AU2006344330A1

AU2006344330A1 - Slab tie for concrete forming system

Info

Publication number: AU2006344330A1
Application number: AU2006344330A
Authority: AU
Inventors: Erwin Boeck
Original assignee: QUAD LOCK BUILDING SYSTEMS Ltd; Wallsystems International Ltd
Current assignee: Wallsystems International Ltd; QUAD-LOCK BUILDING SYSTEMS Ltd
Priority date: 2006-06-09
Filing date: 2006-06-09
Publication date: 2007-12-13
Anticipated expiration: 2026-06-09
Also published as: AU2006344330B2; EP2027346A4; EP2027346A1; WO2007140570A1; ZA200809058B

Description

WO 2007/140570 PCT/CA2006/000961 SLAB TIE FOR CONCRETE FORMING SYSTEM Technical Field [0001] This disclosure pertains to support of interlockable foam 5 panels used to construct forms for casting concrete walls in building construction; namely support in regions where a horizontal concrete slab is to join the wall. Background 10 [0002] United States Patent No. 5,704,180 issued 6 January 1998 (which is incorporated herein by reference) discloses an insulating con crete form system utilizing interlocking foam panels and connectors. The panels have opposed upper and lower ends, with a plurality of coplanar passages extending into the upper ends at regularly spaced intervals. An 15 equal plurality of coplanar passages extend into the panels' lower ends at the same regularly spaced intervals, to vertically align each upper end passage with a corresponding lower end passage. Each connector has a first bar which interconnects transversely opposed first and second paral lel, vertically extending planar members; and, a second bar interconnect 20 ing identical transversely opposed third and fourth parallel, vertically extending planar members. A latticework interconnects the two bars in spaced parallel relationship and maintains separate coplanar alignment of the first and third planar members, the second and fourth planar members, and the two bars. The panels' upper and lower end passages are sized and 25 shaped to receive corresponding halves of one of the connector planar members. [0003] In accordance with the '180 patent, a concrete wall form is constructed by positioning a first outward foam panel parallel to a first inward foam panel. The two panels are transversely and horizontally 30 interlocked by extending the lower halves of the first and third planar members of a first plurality of connectors into the upper end passages of the first outward panel; and by extending the lower halves of the connec tors' second and fourth planar members into the upper end passages of the first inward panel. The wall form is then vertically extended by fitting the WO 2007/140570 PCT/CA2006/000961 -2 lower end passages of a second outward panel over the upper halves of the first and third planar members of the connectors which interlock the first inward and outward panels, and by fitting the lower end passages of a second inward panel over connectors' second and fourth planar members. 5 The second panels' upper ends are then transversely and horizontally interlocked by extending the lower halves of the first and third planar members of a second plurality of connectors into the upper end passages of the second outward panel; and by extending the lower halves of the second plurality of connectors' second and fourth planar members into the 10 upper end passages of the second inward panel. The wall form is further vertically extended to its desired height by adding further outward and panels and connectors as aforesaid. Concrete is poured into the wall form. When the concrete sets it forms a wall of the desired size and shape. The foam panels remain attached to the wall and serve as insulation. 15 [0004] It is sometimes necessary to join a horizontal concrete slab to a wall. In such cases a vertical wall form is constructed as above, with the form extending vertically above the region where the horizontal concrete slab is to join the wall. However, the form's inward foam panels cannot extend through the region where the horizontal concrete slab is to join the 20 wall. This makes it difficult to support the outward foam panels adjacent the region where the horizontal concrete slab is to join the wall. Specifi cally, the outward foam panels extend vertically past the region where the horizontal concrete slab is to join the wall, but no inward foam panels extend vertically through that region, so connectors cannot be used to 25 interlock the outward and inward panels in that region. This weakens the wall form in that region, typically requiring some form of external bracing to support the outward foam panels adjacent the region where the horizon tal concrete slab is to join the wall. This disclosure addresses that prob lem. 30 [0005] The foregoing examples of the related art and limitations related thereto are intended to be illustrative and not exclusive. Other limitations of the related art will become apparent to those of skill in the art upon a reading of the specification and a study of the drawings.

