CA1254398A - Corner forming apparatus for a concrete wall form - Google Patents

Abstract

ABSTRACT OF THE DISCLOSURE
In the corner forming apparatus of the present in-vention, an inside corner forming member is provided, for use with a pair of panels to form the inside corner in a concrete wall form. The corner forming member is securable to a panel-support beam member, and is substantially L-shaped. A seating flange projects from the inner surface of one leg of the L-shaped mem-ber at an intermediate location therealong, this seating flange being substantially parallel to the other leg of the member.
That portion of the leg which extends beyond the seating flange is substantially equal to the thickness of one of the pair of panels and is adapted to shield an edge of that panel when said panel is seated on the seating flange. The other leg of the L-shaped mem-ber is securable to the panel-support beam member, and is pro-vided with at least one aperture therein to receive fastening ele-ments for securing the other of the pair of panels to the other leg such that a surface of the other panel and the outer surface of said one leg are substantially coplanar.

Description

12~4~39~3 This application is a division of our Canadian Patent Application Serial Number 519,585 filed Oct, 1, 1986 which, in turn, is a division of our Canadian Patent Application Serial Number 394,116 filed January 14, 1982.
This invention relates to an assembly for use with con-crete wall forms and, more particularly, to an inside corner forming member alone or in combination with such assembly and/or outside corner walers.
In concrete wall construction, the wall form typically is assembled at a job site. Even today these forms are often custom-built from wooden studs sheathed with plywood for one-time use. Advantageously, on larger construction sites, reusable mobile wall forms are used, typically ganged together and shifted as the height and length of the concrete wall is formed.
Various structures are used as backing support to the plywood panels so as to resist the forces exerted on those wall form panels during the formation of the concrete walls. As one example of such support structures, wooden studs are secured to the panel and then load-gathering horizontal wales are secured to the vertical studs, with the latter occasionally backed by vert-ical strongbacks, thereby providing a rigid support for t:he panel.
In a more modern application, the panels are backed by horizontal joists, or beams, which in turn are secured by vertical steel double-channel wales. Recently, these joists and wales have been formed of aluminum, resulting in light weight, easily handled, strong, and rigid components, relatively easy to manufacture, and ~2~3g~

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readily reusable.
These structures are described in various editions of Formwork for Concrete by M . K . Hurd published by the American Concrete Institute since 1963 (e.g. see Figures 4-11, 6-2, 9-34, 9-35, and 11-17 of the 2nd editon).

~2~39~

/~n e~camplc of Oll sitc concrcLc Illol~ls collstrut:to/l ot such wall forms is described in Unitcd Statcs ratcnt No.
4,14~,690. Evcn to~ay custom-built l~ood cornors rclllaill the standard construction tcchniquc. Ihis is truc in sl)itc of numcrous suggcstc~ improvcmcnts ovcr thc ycars. Scc for cxal~ lc, Unito~ Statos Patcnt Nos. ~ ,G~0 issuc~l ~larch 20, 1'~7'~ to Peter J. Avery; 1,051,329 issucd Jallu.lry 21, lY13 to G.L.
I-libbard; 2,313,880 issucd ,~larcll 16, l(J-I3 to R.l~. I,c~gctt, Sr.;

2,789,337 issued ~larcll 23, l'J57 to .~. Arricllilli all~l (,corge ~.
van Sickle; and 2,826,801 issuc-l ~larcll IS, 1'~55 to ~J.I. ,~lonctti, Vernon R. Schimmcl and Johll ~;. Sylllolls.
In another problcm witll thc prior art, thc c.lgc of thc plywood panel used to form tllc insidc corncr is not protcctc~.
This means that thc edF,c oftcn bccoalcs chippc(l or split wllcll that panel is shiftc~ to othcr locatiolls or is othcrwisc mallipu-lated. This can affcct thc intcgrity of thc mold (causing leaks), the quality of tllc finisllcd concrctc, as wcll as tllc life of tllc pancls; thus a~ lg to thc cxpcnse ol constructioll.
Also, mally insidc corncr formillg mombers gcncrally are secured only to the pancls whicll 31C uscd thcrcwitll. Witllout~
additional rigid support, the insidc corncr asselnbly may bc undesirably weak.
Therefore, the present invention is dircctc~ to providing corner forming apparatus whicll avoid the aforenoted disadvantages.
Tllis invention is also directed to provide an improved inside corner concrete form assembly wllicll is relativcly inexpen-sive to manufacture, exhibits dcsirablc rigidity, an~ can bc easily and quickly reused at other locations on a job sitc.
Tlle inVCntiOIl is furtllcr dircctc~ to provi~c all insi~c corner forming member whicll can be rigidly securc~

