Form for concrete walls

[0001] The present invention relates to concrete form systems. More particularly, the invention relates to insulated, shaped forms which are used to define sections of concrete walls having corners, joints or intersections of walls.

[0002] In the field of constructing concrete walls, insulating concrete form (ICF) systems are used. In particular, ICF systems provide forms to define external boundaries of concrete walls. In the forms, panels of insulating foam are used to define the boundaries. The foam panels are linked and separated by ties that typically comprise flange portions that are embedded in each of the opposed foam panels and a web portion extending there-between. The flanges can be embedded or mated with the panels by moulding the foam panels around them or by sliding the flanges into slots in the foam panels, or by any other manner as will be apparent to persons skilled in the art.

[0003] To make a concrete wall using an ICF system, first an outline of a wall is made by assembling and stacking, as appropriate, a series of forms to define the outline. Next, concrete is poured into the form. Once the concrete has set, the foam panels are left in place thereby providing both sides of the concrete wall with integral insulating layers. The ICF systems are also available in pre-made forms of standard dimensions that can be stacked both vertically and horizontally to create any desired configuration of form. An example of an ICF system is provided in U.S. Pat. No. 5,896,714 (the disclosure of which is incorporated herein by reference). This results in a vertically continuous nailing surface for securing wall finishing material such as vapour barriers, additional insulation, wall boards and the like. Other ICF form systems are taught in the following U.S. Pat. Nos. 4,229,920; 5,429,933; 6,253,523; 6,401,419; and 6,412,245 (the disclosures of which are incorporated herein by reference).

[0004] A typical concrete wall is not just straight: it can also have corner sections, bent sections, and sections having one, two or more walls meeting at particular location(s) along the wall. Prior art ICF forms of various shapes and sizes are available for such non-straight sections. For example, corner forms are L-shaped having two straight wall sections meeting at 90 degrees at the corner. As concrete is poured into an existing corner form, the walls at the corner are more prone to bulging outward, as there are additional stresses imparted on the form from the concrete filling the adjacent ends of the form. Such stresses are typically not present in straight forms. Typical ties in the present forms do not effectively retain the walls in place when exposed to such multi-directional stresses.

[0005] There is a need to provide a form for corner units which addresses deficiencies in the prior art.

[0006] In a first aspect, a form for use in a concrete wall forming system is provided. The forming system defines wall sections meeting at an intersection region. The form comprises panels, arranged in a spaced relationship to each other to define a volume for each wall section and an intersection volume for the intersection region. The form also comprises a tie having a corner piece with webs spanning outwardly therefrom. The tie is inserted within one panel about the transition zone such that the webs span through the transition zone from about a corner of the panel to points about a corner in an adjacent panel. The tie may be generally horizontally oriented among the panels.

[0007] In the form, the wall sections may comprise first and second sections meeting at a predetermined angle at the intersection region. Also, the panels may comprise inner and outer panels. Also, the tie may further comprise: a span linking two ends of two webs; a vertical flange located about an end of one web; and a second vertical flange located about the corner piece.

[0008] In the form, all ends of the webs may be connected via horizontal spans.

[0009] In the form, the tie may be arranged in a stack with other ties about the intersection region.

[0010] In the form, the tie may further comprise an interior web joining the webs about their anterior ends.

[0011] In the form, the tie may further comprise a bar alignment feature located on the webs within the transition zone.

[0012] In the form, the tie may further comprise a third vertical flange aligning with an interior face of outer panel; and a fourth vertical flange aligning with an interior face of inner panel.

[0013] In the form, a second tie may be stacked on top of the tie.

[0014] The form may further comprise a third tie located along said volume between the panels; and a physical feature in a panel indicating that the third tie is located about said physical feature.

[0015] In the form, the tie may provide a flange area for receiving a fastener therethrough.

[0016] In a second aspect, a tie for use in a form used in a concrete wall forming system is provided. The tie comprises: a corner piece with webs spanning radially, horizontally outwardly therefrom; a span linking two ends of two webs; a vertical flange located about an end of one web; and a second vertical flange located about the corner piece.