WO 2007/140570 PCT/CA2006/000961 -3 Brief Description of Drawings [0006] Exemplary embodiments are illustrated in referenced figures of the drawings. It is intended that the embodiments and figures disclosed 5 herein are to be considered illustrative rather than restrictive. [0007] Figure 1 is an isometric illustration of a slab tie connector. [0008] Figure 2 is an isometric illustration of a bracket for use with the Figure 1 slab tie connector. [0009] Figure 3 is an isometric illustration showing one end of the 10 Figure 1 slab tie connector engaging a foam panel and showing the Figure 2 bracket fastened to a board. [0010] Figure 4 is an isometric illustration showing the Figure 3 board repositioned to engage the bracket with the slab tie connector. [0011] Figure 5 is an isometric illustration showing four vertically 15 interlocked outward foam panels extending parallel to three vertically interlocked inward foam panels, with the Figure 1 slab tie connector and two conventional (non slab tie) connectors transversely interlocked be tween the outward and inward panels, and with a board-fastened Figure 2 bracket engaging the slab tie connector. 20 [0012] Figures 6A through 6G are side elevation views sequentially depicting formation of a vertical concrete wall and a horizontal concrete slab utilizing the Figure 5 arrangement. [0013] Figure 7 is an isometric illustration showing another arrange ment like that of Figure 5 after formation of another lower vertical con 25 crete wall and another horizontal concrete slab. [0014] Figures 8A and 8B are top plan and side elevation views respectively of a portion of one end of an alternative slab tie connector; Figures 8C and 8D are front elevation and isometric views respectively of the one end of the alternative slab tie connector. 30 WO 2007/140570 PCT/CA2006/000961 -4 Description [0015] Throughout the following description specific details are set forth in order to provide a more thorough understanding to persons skilled in the art. However, well known elements may not have been shown or 5 described in detail to avoid unnecessarily obscuring the disclosure. Accordingly, the description and drawings are to be regarded in an illus trative, rather than a restrictive, sense. [0016] Figure 1 depicts a slab tie connector 10 for interlocking foam panels as explained below. Slab tie connector 10 has four outwardly 10 disposed, parallel, vertically extending planar members 12, 14, 16, 18. Bars 20, 22 respectively extend between planar members 12, 14 and 16, 18 to hold them in fixed, spaced, parallel relationship with members 12, 16 being coplanar; and, members 14, 18 being coplanar. The vertical extension of each of members 12, 14, 16, 18 away from bars 20, 22 is 15 equal. Bars 20, 22 are in turn rigidly interconnected by struts 24, 26 which maintain a fixed displacement between bars 20, 22. The ends of bars 20, 22 flare outwardly and upwardly or downwardly to merge with the outer ends of the respective planar members, as illustrated, for exam ple, by reference numerals 28, 30, 32, 34. This enhances slab tie connec 20 tor 10's structural integrity without unduly weakening the foam panels. Opposed pairs of notches 36, 38, 40 are provided in the upper central portions of bars 20, 22 to facilitate interlocking of connectors as explained in the '180 patent. Additional pairs of somewhat shallower notches 42, 44 are provided in the upper portions of bars 20, 22 to receive reinforcing 25 rods as explained in the '180 patent. But for the requirement that bars 20, 22 and notches 34, 36 be shaped and sized for interlocking engagement as explained in the '180 patent, the cross-sectional shape of bars 20, 22 is arbitrary. [0017] A protrusion 46 is formed centrally on the outward face of 30 one (but not both) of planar members 12 or 16. As shown in Figure 1, protrusion 46 is formed centrally on the outward face of planar member 16. Protrusion 46 includes a first portion 48 which extends generally perpendicularly outwardly away from the outward face of planar member WO 2007/140570 PCT/CA2006/000961 -5 16. Protrusion 46 also includes a second portion 50 which is spaced outwardly from the outward face of planar member 16. Second portion 50 extends generally perpendicularly to first portion 48 and generally parallel to the outward face of planar member 16. The upper and lower edges 52, 5 54 of first portion 48 may be beveled. Slab tie connector 10, including protrusion 46, may be formed as a unitary plastic casting. [0018] Figure 2 depicts a bracket 60 for interlockably engaging slab tie connector 10 as explained below. Bracket 60, which may be formed of aluminum or other suitable material, includes first and second portions 62, 10 64 which perpendicularly intersect one another. One or more apertures 66 are formed through first portion 62. A slot 68 is formed through second portion 64 and extends vertically upwardly from lower edge 70 of second portion 64. Slot 68 extends a substantial distance, e.g. approximately two thirds the height of second portion 64. A notch 72 is formed through 15 lower edge 70, at the lower end of slot 68. [0019] Protrusion 46 and bracket 60 together constitute a coupling for supporting an outward concrete form panel interlockably engaging an inward concrete form panel in a region where a horizontal concrete slab is to join a concrete wall formed between the panels, as explained below. 20 [0020] Figure 3 depicts an expanded polystyrene foam panel 80 interlocked with one end of slab tie connector 10 by extending the lower halves of slab tie connector 10's planar members 12, 16 into upper end passages formed in panel 80, as explained in the '180 patent. During such extension, lower edge 54 of first portion 48 of protrusion 46 on planar 25 member 16 contacts and slices through upper end 82 of panel 80's outward face 84, until the lower halves of slab tie connector 10's planar members 12, 16 are fully inserted into panel 80's upper end passages. Such slicing is assisted if lower edge 54 is beveled as aforesaid, and may also be assisted by preforming slots in upper end 82 of panel 80's outward face 30 84. Such slicing does not significantly weaken panel 80, and leaves part of first portion 48 and all of second portion 50 extending vertically outside panel 80's outward face 84, and approximately centered across panel 80's upper end 82, as seen in Figure 3.