i439~3 ~ 3 - 60939-1413E

to a particular panel and then used with that panel, in conjunct-ion with another panel, to form either an inside corner or, when a corner is not needed may be used merely as an extension in a wall form (without the need to remove the inside forming member).
This invention also is directed to provide protection of the forming edge of the inside panel from damage which may be caused during transport, assembly, disassembly, and other hand-ling; to insure a good architectural finish.
As well, the invention is directed to provide an inside corner forming member which is used with conventional fastening hardware such that it can be easily and quickly assembled when originally setting up the wall form.
SUMMARY OF THE INVENTION
According to a broad aspect of the invention there is provided an inside-corner forming member for joining a pair of wall forms at right angles comprising an elongated L-shaped ex-truded aluminum member having two legs one of said legs having two planar outer longitudinal surfaces which are at right angles to each other, the other of said legs having a first portion ex-tending inwardly at right angles from its joinder with said oneleg and having a further portion offset to the side in the direct-ion of said one leg for stripping clearance.
BRIEF DESCRIPTION OF THE DR WINGS
The following detailed description, given by way of example, will best be understood in conjunction with the accomp-anying drawings in which:

39~3 FIGURE 1 is an isometric view of the inside corner forming member in accordance with the present invention;
FIGURE 2 iS an isometric view of the use of this inside corner forming member attached to the plywood panel and joist of one wall form and joined at right angles to a second wall form;
FIGURE 3 is a plan view of the combination shown in FIGURE 2;

FIGURE 4 iS an isometric view of the combination of the inside corner forminy member and unique outside corner forming assembly for use in forming a poured concrete corner wall; and FIGURE 5 located on the second sheet of the drawings is a top view of the inside corner forming member used in another alignment to demonstrate the flexibility thereof, for linear in lieu of corner orientation.

DETAILED DESCRIPTION OF A PREFERRED EMBODIMENT

Referring now to the drawings, FIGURES 1-3 illustrate the inside corner forming member 10 as being substantially L-shaped with a pair of legs 22 and 24. In one embodiment the in-side corner forming member is constructed of extruded aluminum, and the respective legs are of unitary construction therewith. A
seating flange 18 prbjects from inner surface 20 of leg 22 in a direction substantially parallel to leg 24. Seating flange 18 is disposed at an intermediate location along leg 22 such that an extension 26 of this leg is formed. As best seen in Figure 3, the inner surface of extension 26 and the seating flange 18 form an acute angle of a slightly less than 90 with respect to each other.

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Leg 24 is substantially Z-shaped and includes a first portion 32, which extends at a substantially right angle from its intersection with leg 22. This first portion 32 ends in an angle portion 34 which angles back in the direction of the seating flange 18. Angle portion 34 ends in a second portion 36 which is substantially parallel to first portion 32. Thus, second portion 2~ ~39~