[0017] In the tie, all ends of the webs may be connected via spans.

[0018] In the tie, there may be features along its top and bottom edges to allow the tie to be stacked with another tie.

[0019] In a third aspect, a form for use in a concrete wall forming system to define wall sections meeting an intersection region is provided. The form comprises: panels arranged in a spaced relationship to each other to define there between a volume for each wall section and an intersection volume for the intersection region; and a tie. The tie has an exterior frame having at least three sides, corners where two adjacent sides meet and a web member spanning generally across an interior volume within the frame. The tie is located in the intersection region with two sides spanning between opposing sides of opposing panels and has each corner embedded within a panel. The tie may be oriented generally horizontally about the panels.

[0020] In the form, the wall sections may comprise two sections meeting at a predetermined angle at the intersection region. Further, the form may have an inner panel and an outer panel. Also, the exterior frame may comprise four sides with four corners. Two sides of the frame may be embedded within the outer panel. Two corners of the frame may be embedded in the outer panel. Another corner may be embedded in the inner panel. Finally, two sides of the frame may span between the inner and outer panels.

[0021] The form may further comprise a vertical tie having a frame located between the panels and having anterior ends embedded within each panel.

[0022] In the form, the sides spanning the interior volume may have at least one bar alignment feature extending vertically from a surface thereof.

[0023] In the form, the sides of the stack which may be embedded within the outer panel may comprise a vertical flange; and the corner which may be embedded in the inner panel may be inwardly notched and may have a vertical flange.

[0024] In the form, the tie may be stacked with another tie to form a stack of ties.

[0025] In the form, the vertical flanges may be each shaped to define continuous sides for the tie.

[0026] In the form, at least one of the continuous sides may have shaped voids defined by edges of the vertical flanges.

[0027] Alternatively, there may be three wall sections meeting at a predetermined angle at the intersection region and there may be three panels in the form. In the form, the exterior frame may comprise four sides and four corners; two of the panels may be corner panels; two corners of the exterior frame may be embedded in the first panel; the other two corners of the frame may each be embedded in the corner panels; two sides of the frame may span between the corner panels and between each corner panel and the other panel; and a fourth side of the exterior frame may be embedded in the other panel.

[0028] In a fourth aspect, a tie for use in an insulating concrete form is provided. The tie comprises: a stackable frame defined by sides, corners where adjacent sides meet, and a web member spanning generally across an interior volume within the frame. The tie is locatable in a volume defined by the concrete form as an intersection region for at least two walls with two sides of the each frame spanning between opposing sides of opposing panels of the concrete form and with each corner of the corners of the each frame being locatable within one panel of the concrete form.

[0029] In a fifth aspect, a form for use in a concrete wall forming system is provided. The form comprises: wall panels forming an intersection region; and a tie having an exterior frame having at least three sides, corners where two adjacent sides meet and a web member spanning generally horizontally across an interior volume within the frame. In the form, the tie is located in the intersection region with two sides spanning between opposing sides of opposing panels of the wall panels and has each corner embedded within one of the opposing panels.

[0030] In the form, the wall panels may comprise two panels forming two wall sections meeting at a predetermined angle at the intersection region; and the form may further comprise a vertical tie located between two opposing panels having anterior ends embedded in each of the opposing panels.

[0031] Alternatively, in the form, there may be three wall panels forming three wall sections meeting at a predetermined angle at the intersection region. For the tie, the exterior frame may comprise four sides and four corners. For the panels, two may be corner panels. For the tie, two corners of the exterior frame may be embedded in one panel; a third corner may be embedded in a second panel; a fourth corner may be embedded in a third panel; a first side may span between two panels; a second side may span between a different set of two panels; a third side may span between a different set of two panels; and a fourth side may embedded in one panel.

[0032] In other aspects various combinations of sets and subsets of the above aspects are provided.