WO 2007/140570 PCT/CA2006/000961 -6 [0021] Figure 3 also depicts a portion of a board 90 (e.g. a piece of 2" by 4" lumber) to which bracket 60 is fastened by driving nails, screws or other suitable fasteners 92 through bracket 60's apertures 66. Care is taken to fasten bracket 60 to board 90 such that bracket 60's second 5 portion 64 is flush with board 90's inward end 94, as seen in Figure 3. [0022] Board 90 is then positioned to engage bracket 60 with protru sion 46 on planar member 16, by sliding bracket 60's notch 72 and slot 68 downwardly over protrusion 46's first portion 48 until the upper end of slot 68 contacts the upper edge 52 of first portion 48, as seen in Figure 4. 10 Notch 72 assists in guiding initial engagement of slot 68 with first portion 48. Such guiding is further assisted if upper edge 52 is beveled as afore said. Protrusion 46's second portion 50 is thus positioned outside and against bracket 60's second portion 64, such that bracket 60 is supported on protrusion 46, thereby firmly supporting board 90 against the outward 15 face of panel 80. [0023] Additional foam panels 100, 102, 104, 106, 108, 110 and conventional (non slab tie) connectors 112, 114 are then interlocked transversely, horizontally and vertically with panel 80 as explained in the '180 patent and as shown in Figure 5 to construct a wall form with verti 20 cally stacked outward panels 80, 100, 102 and 104 extending generally parallel to vertically stacked inward panels 106, 108 and 110. Although only one slab tie connector 10 and two conventional connectors 112, 114 are shown in Figure 5, in practice additional slab tie connectors (not visible, but for example to support additional boards 90 as seen in Figure 25 7) are interlocked transversely, horizontally and vertically between and at spaced intervals along panels 80, 102 and 108, 110 to provide an addi tional protrusion 46 at each spaced interval. As shown in Figure 7, additional brackets fastened to additional boards 90 engage the additional protrusions on the additional slab tie connectors. In North American 30 construction, the spacing interval between the additional protrusions and boards is typically one foot.