ls seen to be of~8et from the ~uncture defined by legs 22 and 24 by reason of angle portion 34, This ~econd portion 36 of leg 24 terminates in a flange 38 (uGed to ~ecure the L-shaped in~ide corner forming member 10 to a panel-~upport beam member 16).
Leg 24, and particularly flr8t po~t~on 32 thereof, i8 provided with a plurality of apertureB 30 which extend along a longitu-dinal axis and which are 8paced from each other by generally 8tandard distances, gee FIG, 1 (these can be circular holes or preferably are rectangular wedge bolt slots).
When assembled to form an lnside corner, L-fihaped membér 10 i6 secured, or fastened to a pair of panels 12 and 14. Typically, these panels are made up of one or more sheets of plywood. Thus, two horizontally oriented 4' x 8' sheets of plywood 12 would be fastened to flange 18 of an 8 foot L-shaped member 10.
FIGS, 2 and 3 illustrate the assembly of L-shaped member 10 with panels 12 and 14 to form an inside corner.
An end portion of the inside surface of panel 12 seat6 upon seating flange 18, and the edge 28 of panel 12 seats against extension 26. Generally, edge 28 i6 at right angles with the inner ~urface of panel 12. However, in FI~. 3, the in-6ide surface of extension 26 is not at right angles with seating flange 18, This acute angle defined by the seating flange and extension serve5 to assure e close fit with the outer portion of edge 28 (to protect the latter and accommo-date any already existing chips or distortions). Panel 12 is fastened to ~eating flange 18 by means of bolts 56 ~hich pas~
through ~uitable openings in the panel, and also through holes 54 ~n the seating flange (the foregolng herein identified as a second fastening mean~). Nuts S8 ~erYe to tighten and sultably secure ~ ~ Z~ ~3 ~

the bolts, whereby panel 12 iB Iigidly fastened to one leg 22 of L-~haped member 10.
Typically, and as mentioned sbove, plywood panel~
12 and 14 when used ln modern wall forms are 6upported by aluminum ~oi6t6 16, and walers (not ~hown). The typlcal ~oi6t 16 has a web 66 lnterconnecting a top hat channel 62 and a base flange 68. In wall for~s, such ~oist~ 16 extend generally horizontally. As best 6hown in FIGS. 4 and 6, flange 68 has a bolt slot channel 70 adapted to recelve the head of a bolt 50. Th~s bolt 50 serve~ to secure a fastening clip 46. The posit~on of clip 46 along the length of 30ist 16 is readily adju6table merely by sliding bolt 50 in channel 70, As 6een in FIG, 3, clip 46 ha6 a hook 48 for grasping i a flange, such as 38 provided on Z-shaped leg 24. Thus, the third fastening means may comprise one or all of the fastening clip 46, hook 48, and flange 38, which cooperatively secure leg 24 ~o joist 16. Thi6 ~oi6t 16 is 6ecured to panel 12 by nails 63 (see FIG. 6). The nail6 63 are driven into a two by three inch wooden nailer 6trip 64, which latter i6 fastened in the U-shaped top hat channel 62 by screws 65. Simllarly, ~oists 16' sre nailed onto panel 14.
Preferrably, the length of extension 26 beyond 6eating flange 18 on leg 22 18 substantially equal to the thicknes6 of panel 12 (see FIG, 3), Thus, when L-shaped member 10 ifi secured to panel 12, edge 28 18 shielded by exten~ion 26 ~o as to minimize damage to this edge. More lmportantly, the ln6ide corner edge of the wall form i6 now defined by the outer right-angle planar metal surfaces of exten6ion 26, and not by the wood of edge 28.
As best shown in FIG, 3, an angle iron 44, compri6ed of legs 44a ~nd 44b, 1B secured to tne inner surface of panel 14, ~ ~V ~ z~ ~39 ~ ~ ( preferably ~uch that leg 44a is ~lightly ~paced from the free edge thereof. Suitable carr~age bolts and nuts may be used to fasten angle iron 44 to panel 14.
Leg 44a is pro~ided with a series of slots 47 i therein ~uch that, when panel 14 having an~le iron 44 ~ecured thereto i~ aligned with L-6haped member 10, these slot~ 47 are in alignment with the slots 30 provlded in leg 24. Then, fastener~, such as wedge boltg 42, pa56 throu~h ali~ned apertures 30 and 47. Wedge bolt 42 has a slot 43 therein, this slot being adapted to receive a wedge bolt 45. As wedge bolt 45 i8 forceably dri~en into slot 43, angle iron 44 is iorced towards leg 24, and the free end of panel 14 is butted against the outer surface of leg 24, resultin~ in the configuration shown in FIG. 3. It may be seen that when angle iron 44 is suitably fastened to leg 2~, leg 44a is preferably slightly spaced from leg 24. This insures that the free end of panel 14 is driven into proper tightly abutting relationship with respect to the outer 6urface of leg 24.
The particular dimensions of leg 24 and of angle iron ) 44, and the location of the respective slots 30 and 47, are such that when panel 14 is fastened to leg 24, the outer 6urface 14a of the panel and the outer surface of leg 22 of the L-shaped member 10 ~xhibit an essentially coplanar relationship. Thus, sn inside corner ls formed between the outer surface of panel 12 (includlng the outer end surface of extension 26, whlch together define one wall of the corner), and the outer surface of panel 14 (includinE the coplanar outer surface of leg 22, which together define the o~her wall of the corner).
In normal operation, the L-shaped member 10 remains fastened to panel 12 and to lts ~oists 16 in the illustrated ~-3~3 ~ 9 ~ 60939-1413E