[0033] The features of the invention will become more apparent in the following detailed description in which reference is made to the appended drawings wherein:

[0034] FIG. 1 is a top perspective view of a form having an interior panel, an exterior panel, a stack of ties in a transition zone in the form and vertical ties in another area in the form according to an embodiment;

[0035] FIG. 2 is top view of the form of FIG. 1;

[0036] FIG. 3 is an end view of the form along line A-A of FIG. 1;

[0037] FIG. 4 is a front view of the form along line B-B of FIG. 1;

[0038] FIG. 5 is a perspective view of the stack of ties in the form of FIG. 1;

[0039] FIG. 6 is a top view of the stack of FIG. 5;

[0040] FIG. 7 is a side view of the stack along line C-C of FIG. 5;

[0041] FIG. 8 is another side view of the stack along line D-D of FIG. 5;

[0042] FIG. 9 is a side view of a single tie of the stack of FIG. 7;

[0043] FIG. 10 is another side view of the single tie of the stack of FIG. 8;

[0044] FIG. 11 is a top perspective view of one of the vertical ties of the form of FIG. 1;

[0045] FIG. 12 is a top perspective view of another form according to another embodiment;

[0046] FIG. 13 is a perspective view of a stack of ties in the form of FIG. 12;

[0047] FIG. 14 is a top view of the stack of ties of FIG. 13;

[0048] FIG. 15 is a side view of the stack of ties along line E-E of FIG. 14;

[0049] FIG. 16 is another side view of the stack along line F-F of FIG. 15;

[0050] FIG. 17 is a side view of a single tie of the stack of FIG. 16; and

[0051] FIG. 18 is another side view of the single tie of the stack of FIG. 17.

[0052] The description which follows and the embodiments described therein are provided by way of illustration of an example or examples of particular embodiments of the principles of the present invention. These examples are provided for the purposes of explanation and not limitation of those principles and of the invention. In the description which follows, like parts are marked throughout the specification and the drawings with the same respective reference numerals.

[0053] FIG. 1 illustrates a form relating to an embodiment. As shown, form 10 is a corner form used for defining a corner of a concrete wall. It has a general L-shape, defined by L-shaped panels 12 and 14 which are set in a spaced relationship to each other such that an interior L volume 16 is formed between them. The L-shape can be considered to be formed from two walls meeting at 90 degrees at a transition region. Form 10 has an interior panel 12 and an exterior panel 14. The panels are connected together by a plurality of ties 18 and 20 as spacing members extending there between. Ties 18 are located in the transition zone of the L-volume 16 and ties 20 are located in the anterior ends of the L in volume 16. Specifically, in the corner section a series of ties 18 are stacked on top of each other forming a stack of ties 18. Ties 20 are generally elongated frames which are oriented vertically between panels 12 and 14. For many forms, the panels are spaced to form a wall having a thickness of 8 inches. Other thicknesses can be provided, such as 10, 12 or 14 inches.

[0054] A feature of an embodiment is that in the transition region in a form, such as in the corner of the above noted form, more lateral support is provided between the panels of the form. Improved lateral support is provided by a series of webs in ties 18 which are oriented horizontally in the form. The beams and webs in ties 18 span from about the interior corner of the form across the volume to be filled with concrete, to points along the exterior corner of the form. The anterior ends of the webs may have flanges on them to assist in supporting the shape of the form as concrete fills the transition zone. The flanges also provide positive areas where fasteners, such as screws, can be inserted through the forms and bind to the flanges. This allows cladding to be placed against the forms and to be fastened to them. In other embodiments, ties 18 may be oriented to be skewed from horizontal.

[0055] Panels 12 and 14 have vertical ridges and grooves running along their height. In locations where a panel 12 or 14 has a tie 18 or 20 embedded therein, a physical feature may be provided on the surface of the panels to indicate that a tie is embedded therein. For example, panels 12 and 14 have recess regions 27 which is slightly inwardly recessed from the main exterior faces of panels 12 and 14. In other embodiments, the physical feature may be a protrusion or any other distinguishing indicator which would identify a tie as being located at that position.