WO 2007/140570 PCT/CA2006/000961 -7 [0024] The uppermost outward panel 104 (Figure 5) extends above the uppermost inward panel 110, with no inward panel being directly horizontally opposite to uppermost outward panel 104. This is because a horizontal concrete slab 124 (Figures 6D-6G or 7) is to be joined to the 5 wall which is to be constructed with the aid of the form shown in Figure 5. More particularly, horizontal concrete slab 124 will extend across the top of the uppermost inward panel 110 toward the uppermost outward panel 104. Since there is no inward panel directly horizontally opposite to uppermost outward panel 104, connectors cannot be used to interlock the 10 upper end of uppermost outward panel 104 to a horizontally opposed inward panel. Some form of external bracing is needed to transversely support uppermost outward panel 104 adjacent the region where horizontal concrete slab 124 is to join the wall. Such bracing is provided by boards 90, which extend vertically and bear against the outward faces of outward 15 panels 80, 100, 102 and 104 at spaced intervals, as seen in Figure 7. Each board 90 is held in place by the engagement of a bracket 60 with a protru sion 46 on one of slab tie connectors 10. [0025] After concrete poured into the wall form hardens, board 90 is removed by rotating it in either direction against the outward faces of out 20 ward panels 80, 100, 102 and 104 until protrusion 46 breaks away from slab tie connector 10. The outward panels, which remain in place to serve as insulation on the finished concrete wall, are thus left free of protru sions. [0026] Breakage of protrusion 46 away from slab tie connector 10 25 can be facilitated by narrowing or otherwise weakening protrusion 46's first portion 48 along the edge of first portion 48 which joins the outward face of planar member 16. This is best seen in Figures 8A-8D, which depict an alternative slab tie connector 10A. An alternative protrusion 46A is formed centrally on the outward face of connector 1OA's planar 30 member 16A. Protrusion 46A's first portion 48A is weakly connected to the outward face of planar member 16A along narrow, frangible portion 74. First portion 48A extends generally perpendicularly outwardly away from the outward face of planar member 16A. Protrusion 46A's second WO 2007/140570 PCT/CA2006/000961 -8 portion 50A is spaced outwardly from the outward face of planar member 16A. Second portion 50A extends generally perpendicularly to first portion 48A and generally parallel to the outward face of planar member 16A. Second portion 50A may extend a short distance across first portion 5 48A, giving portions 48A, 50A a cross-sectional "T" shape as seen in Figure 8A, provided portion 50A does not impede sliding engagement of bracket 60 with protrusion 46A as previously explained in relation to protrusion 46. [0027] Figures 6A-6G sequentially depict formation of a vertical 10 concrete wall and a horizontal concrete slab utilizing slab tie connector 10. Figure 6A depicts the wall form described above in relation to Figure 5. Figure 6B depicts the same wall form, after pouring of concrete between vertically stacked outward panels 80, 100, 102 and vertically stacked inward panels 106, 108, 110 to form vertical concrete wall portion 116. 15 Figure 6C depicts installation of floor bracing beam 120 and floor bracing joist 122 above vertical concrete wall portion 116. Figure 6D depicts pouring of additional concrete atop vertical concrete wall portion 116 and atop joist 122 to form horizontal concrete slab 124. Figure 6D also depicts installation of metal track member 126 atop horizontal concrete 20 slab 124. Track member 126 extends parallel to outward panel 104 and is spaced inwardly therefrom by a distance equal to the transverse spacing between the outward and inward vertical wall form panels. Figure 6E depicts installation of additional conventional (non-slab tie) connectors and foam panels atop outward panel 104 and atop track member 126 to provide 25 another vertical wall form 128 atop horizontal concrete slab 124, in vertical alignment with vertical concrete wall 116. Figure 6F depicts the Figure 6E structure after removal of board 90 and breakage of protrusion 46 away from slab tie connector 10 as previously explained. Figure 6G depicts vertical extension of wall form 128 by installation of additional 30 (non-slab tie) connectors and additional outward and inward foam panels interlocked by the connectors. [0028] While a number of exemplary aspects and embodiments have been discussed above, those of skill in the art will recognize certain WO 2007/140570 PCT/CA2006/000961 -9 modifications, permutations, additions and sub-combinations thereof. There is no need to form protrusions 46 on both of members 12 and 16 since boards 90 are typically transversely spaced apart from one another at one foot intervals (in North American construction), which exceeds the 5 typical transverse spacing between members 12, 14. Protrusions 46 are not required on either of slab tie connector 10's inward members 14, or 18 since external bracing via boards 90 is required only against the outward faces of outward panels 80, 100, 102 and 104. It is intended that the following appended claims and claims hereafter introduced are interpreted 10 to include all such modifications, permutations, additions and sub-combi nations as are within their true spirit and scope.