manner. Thus, to form the inside corner forming mold, panel 14 is secured to leg 24 of the L-shaped member. This fastening operation is carried out quickly and easily by the first fasten-ing means, namely by inserting wedge bolts 42 into properly align-ed apertures in leg 24 and in angle iron 44 and securing it with wedge bolt 45. To disassemble this assembly, wedge bolt 45 is removed from slot 43 and wedge bolt 42 is withdrawn from the aligned apertures. Then, by reason of the illustrated offset 34, panel 14 (together with the joists 16' secured thereto) may be stripped away from the set concrete wall in the direction in-dicated by arrow A, and then swung free of the L-shaped member 10. The offset between flange 38 at the terminating end of leg 24 and the juncture between legs 22 and 24 permits this relat-ively free and unobstructed movement of the wall form comprising panel 14. Panel 14 then may be re-used in additional assemblies, such as in a straight-wall forming assembly, another corner-forming assembly, or the like. Panel 12, carrying L-shaped mem-ber 10 can be re-used for constructing a new inside corner assem-bly (or as described below with respect to Figure 6 may be used in straight wall forming).
Turning now to FIG. 4, there is illustrated in combinat-ion with the inside corner forming member 10, an outside corner form assembly 80.
Outside corner form assembly 80 is comprised of a pair of angularly abutting panels 82 and 84. When combined with the inside corner form assembly described above, typically panels 82 ~,2~3sa and 84 will be parallel to and spaced from panels 12 and 14.
These can be exteriorly braced or interiorly joined by convent-ional tie-rods (not shown). For convenience, the same reference numerals, but with differentiating letter designations, are used to identify similar elements. For an example, two horizontal joists 16a & b are shown secured to the outer surface of panel 82.
Outside corner aluminum walers 86 and 88, of a new design are shown vertically mounted across the horizontal joists 16a & b and 16c & d by fastening clips 46a etc. Fastening clips 46a & b clamp the lips of flanges 90 and 92; and similarly fast-ening clips 46c & d clamp the lips of flanges 94 and 96.
Corner waler 86 is formed of a major leg 87 and a minor leg 89 joined at right angles by a top web 95. Waler 88 similarly has legs 91 and 93 and web 97. The major and minor legs (such as 87 and 89) preferably are dimensioned so that they seat on the flange 68a of their respective joist 16a at approx-imately a 45 angle. Each top web 95 or 97 has a longitudinally disposed series of apertures (not shown) for accommodating a tie-rod 98 therethrough. Advantageously in an eight foot outside corner waler, there would be seven 4" x 1 1/4" apertures. The tie-rod 98 passes through such an aperture and is secured to waler 86 by means of a wing nut 100. Nut 100 preferably seats against a reinforcing thrust plate 104. Similarly, tie-rod 98 is secured at its other end to waler 88 by wing nut 102 screwed against plate 106. The angled tie-rod 98 tightly secures the ~Z5~i39~