[0056] Generally a form, such as form 10, is created in two parts: (1) the ties; and (2) the form encasing the ties. The ties 18 and 20 preferably are formed through an injection mould process. Once the ties are formed, for 10 can be made through an expandable polystyrene (EPS) process wherein a mould (not shown) is built for creating a specific shape of that form. For corner form 10, three main regions are provided in its mould. Two regions define the volumes of the interior and exterior panels (12, 14) for the form. A third region is defined between the two regions and it defines a void which ultimately defines the volume 16 to be filled by concrete for the form. Within the third region, the mould allows ties 18 and 20 to be mounted therein. For form 10, ties 18 and 20 are positioned in the mould such that they span the void of the third region and the lateral ends are located within each of the first two regions. Generally, ties 18 and 20 are positioned to span the void at 90 degrees to the face of the walls. Once all ties 18 and 20 are mounted in their specified locations, particulate Styrofoam is blown into the first two regions, forming panels 12 and 14. When the foam cures in the first two regions, the lateral ends of the ties 18 and 20 are encased in the foam. As such, form 10 is an integral piece comprising panels 12 and 14 which are linked together by ties 18 and 20. For other forms, ties 18 and 20 may be inserted and fixed within their respective panel via shaped slots in each form.

[0057] Details are now provided on ties 18 and 20. In the embodiment, ties 18 and 20 are formed from a plastic material and can be made using any known moulding or forming technique.

[0058] Referring to FIGS. 1 and 11, tie 20 comprises a central, planar web portion 26 and two flanges on opposite ends of the web portion. The flanges are embedded within the foam panels 12 and 14 and are preferably designed to extend over the entire height of each panel. In this way, when the forms are stacked and the ties vertically aligned, the flanges provide continuous strips to which fasteners etc. may be attached.

[0059] Referring to FIGS. 1 and 5 to 10, tie 18 provides structurally support to keep panels 12 and 14 in their proper spaced relationship in the transition zone of form 10. In particular, tie 18 is a horizontally oriented tie which provides a series of web members 46 which span from notched corner 35 (which is embedded into the corner of form 14) to locations which are embedded into locations along the corner of form 12. At the end of each web member 46, which is embedded into panel 12, a vertical flange 38 extends above and below the anterior end of web member 46. A central web 46A span from notched corner 34 to the corner of outer panel 12. A series of flanges 38A form a corner which is also contained within outer panel 12.

[0060] To enhance structural strength among the webs 46 when they are located in panel 12, the anterior ends of webs 46 are connected together by spans 62. Additional webs 30 extend outwardly from notched corner 34 at 90° to the corner and extend into panel 12. Flanges 38 extend above and below the anterior ends of webs 30 in panel 12. In other embodiments, either of spans 62 or webs 30 may be left out.

[0061] As such, when viewed from above (in FIG. 3), flanges 38, 38A and span 62 form a continuous side 28. As such when tie 18 is viewed from above, it has an outline of a four-sided flame having two sides 28 and two webs 30 all connected together, forming a general outline of a square. In other embodiments, a frame may have 3, 5 or more sides. Also, the shape of the outline of the frame may be any suitable polygon (when viewed from above). For tie 18 as shown, sides 28 meet at a flush corner 32 at a right angle. The middle portions of webs 30 are meant to be located in the volume 16. The notched corner 34 is encased within panel 14 at its corner. Sides 28 are encased within panel 12. Vertical flange 40 is attached to the exterior transverse edges of webs 30 about notched corner 34 to provide a vertically-oriented member to resist horizontal displacement of webs 30 from panel 14.

[0062] Sides 28 have an interior web 42 running in a spaced relationship to the outer edge of side 28 with interior webs 44 attaching between side 28 and interior web 42.