Claims

1. A coupling for supporting an outward concrete form panel (80) adjacent a region where a horizontal concrete slab (124) is to join a 5 concrete wall (116) formed between the outward panel and an inward concrete form panel, the coupling comprising: a connector (10) having at least one bar (20, 22) interconnect ing transversely opposed first (12, 14) and second (16, 18) parallel, vertically extending planar members; 10 a protrusion (46) on an outward face of one of the planar members (16); the protrusion (46) having a first portion (48) extending generally perpendicularly outwardly away from the outward face of the one of the planar members (16); 15 the protrusion (46) having a second portion (50) spaced outwardly from the outward face of the one of the planar members (16), the second portion (50) extending generally perpendicularly to the first portion (48) and generally parallel to the outward face of the one of the planar members (16); 20 a bracket (60) having generally perpendicularly intersecting first and second portions (62, 64); and a slot (68) formed through the second portion (64) of the bracket (60), the slot (68) extending vertically upwardly from a lower edge (70) of the second portion (64) of the bracket (60). 25

2. A coupling as defined in claim 1, wherein the slot (68) extends a substantial distance through the second portion (64) of the bracket (60). 30

3. A coupling as defined in claim 1, wherein the slot (68) extends through approximately two-thirds of the second portion (64) of the bracket (60). WO 2007/140570 PCT/CA2006/000961 - 11

4. A coupling as defined in claim 1, further comprising a notch (72) formed through the lower edge (70) of the second portion (64) of the bracket (60), at the lower end of the slot (68).

5 5. A coupling as defined in claim 1, wherein the protrusion (46) is formed centrally on the outward face of the one of the planar mem bers (16).

6. A coupling as defined in claim 1, wherein an upper edge (52) of the 10 first portion (48) of the protrusion (46) is beveled.

7. A coupling as defined in claim 1, wherein a lower edge (54) of the first portion (48) of the protrusion (46) is beveled. 15

8. A coupling as defined in claim 1, wherein the connector (10) and the protrusion (46) are formed as a unitary plastic casting.

9. A coupling as defined in claim 1, further comprising at least one aperture (66) formed through the first portion (62) of the bracket 20 (60) to receive a fastener for fastening the bracket (60) to a board (90).

10. A coupling as defined in claim 1, wherein the protrusion (46) is narrowed along an edge (74) of the protrusion (46) attached to the 25 outward face of the one of the planar members (16).

11. A coupling as defined in claim 1, wherein the protrusion (46) is frangibly attached (74) to the outward face of the one of the planar members (16) for frangible separation of the protrusion (46) from 30 the outward face of the one of the planar members (16).