~ 60939-1413E

outside corner joint and yet is easily disassembled. The com-plete outside corr.er assembly ~ypically will have more than one tie-rod 98 joining walers 86 and 88.
These ties 98 are preferably set at 45 to the joists 16a, 16c; but because of the spacing between flanges 90 and 92, this can be appreciably varied. This usually is not possible with the prior art.
When this outside corner form assembly is used in com-bination with the aforedescribed inside corner forming assembly 10, a tight and efficient corner wall mold is established.
One advantageous feature of the present invention is that specially dedicated accessory hardware is not needed. The bolts, clips, nuts, angles, and tie-rods are all derived from ex-isting equipment. Only the ouside waler and the inside corner forming member are unique.
Another advantageous feature is that the inside corner forming member, normally secured to panel 12, need not be dedicat-ed solely for forming corners. If necessary, panel 12 may be linearly joined to an adjacent panel, such as panel 14 in the manner shown in FIG. 5, in order to form a straight wall mold.
Referring more particularly to FIG. 5, there is illustrated a modified combination of panel 12 linearly secured to panel 14 through the L-shaped member 10. Instead of the angle 44 being secured to the leg 24 (such that panel 14 forms a right angle inside corner with panel 12); in FIG. 5 the angle 44 is fastened by one of its legs 44b to the outer face of leg 22 by a pair of wedge bolts 42 and 45 (through optional holes 40 in leg ~2~39~

22).
Thus, panels 12 and 14 may be used in combination to form a straight-wall mold by using optional apertures 40. This demonstrates the flexibility of L-shaped member 10. However, when the L-shaped member is used in the inside corner configur-ation shown in FIGS. 1-4, the apertures 40 would have to be fitted plugs 108, formed of plastic or other suitable material.
Modifications in the foregoing preferred embodiment may be made without departing from the spirit and scope of the invent-lon. For example, include different fastening means to secure L-shaped member 10 to the respective panels and to the panel-sup-port beam members. The particular dimensions of the respective legs of member 10 are not critical and may vary with different applications. Also, the particular panels with which this member is used need not be limited solely to flat plywood panels. For example, fiber glass panels shaped for architectural details may be used. Furthermore, various other applications of the corner forming member are within the scope of this invention in its broader aspects; including use on a wall form having wooden studs instead of aluminum joists 16 where the leg 24 would be clamped or otherwise affixed to the nearest stud (either directly or by shims, as may be necessary). Thus it can be compatible with most any wall form that a contractor may have in his inventory.
Although primarily intended for use in forming right angle walls of uniform thickness, the illustrated structure has some leeway for variability in the angle of the wall and/or ~z~9~

in the top-to-bottom thickness. Also within the broader scope of the invention, the structure itself can be modified to mold dif-ferent angles, shapes, or thicknesses.
As seen in dash-dot outline in Fig. 3, the length of said second portion 36 can be usefully employed to allow for accommodating different lengths of joists 16a and/or panels 12 (preferably by up to 3 inch variations).
Two wall forms, each having its own L-shaped member, can be joined in linear orientation by securing the respective L-shaped member face-to-face. Thus referring to the linear orient-ation of panels 12 and 14 shown in Figure 5, this structure would be modified by replacing the angle 44 by a second L-shaped member 10' ~not shown) mounted on joist 16' and panel 14 (whereby leg 22' of L-shaped member 10' is joined face-to-face with the leg 22 of member 10).
Although illustrated for use vertically, the L-shaped member is also very usefully employed in a horizontal orientation (for example, in forming an overhead inside corner in a tunnel).
Similarly, this horizontal orientation can be used in joining stacked wallforms vertically (this can be best visualized if one views Fig. 5 for this purpose as being rotated 90 degrees, such that the panels 12 and 14 are in a vertical plane).

Claims

THE EMBODIMENTS OF THE INVENTION IN WHICH AN EXCLUSIVE
PROPERTY OR PRIVILEGE IS CLAIMED ARE DEFINED AS FOLLOWS:

1. An inside-corner forming member for joining a pair of wall forms at right angles comprising an elongated L-shaped ex-truded aluminum member having two legs one of said legs having two planar outer longitudinal surfaces which are at right angles to each other, the other of said legs having a first portion ex-tending inwardly at right angles from its joinder with said one leg and having a further portion offset to the side in the direct-ion of said one leg for stripping clearance.