[0063] Along the exposed sections of each web 30 between panels 12 and 14, vertical bars 50 and 52 are provided which extend above and below each web 30 in a spaced relationship to each other. Vertical bars 50 are slightly longer than bars 52. Each bar has a tapered side, providing a gusset between each set of bars. As such, a U-shaped gap 54 is formed between bars 50 and 52. The gaps 54 and bars 50 and 52 provide a bar alignment feature for re-bars which can be inserted within form 10. Use of re-bars in concrete walls provides known strengthening benefits. At the exposed ends of each web 30, additional vertical bars 56 with gussets 58 are provided. The anterior surfaces of the vertical bars 56 abut against panels 12 and 14. It will be appreciated that in other embodiments, different combinations, sizes and shapes for vertical bars and gussets may be provided on one or both surfaces of one or more webs 30. For example, in other embodiments, vertical bars and gussets may be provided only on one surface of each web 30.

[0064] As shown in FIGS. 5 to 8, ties 18 are aligned on top of each other forming a volume resembling a rough cube in outline to provide a stack of ties 18 around the transition zone of form 10. It will be appreciated that the top view of the stack of ties 18 is identical to the view for a single tie 18. The stack of ties 18 forms a series of generally flush vertical walls, comprised of spans of vertical flange 40 around notch 34 and spans of vertical flange 38. Gaps 60 may be formed by voids in each of the vertical flanges 38 and 40.

[0065] In other embodiments for the stack, a single tie spanning a large portion of the height of form 10 may be used; alternatively, two, three, four, five or more ties may be aligned together to form a stack of ties. In one embodiment, ties 18 are formed into a stack where each adjacent tie 18 rests on top of its neighbour below. The dimensions and widths of the top and bottom edges of the forms may be sufficiently large to facilitate ties being stacked on top of other ties. In another embodiment, a space may be provided between adjacent ties in the stack. A notable features is that the stack provides more complex structural features which may be difficult to manufacture in a single tie.

[0066] In another embodiment, an interlock system may be provided for the ties 18 to form the stack of ties. Features may be provided on the top and bottom edges of ties 18 to facilitate the alignment and locking of ties 18 when they are stacked together. The features can be any positive and negative features which provide some alignment and/or locking means for adjacent the ties 18.

[0067] In yet another embodiment, individual ties 18 in the stack can be separately bound, welded, glued or otherwise attached to an adjacent tie 18 immediately above or below it, using bonding techniques known in the art.

[0068] As such, form 10 has vertical rigidity provided by an integral support provided along the length of tie 20 and horizontal and vertical rigidity provided along each member 18. The stack of ties 18 provides a network of horizontal and vertical support elements, strengthening the corner of form 10, as concrete is provided therein.

[0069] Although the corner form of FIG. 10 is illustrated as having a 90° bend, it will be understood that any desired angle can be provided.

[0070] Panels 12 and 14 are provided with a number of features that enable adjacent forms to engage each other so as to ensure that, once a wall of forms is assembled, the forms are maintained in position. These interlocking features comprise, firstly, a longitudinally extending tongue 22 provided on the top of each panel 12 and 14 and a longitudinally extending groove 24 provided on the bottom of each panel. The tongues 22 and grooves 24 are collectively shaped so as to permit the tongues on the tops of the panels of one form to cooperate and engage with the grooves on the bottoms of the panels of an adjacent form when the forms are stacked. This engagement serves to lock the forms together and restrict adjacent panels from moving with respect to each other. Further, each end of the panels is provided with either a tongue or groove to engage the panel of an adjacent form. However, as shown in FIG. 1, the tongues and grooves on the sides of the panels are oppositely provided. That is, on one side of the form, one of the panels 12, is provided with a tongue 22 while the other panel 14, is provided with a groove 24.

[0071] It will be appreciated that the features may be provided as complementary “positive” and “negative” features formed to cooperate and mate with each other. As noted in more detail below, a “positive” feature, generally, is any outward formation on the edge of the panel, while a “negative” feature, generally, is any inward formation on the edge.

[0072] FIGS. 12 to 18 illustrate another embodiment for a form 100 which is used when three wall sections meet at an intersection region at a “T” junction. For the sake of consistency, where similar elements exist between form 10 and form 100, the reference number for the corresponding element in form 100 will be identified by adding “100” to the reference number.

