] To remove the braces 160 and strongback 150 from the panels 100, the
braces
160 are rotated about the pin 162 (or similar rotatable attachment mechanism)
so that the second
end 166 of the brace 160 is removed from the ground. The hooks 152 in the
strongback 150 are
then removed from the notches 154 in the furring channel 106 and the
strongback 150 is thereby
separated from the panel 100.
[0118] It is recognized that the braces 160 can be attached at the outer
surfaces of either
side of the wall in order to align and/or brace both the inner and outer
panels 100.
[0119] The strongbacks 150 can be attached to a subset of the furring channels
106. For
example, every third furring channel 106 may have a strongback 150 and brace
160 attached to
it.
[0120] Using the webbings 900, 1000 as described herein allows opposing panels
100 in
an insulated concrete form to settle with respect to the ground or surface
below. For example the
panels 100 may move up and down (substantially vertically) with the natural
inclinations of the
ground or surface below. However, the panels 100 are restricted from moving
transversely or
horizontally relative to one another due to both the interlocking of the webs
900, 1000 and
furring channels 106 or half furring channels 106 when they are slidably
engaged with one
another and/or the fact the webbings 900, 1000, are simultaneously attached to
both opposing
panels 100.
[0121] Panel 100 sizes can be larger than are normally used for insulated
concrete forms.
For example, panel sizes may be 4 x 8 or 4 x 4 foot. The outside wall could be
an 8 x 8 feet panel
and the inside could be a 24 x 24 foot panel. The panels can, for example, be
made out of wood,
fibre glass composite, metal, carbon fibre composite, insulating foam or any
suitable material
with desirable physical properties for use in building construction.
[0122] It is recognized that the interior of the insulated concrete form can
be filled with
earth or mud instead of cement.
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[0123] An embodiment shown in Figures 28 to 40 will now be described. A
furring
channel 106 may be as described above except that the furring channel 106 may
be a double
sided furring channel 106 as shown in figures 28 and 29. A double sided
furring channel 106 is
symmetrical about its front plate 710 so that there are two inner plates 708
opposite each other
and on opposite sides of the front plate 710 as shown in figure 28. A half-
furring channel 106
may also be double sided, forming a double sided half furring channel 106 as
shown in Figure
29. The half furring channel 106 shown in the Figure 29 is also symmetrical
about its front plate
708 so that there are two inner plates, one opposite and on opposing sides of
the front plate 708
from the other. An internal portion 706 extends from either side of the front
plate 710.
[0124] As discussed in relation to a half-furring channel, the double-sided
half-furring
channel 106 is embedded at the edge 126 of the panel 100 so that when two
panel edges 126 are
adjacent each other the two double sided half furring channels 106 abut to
form the shape of a
single double-sided furring channel 106. This embodiment is shown, for example
in Figures 30
and 31.
[0125] A panel 100 having a plurality of double sided furring channels 106
embedded
therein is shown in Figure 32. A panel 100 with double sided furring channels
106 can receive
and removeably attach to webbing 900, 1000 on either side of the panel 100
(i.e. on either end or
side of the double sided furring channel 106) in a similar manner as described
above in relation
to a furring channel 106. The webbing 900, 1000 attached to one side of the
panel 100 slidingly
engages with the furring channel 106 of another panel 100 as shown at 77 in
Figure 33. The
webbing 900, 1000 extending from the opposite side of the panel 100 engages
with an embedded
lattice 302 or an attached wire mesh 81 in the following way: The wire mesh 81
is secured to a
furring channel 106 which in turn slidingly engages with the webbing 900,
1000.
[0126] The resulting configuration is a wall with a central sandwiched panel
100 and
two cavities on either of the central panel's 100 sides. The cavity on which
the embedded lattice
reinforcement 302 or wire mesh 81 borders may be filled in with soil or any
suitable medium to
support the growth of plants, flowers, grass and other vegetation, forming a
"green wall." The
opposite cavity is between two foam panels 100 and may be filled with cement
or other materials
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as described above. The embedded lattice reinforcement 302 or wire mesh 81 may
alternatively
be used in conjunction with a planar structural lattice 82.
[0127] In another embodiment, the panels 100 may all be planar for panels 100
wherein
one or more holes are made in one of the exterior panels 100 for allowing
vegetation to grow
through.
[0128] The structural lattice 82 may be of different sizes and shapes. For
example, the
structural lattice 82 may form a plurality of square shapes of a certain size
(see figure 35 for
example) to support the weight of larger plants growing on the surface of the
wall.
[0129] In another embodiment (shown in Figures 35 and 36), dowels 83 extend
from the
central panel 100 to the structural lattice 82. The dowels 83 may be metallic
rods that are
punctured into the panel 100 to be cast into the concrete in the adjacent
cavity. After the concrete
has cured the structural lattice 82 is supported by hooking it onto the dowels
83 to help support
the weight of plants and resist soil pressure. . The dowels 83 provide further
support for the
structural lattice 82 and wall and in another embodiment provide the sole
attachment of the
structural lattice 82 to the central panel 100. The dowels 83 may be attached
in another suitable
way known to a person of ordinary skill in the art.
[00102] As shown in Figure 37 the double sided furring channels 106 may be
used to
construct a wall with a single cavity. The double sided furring channels 106
may be on either or
both panels in this embodiment.
[00103] In another embodiment (shown in Figure 38) the double sided furring
channel 106
can be used embedded in a central panel 100 with two insulating foam panels
100 on opposite
sides, thereby forming a wall with two cavities and wherein each cavity is
enclosed by insulating
foam panels 100.
[00104] Although specific embodiments of the invention have been described
herein, it
will be understood by those skilled in the art that variations may be made
thereto without
departing from the spirit of the invention or the scope of the appended
claims.
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