12. A method of supporting an outward concrete form panel (80) adja cent a region where a horizontal concrete slab (124) is to join a WO 2007/140570 PCT/CA2006/000961 - 12 concrete wall (116) formed between the outward panel and an inward concrete form panel, the method comprising: providing a connector (10) having at least one bar (20, 22) transversely interconnecting opposed first (12, 14) and second (16, 5 18) parallel, vertically extending planar members; forming a protrusion (46) on an outward face of one of the planar members (16), the protrusion (46) having: a first portion (48) extending generally perpendicularly outwardly away from the outward face of the one of the 10 planar members (16); a second portion (50) spaced outwardly from the out ward face of the one of the planar members (16), the second portion (50) extending generally perpendicularly to the first portion (48) and generally parallel to the outward face of the 15 one of the planar members (16); extending the one of the planar members (16) into an upper end of the outward panel (80) to leave the second portion (50) of the protrusion (46) extending vertically outside an outward face of the outward panel (80); 20 providing a bracket (60) having perpendicularly intersecting first and second portions (62, 64); forming a slot (68) through the second portion (64) of the bracket (60), the slot (68) extending vertically upwardly from a lower edge (70) of the second portion (64) of the bracket (60); 25 fastening the first portion (62) of the bracket (60) to a board (90); and positioning the board (90) to slide the slot (68) downwardly over the first portion (48) of the protrusion (46), to position the second portion (50) of the protrusion (60) outside the second portion 30 (64) of the bracket (60), such that the bracket (60) is supported on the protrusion (46) and the board (90) is supported against the outward face of the outward panel (80). WO 2007/140570 PCT/CA2006/000961 - 13

13. A method as defined in claim 12, further comprising, after forma tion and hardening of the horizontal concrete slab (124) and the concrete wall (116): rotating the board (90) against the outward face of the out 5 ward panel (80) until the protrusion (46) breaks away from the connector (10); and removing the board (90) and the protrusion (46).

14. Apparatus for supporting an outward concrete form panel (80) 10 adjacent a region where a horizontal concrete slab (124) is to join a concrete wall (116) formed between the outward panel (80) and an inward concrete form panel, the apparatus comprising: a board (90); a connector (10) having at least one bar (20, 22) interconnect 15 ing transversely opposed first (12, 14) and second (16, 18) parallel, vertically extending planar members; a protrusion (46) on an outward face of one of the planar members (16); the protrusion (46) having a first portion (48) extending 20 generally perpendicularly outwardly away from the outward face of the one of the planar members (16); the protrusion (46) having a second portion (50) spaced outwardly from the outward face of the one of the planar members (16), the second portion (50) extending generally perpendicularly to 25 the first portion (48) and generally parallel to the outward face of the one of the planar members (16); a bracket (60) fastenable to the board (90), the bracket (60) having generally perpendicularly intersecting first and second por tions (62, 64); and 30 a slot (68) formed through the second portion (64) of the bracket (60), the slot (68) extending vertically upwardly from a lower edge (70) of the second portion (64) of the bracket (60). WO 2007/140570 PCT/CA2006/000961 - 14

15. Apparatus as defined in claim 14, wherein the slot (68) extends a substantial distance through the second portion (64) of the bracket (60). 5

16. Apparatus as defined in claim 14, wherein the slot (68) extends through approximately two-thirds of the second portion (64) of the bracket (60).

17. Apparatus as defined in claim 14, further comprising a notch (72) 10 formed through the lower edge (70) of the second portion (64) of the bracket (60), at the lower end of the slot (68).

18. Apparatus as defined in claim 14, wherein the protrusion (46) is formed centrally on the outward face of the one of the planar mem 15 bers (16).

19. Apparatus as defined in claim 14, wherein an upper edge (52) of the first portion (48) of the protrusion (46) is beveled.

20 20. Apparatus as defined in claim 14, wherein a lower edge (54) of the first portion (48) of the protrusion (46) is beveled.

21. Apparatus as defined in claim 14, wherein the connector (10) and the protrusion (46) are formed as a unitary plastic casting. 25

22. Apparatus as defined in claim 14, further comprising at least one aperture (66) formed through the first portion (62) of the bracket (60) to receive a fastener for fastening the bracket (60) to the board (90). 30

23. Apparatus as defined in claim 14, wherein the protrusion (46) is narrowed along an edge (74) of the protrusion (46) attached to the outward face of the one of the planar members (16). WO 2007/140570 PCT/CA2006/000961 - 15

24. Apparatus as defined in claim 14, wherein the protrusion (46) is frangibly attached (74) to the outward face of the one of the planar members (16) for frangible separation of the protrusion (46) from the outward face of the one of the planar members (16). 5