[0073] As such, in FIG. 12 form 100 has one long vertical panel 112 and two opposed corner panels 114A and 114B, arranged such that a spaced volume 116 forming a T is provided between adjacent panels.

[0074] Ties 120 and 118 are provided between the adjacent panels. At the central portion of form 100, ties 118 are inserted to provide structural support to panels 114A, 114B and 112. As shown, ties 118 are the only ties linking all three panels together. Ties 120 are used to link together two panels (e.g. panels 112 and 114A; panels 112 and 114B; panels 114A and 114B).

[0075] Referring to FIGS. 12 to 18, tie 118 is generally a four-sided frame having side 128 and three webs 130. Where side 128 meets a web 130, a flush corner 136 is formed. Where two webs 130 meet, notched corner 134 is formed. The middle portions of webs 130 are meant to be located in the volume 116. Notched corners 134 are encased within panels 114 at their corner. Side 128 is encased within panel 112. A vertical edge 138 runs along the exterior edge of side 128 and extends above and below side 128. Edge 138 provides additional support for tie 118 in panel 112, effectively embedding a vertically-oriented member to resist horizontal displacement of side 128 from panel 112. Vertical edge 140 is attached to the exterior transverse edges of webs 130 about notched corner 134 to provide a vertically-oriented member to resist horizontal displacement of webs 130 from panel 114.

[0076] Side 128 has an interior flange 142 running in a spaced relationship to the outer edge of side 128 with interior webs 144 attaching between side 128 and interior flange 142.

[0077] Additional web members 146 span generally radially from each notched corner 134 to a location along side 128. Each web member 146 provides additional lateral support between sides 112 and 114. Additional web members 148 are provided about corner 134 and link webs 130 to web members 146.

[0078] Along the exposed sections of each webs 130 between walls 114 and 112, vertical bars 150 are provided which extend above and below each webs 130 in a spaced relationship to each other. A gap 154 is formed in the space between bars 150. The gaps 154 and bars 150 provide an alignment mechanism for re-bars which can be inserted within form 100. At the exposed ends of each webs 130, additional vertical bars 156 with gussets 158 are provided. The anterior surfaces of the vertical bars 156 abut against panels 112 and 114. It will be appreciated that in other embodiments, different combinations, sizes and shapes for vertical bars and gussets may be provided on one or both surfaces of one or more webs 130.

[0079] As shown in FIGS. 13 to 16, ties 118 are stacked on top of each other to provide a stack of ties 118 around the central portion of form 100. The stack of ties 118 forms a series of generally flush vertical walls, comprised of spans of vertical edges 140 around notch 134 and spans of vertical edges 138. Gaps 160 are formed by gussets 162 which extend between vertical bars 156 and edges 160 of webs 130.

[0080] It will be appreciated that a notable feature of an embodiment is the use of a generally horizontally-oriented tie in a section of a form where a transition of a direction of a wall or a meeting of one wall into another wall exists. By stacking two or more generally horizontally-oriented ties in that region increases the support along the vertical sides of the panels. In other embodiments, the horizontally-oriented ties portions of one or more ties may extend out from the basic volume formed by the stack of ties.

[0081] In other embodiments, the ties for a form can be with the panels by sliding anterior flanges of the ties into slots in the foam, or by any other manner as will be apparent to persons skilled in the art.

[0082] In other embodiments, other shapes and sizes can be provided for the forms to create other non-straight sections for a wall. For example, forms can be provided having bend along their length which is not 90 degrees. A corner can be defined by any angle which is architecturally sound. For example a corner may be between 15 degrees to 165 degrees between the wall sections. Forms can also be provided having multiple wall sections meeting at different locations along a section of a wall or a cross-form for four walls meeting at a transition zone. Each wall section may meet other wall sections at architecturally sound angles.

[0083] Although the invention has been described with reference to certain specific embodiments, various modifications thereof will be apparent to those skilled in the art without departing from the spirit and scope of the invention as outlined in the claims appended hereto. The entire disclosures of all references mentioned above are incorporated herein by reference.